Environmentally benign flame retardant nanocoating for PIR foam
A water-based polyelectrolyte complex nanocoating designed for PIR foam insulation offers enhanced flame retardancy while maintaining high thermal insulation (R-value). This environmentally benign, lightweight coating meets stringent fire safety standards and is commercially viable.
Overview
This innovative nanocoating technology is designed to enhance the fire resistance of polyisocyanurate (PIR) foam used in insulation applications. Developed by Texas A&M University, the water-based polyelectrolyte complex coatings range from 100 to 1000 nm in thickness. These coatings are applied through either dip or spray coating methods and are engineered to meet strict fire safety standards, including Class A fire ratings per UL790 and ASTM E84, as well as the ASTM E136 non-combustibility standard. The coating maintains a high R-value of 7 or greater per inch, ensuring effective thermal insulation while offering self-extinguishing properties. The environmentally benign nature of the coating makes it a sustainable choice for insulation applications.
Technical specifications
- Composition: The coatings are based on intumescent and ceramic-generating technologies using phosphate, boron, and nitrogen-rich polyelectrolytes.
- Application methods: Dip coating and spray coating ensure easy and efficient application to PIR foam.
- Testing and validation: Characterization techniques include electron microscopy, x-ray photoelectron spectroscopy, dynamic mechanical analysis, and thermogravimetric analysis. Flame retardant behavior is assessed using cone calorimetry and torch testing.
- Environmental impact: The coatings are lightweight and environmentally benign, offering a sustainable solution without compromising performance.
Technology readiness level
This technology has reached Technology Readiness Level 6, indicating it has been demonstrated in a relevant environment and is nearing commercial viability. Further in-house evaluations and optimizations are ongoing to enhance adhesion and performance.
About Texas A&M University, College Station
Texas A&M University in College Station is a comprehensive public research university and the flagship of The Texas A&M University System, combining broad academic strengths with a strong applied‑research culture. Industry collaborates on the Texas A&M‑RELLIS campus—an integrated education, research and testing environment that supports large‑scale experimentation and proving grounds—and through the Texas A&M Transportation Institute’s facilities in Bryan‑College Station. A statewide extension network connects university expertise to companies and communities across all Texas counties, enabling rapid piloting and deployment. Research is supported by competitive federal funding from agencies such as NSF, NIH, DOE, USDA and DoD, alongside state and industry sponsorship. Texas A&M Innovation provides IP management, licensing and commercialization pathways across the system.
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