Flexible water-resistant intumescent coatings: Fabrication, characterization, and fire protective performance

In this study, a flexible water-resistant fire protective coating was fabricated by dip-coating with hyperbranched polyester (HBPE), polyvinyl formal-acetal (PVFA) and HBPE-modified ammonium polyphosphate (APP). HBPE with terminal carboxyl groups, generally being toughening additive, now was used as the surface modifier, film-forming agent and charring agent in this article. The slippery polypropylene (PP) was taken as the substrate to investigate the adhesion and fire protection performance of the coating. The plasma treatment enhanced the surface energy of PP, the hydrogen bonds between the coating and the substrate improved the adhesion, and the cooperation of HBPE and PVFA achieved the flexibility of the flame-retardant coating. Covered with a coating in an average thickness of 180 mu m the limiting oxygen index (LOI) of PP reached 32.2%, with an increase of 78.9%, and the vertical burning test (UL-94) passed V-0 rating. Cone calorimeter test (CCT) showed that peaks of heat release rate (HRR) and smoke production rate (SPR) were reduced by 79.5% and 60.4%, respectively. The structures of P-O-C, P-O-Si and P-O-Phi formed during the thermal decomposition, leading to a stable char layer. All these results show that intumescent coating is of high efficiency in flame retardant and smoke suppression performance.