Inorganic nanoparticle thin film that suppresses flammability of polyurethane with only a single electrostatically-assembled bilayer.

In an effort to reduce the flammability of polyurethane foam, a thin film of renewable inorganic nanoparticles (i.e., anionic vermiculite [VMT] and cationic boehmite [BMT]) was deposited on polyurethane foam via layer-by-layer (LbL) assembly. One, two, and three bilayers (BL) of BMT-VMT resulted in foam with retained shape after being exposed to a butane flame for 10 s, while uncoated foam was completely consumed. Cone calorimetry confirmed that the coated foam exhibited a 55% reduction in peak heat release rate with only a single bilayer deposited. Moreover, this protective nanocoating reduced total smoke release by 50% relative to untreated foam. This study revealed that 1 BL, adding just 4.5 wt % to PU foam, is an effective and conformal flame retardant coating. These results demonstrate one of the most efficient and renewable nanocoatings prepared using LbL assembly, taking this technology another step closer to commercial viability.

Oxygen barrier of multilayer thin films comprised of polysaccharides and clay.

Multilayered thin films of chitosan (CH), carrageenan (CR) and montmorillonite (MMT) clay, deposited using the layer-by-layer technique, were studied in an effort to produce fully renewable polysaccharide-based thin films with low oxygen permeability. Ten 'trilayers' of CH/MMT/CR (<40 nm thick) on PET film reduced its oxygen permeability (1.76×10(-15) cm(3) cm/cm(2) s Pa) by an order of magnitude under dry conditions. By adding an additional layer of CH to the trilayer sequence, a 'quadlayer' film of CH/CR/CH/MMT (<60 nm thick) was created, which was able to reduce oxygen permeability of PET by two orders of magnitude under the same conditions. This high oxygen barrier is believed to be due to the unique nanostructure of these films, often referred to as a "nanobrick wall" structure, as well as a strong association amongst the oppositely charged polysaccharides. Combining fully renewable and food contact approved ingredients with high gas barrier and optical transparency makes this technology promising as a foil replacement for food packaging.

Clay-chitosan nanobrick walls: completely renewable gas barrier and flame-retardant nanocoatings.

Thin films prepared via a layer-by-layer (LbL) assembly of renewable materials exhibit exceptional oxygen barrier and flame-retardant properties. Positively charged chitosan (CH), at two different pH levels (pH 3 and pH 6), was paired with anionic montmorillonite (MMT) clay nanoplatelets. Thin-film assemblies prepared with CH at high pH are thicker, because if the low polymer charge density. A 30-bilayer (CH pH 6-MMT) nanocoating (~100 nm thick) reduces the oxygen permeability of a 0.5-mm-thick polylactic acid film by four orders of magnitude. This same coating system completely stops the melting of a flexible polyurethane foam, when exposed to direct flame from a butane torch, with just 10 bilayers (~30 nm thick). Cone calorimetry confirms that this coated foam exhibited a reduced peak heat-release rate, by as much as 52%, relative to the uncoated control. These environmentally benign nanocoatings could prove beneficial for new types of food packaging or a replacement for environmentally persistent antiflammable compounds.