Flame retardant coating on polyurethane

foam as insulation panel

Dr. S.B.Vhanbatte, Puja Gawande
Email: Gawandepuja91@gmail.com
Department of Textiles
D.K.T.E.S.s Textile & Engineering Institute, Ichalkaranji-416115 (M.S) India
Issue August, 2015

Volume 08, Issue 08

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Abstract
Thebuilding insulation materials are the building materials which form the thermal envelope for
the building or otherwise reduce heat transfer. Majority of insulation in buildings is for thermal
purposes, other insulations are for acoustic, fire, impact etc. Insulation reduces unwanted heat
loss or gain and can decrease the energy demands of heating and cooling systems.Attempt were
made to develop suitable rigid PU foam based material and to develop suitable flame retardant
coated fabric for preparing laminated composite of structural insulated panels. Polyurethane
provides good insulation and its use is increasing because it is light weight material with very
high thermal insulation.
Key Words: Energy, flame retardant coating, Rigid-polyurethane foam, thermal insulation
1. Introduction
Rigid foam depends on chemical composition and the rigidity of the resin used as a matrix and
the type of cross linking that exists between the molecules. Whereas rigid foams have one above
room temperature it is a solid foam material. PU rigid foam has been growing rapidly in many
industries due to its excellent combination of energy conservation, good mechanical strength
with lighter weight. Their low thermal conductivity is due to a unique combination of blowing
agent properties, cell size, and closed cell morphology so it is suitable for the industrial
application and commercial building.It has added functionality of flame retardancy.
2. Experimental Work
a. Material used

100% polyester fabricand PC blended fabrics used.

THPC based or suitable flame retardant chemical used.

Rigid polyurethane foam ingredients: Isocyanate, Polyol, catalyst, stabilizers

blowing agents.

and

b. Methodology

Development of base F/R fabric

Polyester and PC blended fabric was treated for flame retarding agents using THPC based
commercial product with predetermined concentrations using coating method and evaluated
flame retarding properties.

Development of PU foam

Closed dies were prepared using plywood frames. Predetermined concentrations of Isocyanate
and Polyolwere stirred together along with catalyst, stabilizers and additives to develop rigid
foam. Variety of foam was developed to achieve maximum insulation value by varying cell size.

Development of insulation panel

Insulation panels were developed with coated textile material for function like flame retardancy
and aesthetic application.
3. Result And Discussion

Table: flame retardant Properties

Air permeability of fabric reduces after coating because material blocks the inter spacing
between the yarns in fabric.Initial air permeability of both the controlled sample under
investigation was significant. As fabric samples were coated with F/R, the air permeability found
reduced drastically. As shown in above table. In case of polyester sample it was almost zero
whereas in case of PC samples it was reduced significantly.Polyester fabric shrinks when
exposed to flame and did not cached the flame when tested by test method. However, during
exposure tip of the specimen found charring with the length of <1cm. PC blended fabric coated
with flame retardant also catches the fire when exposed to flame during testing.
3.1 Effect of PU foam on compressive properties

Fig: compressive strength of PU foam

The compressive value of rigid PU foam in the presence of different cell size. It has been found
the polymeric material had produce more no of micros pores.
The structural analysis polymer with micro molecular have thicker walls comparatively the
stronger behavior of rigid polyurethane foam is primarily a function of its density. As shown in
above fig, when cell size increases compressive strength increase drastically .When looking at
material behavior under pressure we differentiate between compressive stress and compressive
strength. Compressive strength is defined as a maximum stress up to the breaking strength.
3.2 Air permeability of PU foam
Low air-permeability of rigid polyurethane foam is because of the block through an employment
of at least polyol, an isocyanate compound, a catalyst, a foaming agent and a foam stabilizer.The
method being featured in that an closed-cell rigid polyurethane foam block having an low airpermeability.
3.3 Thermal insulation of rigid foam
The thermal conductivity of PU foam depends on the foam density, cell size, cell orientation,
ratio of close to open cell content. The thermal conductivity is very low for polymer foams
because the amount of solid in the foam is very small and small closed cell structure.The gas
phase contributes the most to heat transfer. The thermal conductivity of a gas decreases with an
increase in molecular weight, so a heavy gas is more desirable as a blowing agent as the density
of the foam increases, the thermal conductivity decreases.
3.4 Adhesiveness of foam to textile material
The adhesion of polyester and PC fabrics on polyurethane coatings depends on the strength of
interactions at the interface between these materials. To increase these interactions, macrocyclic
ligands such as pyrogallolarenes have been fixed on the surface of polyester fabrics.

In case of PET Before coating adhesivity is high but after coating adhesivity is decreased
drastically. Because of these molecules have two well-separated regions.

Fig (a) PET

w/o coating

Fig (b) PET

with coating
One possesses hydrophobic and the other hydrophilic properties. The hydrophobic part is used
for the fixation of the molecules on the polyester surface.

Fig (c) PC
without coating

Fig (d) P/C

with coating
In case of PC,it is cotton that may add adhesivity of PU foam to fabric. In both conditions
adhesivity increase because of hydroxyl groups of the hydrophilic parts interaction with the
urethane groups of the polyurethane .The increase in adhesion depends on the chemical nature of
the macrocyclic molecule on the fiber surface. Adhesion strength is a measure of the strength of
the bond between the base material and coating or film laminate that protects it. It is useful for
evaluating the strength of welded joints for connecting strips of fabric into fabricated assembly.
Conclusion
The structure of polyurethane foams depends on the ratio of polyol and isocyanate as its structure
is having good mechanical properties dimensional stability, and less moisture absorbency, good
adhesivity. In commercial buildings or industry such as sport houses, cold storages; use of
insulating panel is highly essential to save energy.
- See more at: http://www.textiletoday.com.bd/flame-retardant-coating-on-polyurethane-foam-asinsulation-panel/#sthash.m17zlIa3.dpuf