MXene/chitosan nanocoating for flexible polyurethane foam towards remarkable fire hazards reductions

MXene/chitosan nanocoating for flexible polyurethane foam (PUF) was prepared via layer-by-layer (LbL) approach. MXene (Ti₃C₂) ultra-thin nanosheets were obtained through etching process of Ti₃AlC₂ followed by exfoliation. The deposition of MXene/chitosan nanocoating was conducted by alternatingly immersing the PUF into a chitosan solution and a Ti₃C₂ aqueous dispersion, which resulted in different number of bilayers (BL) ranging from 2, 5 and 8. Owing to the utilization of ultra-thin Ti₃C₂ nanosheets, the weight gain was only 6.9% for 8 BL coating of PUF, which minimised the unfavourable impact on the intrinsic properties of PUF. The Ti₃C₂/chitosan coating significantly reduced the flammability and smoke releases of PUF. Compared with unmodified PUF, the 8 BL coating reduced the peak heat release rate by 57.2%, alongside with a 65.5% reduction in the total heat release. The 8 BL coating also showed outstanding smoke suppression ability with total smoke release decreased by 71.1% and peak smoke production rate reduced by 60.3%, respectively. The peak production of CO and CO₂ gases also decreased by 70.8% and 68.6%, respectively. Furthermore, an outstanding char formation performance of 37.2 wt.% residue was obtained for 8 BL coated PUF, indicating the excellent barrier and carbonization property of the hybrid coating.