Aluminium Hydroxide/Graphene-reinforced Rigid Polyurethane Foam Hybrid Composites

Abstract

In this study, rigid polyurethane foams (RPUF) were successfully modified using 30 wt.% aluminium hydroxides (ATH), 1.0 pphp silicone surfactant, and different concentrations of graphene, using a one-shot one-step foaming method. This study aims to improve the compressive strength, flame retardancy, and thermal properties of RPUF by creating a synergistic effect between ATH and graphene in fire-retardant RPUF hybrid composites. The effects of a fixed amount of ATH and silicone surfactant and various loadings of graphene on RPUF were investigated. The results show that 0.5 wt.% graphene loading confers the best compression performance on the hybrid composite. Their compressive strength value of 12.58 KPa was higher than virgin RPUF (4.07 KPa) and RPUF/ATH (9.89 KPa). FTIR confirmed the functional groups in the virgin RPUF but could not identify new functional groups in most modified composites. The smallest amount of graphene addition (0.5 wt.%) produced a more stable hybrid composite structure. At 3.0 wt.% graphene addition, the maximum decomposition temperature of the RPUF/ATH hybrid composite was recorded (539oC), which was enhanced by 50% compared to virgin RPUF (296oC), and the highest char residue of 17.46% was observed. The incorporation of graphene enhanced the thermal firmness of the hybrid composite. The study also revealed an enhancement in the fire resistance of the hybrid composite. The LOI and UL-94 results showed that incorporating 3.0 wt.% enables increased LOI value and V-0 classification compared to virgin samples. This hybrid composite can be used in high-performance building insulation applications.