Cobalt-doped iron-based Prussian blue analogue cubes anchored to phosphorus‑nitrogen-covered BN surfaces for enhancing the flame retardancy of epoxy coatings

Abstract

Prussian blue analogue (PBA) is considered to be a very promising inorganic nano-flame retardant material due to its structure enriched with transition metal elements. Here, hexachlorocyclotriphosphazene (HCCP) and p-phenylenediamine (p-PDA) were first loaded onto the boron nitride surface (BN/PCP) via a polymerization reaction to impart richer flame retardant characteristics. Then, Co-Fe-based PBA nanoparticles were homogeneously anchored on the BN/PCP surface to obtain the BN/PCP@PBA hierarchical nano-flame retardant. It is worth mentioning that this novel composite flame retardant effectively combined the superior barrier properties of BN, fire retardancy of N, P elements and the accelerated carbon conversion effect of Co-Fe/PBA. The test results showed that the loading of PCP on the BN surface could effectively improve the thermal insulation performance of EP, while Co-Fe/PBA had good catalytic carbon formation effect at high temperature. Specifically, the backside of the BN/PCP@PBA filled EP sample displayed the lowest temperature during flame attack (164.1 °C) compared to the other specimens, proving its best thermal insulation. The BN/PCP@PBA/EP obtained the maximum expansion height and expansion rate values (27.6 mm and 21.07) in the furnace chamber experiments, which are crucial for its fire resistance. In addition, BN/PCP@PBA/EP retained the highest residual char (32.6 %) and achieved the lowest smoke density rating (36.9 %), demonstrating its high carbon conversion and fume suppression. Carbon residue analysis confirmed that the char layer of BN/PCP@PBA/EP was more complete and the metal oxides were uniformly embedded in the carbon residue skeleton, which ensured good flame protection for the substrate.