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Improving the flame retardancy of polymeric materials is an imperative yet challenging task without deteriorating their intrinsic properties. Herein, we reported a facile approach to grow zinc-aluminum layered double hydroxide (Zn-Al LDH) nanostructures on the surfaces of polymer substrates in order to overcome their high fire hazards. CO2 induced growth of Zn-Al LDH allowed slow and homogeneous nucleation, leading to the as-synthesized Zn-Al LDH with ultra-large size (several microns) and perfect hexagonal shape. The Zn-Al LDH uniformly covered the surfaces of substrates and provided excellent flame-retardant effect. Cone calorimeter measurements revealed that the peak heat release rate of Zn−Al LDH-coated wood and rigid polyurethane foam (RPUF) were significantly decreased by 55% and 51%, respectively, compared to those of the pristine wood and RPUF; also, Zn−Al LDH-coated wood and RPUF showed notable reduction in total smoke production up to 47% and 28%, respectively. These findings demonstrate that CO2 induced synthesis of Zn-Al LDH nanostructures is a feasible and effective solution to polymeric materials with desirable flame-retardant and smoke-suppression properties.

CO2 Induced Synthesis of Zn-Al Layered Double Hydroxide Nanostructures towards Efficiently Reducing Fire Hazards of Polymeric Materials