Crystallization of sodium metaborate on the surface of layered double hydroxide imparts high flame retardancy properties to epoxy coatings

Abstract

To address the phenomenon of rapid fire spread in high-rise steel buildings, this paper used the in situ growth method to crystallize sodium metaborate (SMB) on the surface of layered double hydroxide (LDH) and grafted Ti-O onto LDH@SMB hybrid material by hydroxyl action. The synthesized LDH@SMB@Ti (LST) hybrid material was then doped into epoxy resin (EP) to prepare a composite coating. The fire test showed that the LST/EP coating makes the steel plate reach a stable temperature in a shorter time, so that the plate temperature did not continue to rise, and the temperature on the back side of the plate was stabilized at 172.9 °C, which was 87.4 °C lower compared to pure EP. This proves that the LST material gives the coating stronger fire retardant properties upfront and strengthens the continuous insulation ability of the char layer. Cone calorimeter tests showed that the total heat release rate (THR) of LST/EP was reduced by 47.3% and the total smoke release rate (TSR) was reduced by 45.4%, proving the excellent fire and smoke suppression performance of LST/EP. In the expansion performance test, the expansion height and expansion rate of LST/EP reached 29.90 mm and 23.36 respectively, and the expansion of char layer was more uniform. This indicates that the addition of LST hybrid material can improve the mechanical strength of char layer and attenuate the heat transfer rate in the vertical direction. The residual char of LST/EP was 33.2% by thermogravimetric analysis, indicating that the addition of LST could reduce the volatilization of volatile components and improve the thermal stability of EP.