Enhancing flame retardancy, anti‐impact, and corrosive resistance of TPU nanocomposites using surface decoration of α‐ZrP.

The development of polyurethane composites with significant flame retardancy and corrosion resistance for widening its practical application is a great importance. In this study, supramolecular wrapped α‐ZrP (MCP@ZrP) was prepared via self‐assembly of melamine, cobalt ions (Co2+) and phytic acid (PA) on the surfaces of α‐zirconium phosphate (α‐ZrP). It was found that both compatibility and dispersion of α‐ZrP sheets in thermoplastic polyurethane (TPU) matrices were improved with the incorporation of organic supramolecular components in TPU/MCP@ZrP nanocomposites. Moreover, their fire‐retardant characteristic was significantly enhanced, along with effective suppression of smoke and toxic gas emission. By adding 5 wt% MCP@ZrP, peak heat release rate, total heat release, total smoke production, and total CO production of such nanocomposites were reduced by 35.66%, 18.01%, 15.52%, and 41.42%, respectively. The generation of a continuous and dense char layer benefited from well‐dispersed MCP@ZrP nanohybrids, which resulted in tortuous effect to impede heat diffusion and prevent the evaporation of volatile gasses. By means of the barrier effect of ZrP, TPU/MCP@ZrP composite films also showed improved anticorrosion performance. Effective interfacial adhesion, achieved by combining MCP supermolecules and α‐ZrP sheets, offers a viable approach to improve protective properties of TPU nanocomposites. Highlights: Supramolecular‐wrapped α‐ZrP was prepared via self‐assembly strategy.MCP@ZrP showed good dispersion and interface adhesion within TPU matrices.MCP@ZrP enhanced the flame retardancy and mechanical performance of TPU.MCP@ZrP preventing smoke and toxic gas evaporation. [ABSTRACT FROM AUTHOR]