A novel bio-based PAbz@PBA maize structure for improving fire protection, toxic gas suppression and mechanical performance of intumescent flame-retardant epoxy coatings

Abstract

In recent years, developing bio-based intumescent flame-retardant (IFR) epoxy coatings for fire protection of steel has become a research hotspot. However, how to endow bio-based IFR epoxy coatings with excellent fire protection, toxic gas suppression, and mechanical properties simultaneously remains a formidable challenge. Here, a bio-based IFR hybrid with the maize structure (PAbz@PBA) was easily constructed by an organic-inorganic hybrid strategy and employed to prepare high-performance IFR epoxy coatings. It has been shown that PAbz@PBA hybrids enhance the curing activity of epoxy coatings in addition to their good dispersion and interfacial compatibility. Notably, the epoxy coating containing 5.0 wt% PAbz@PBA (EP-5%PAbz@PBA) exhibits more efficient fire protection (peak heat release rate and total heat release are reduced by 48.3 % and 34.0 %, respectively), smoke suppression (total smoke production is decreased by 35.9 %), and toxic gas suppression (peak CO production rate is reduced by 39.6 %) compared to the virgin epoxy coating. Meanwhile, the heat insulation performance of EP-5%PAbz@PBA shows superiority compared to that of the virgin epoxy coating, as reflected by its lowest backside temperature (66.3 °C). Furthermore, compared with the virgin epoxy coating, EP-5%PAbz@PBA exhibits improved flexural and impact strengths. This work offers a viable idea for designing bio-based PAbz@PBA hybrids and preparing IFR epoxy coatings with various excellent properties.