Novel multifunctional DOPO-containing polyaniline for highly efficient flame retardance and static electricity control for rigid polyurethane foam

DPA@NC, a novel material, was developed by conjugating polyaniline with DOPO and needle coke (NC). It was subsequently incorporated into rigid polyurethane foam (RPUF) to enhance its anti-static electricity and flame retardancy properties. This study aimed to provide insights into the chemical composition, morphology, and volume resistivity of DPA@NC. The introduction of DPA@NC into RPUF resulted in a composite with significantly reduced volume resistivity, measuring at 6.34×107 Ω·cm-1. Furthermore, the incorporation of 25 wt.% of DPA@NC remarkably improved the flame retardancy of the RPUF composite, achieving an HB rating in the horizontal combustion test and the limiting oxygen index of 27.2 %. The DPA@NC could significantly increase the ignition time by 333 % and reduce the peak heat release rate and total heat release to 321.6 kW/m2 and 101.8 MJ/m2, respectively. By investigating the flame retardant mechanism, the as-developed DPA@NC played important roles in both condensed and gaseous states. Overall, the DPA@NC represented a promising candidate to broaden the applicability of RPUF in modern smart electronic devices.