Rigid polyurethane foams were prepared by the one-step expandable foam method using casting molding followed by forming clay-based composites. Polyurethane/vermiculite foam composites (PU/VMT) were controlled based on adding the percentage of clay in the formulation. The effects of composite modifications were evaluated by X-ray diffraction (XRD), thermogravimetric analysis (TG/DTG), and scanning electron microscopy (SEM/EDS) applied to the flame retardancy explored by the vertical burn test. The results indicated that adding clay controlled the particle size concerning polyurethane (PU) foams. However, they exhibited spherical structures with closed cells with relatively uniform distribution. XRD analysis showed the peaks defined at 2θ = 18° and 2θ = 73° relative to the crystallinity in formation and interaction of rigid segments were identified, as well as the influence of crystallinity reduction in composites. In the flame test, the flame retardant surface was successful in all composites, given the success of the dispersibility and planar orientation of the clay layers and the existence of an ideal content of vermiculite (VMT) incorporated in the foam matrix.
Keywords: flame retardant; polymer–clay composites; polyurethane foams.