Exploring catalytic carbonization of MXene-encased fiber coatings for exceptionally flame-retarded flexible polyurethane foams

Flexible polyurethane foams (FPU) are widely used in heat insulation but pose fire risks due to their flammability. In this study, we specifically introduce a novel flame-retardant coating for FPU based on MXene-encased aramid fibers (ANF@MXene). This coaxial cable structure, with MXene nanosheets “bridging” on the PDA modified ANF surface, is applied to FPU using an impregnation method. The hollow tubular MXene structures formed during pyrolysis and combustion enhance fire safety by promoting the generation of a graphitic carbon layer to some extent. Through dip-coating of ANF@MXene onto the surface of FPU, we observed a significant improvement in flame retardancy and smoke suppression of composite FPU. This method presents a promising strategy for fabricating highly fire-safe FPU, paving the way for advanced fire protection solutions across various industries.