3D printed sandwich materials filled with hydrogels for extremely low heat release rate.

Additive manufacturing is a powerful tool to design materials with original properties. An innovative design of poly (Ethylene Vinyl Acetate) (EVA) containing 30 wt.-% of Aluminum TriHydroxide (ATH) was reported in a previous paper and liquids (water or potassium carbonate aqueous solution) were incorporated in the 3D printed structure. These multi-materials showing interesting properties, but stability, control and processing of these liquid-containing systems were an issue due to porosity of the polymeric matrix. To overcome this issue, the use of hydrogels is considered in this study: being either solid or highly viscous, hydrogels can retain water in the design, despite the high porosity of the EVA/ATH matrix. In this paper, the liquid phase was substituted by flame retardant hydrogels (based on agar, alginate or poly (vinyl alcohol) - PVA), containing in particular vermiculite platelets and for the hydrogel based on alginate, K 2 CO 3 as flame retardant fillers. Excellent behavior under a 50 kW/m2 heat flux during a cone calorimeter test was obtained, with fast extinguishment of the flame and a low peak of Heat Release Rate (pHRR) and Total Heat Release (THR). The physical barrier formed by vermiculite platelets during the test, as well as the condensed phase mechanism of K 2 CO 3 were found to be responsible for these excellent results, as found by confocal microscopy observations, electron probe micro analysis and X-Ray diffraction experiments. Image 1 • New concept of flame retardant sandwich 3D printed materials. • Creation of biphasic material containing hydrogel. • Action in gas (K 2 CO 3) and condensed (clay and K 2 CO 3) phases. [ABSTRACT FROM AUTHOR]