Impact of Nanoclay on Fire Retardancy and Environental Durability of Post Consumer Carpet Composites

Abstract

A simple vacuum assisted resin transfer molding (VARTM) process was previously used to scale-up the fabrication of large-size composite specimens from recycled post-consumer waste carpet. These composites exhibited superior mechanical and sound absorption properties compared to other types of infrastructure materials such as wood, concrete and particleboard. The process is simple and can be used with different resin types ranging in cost (polyurethane, polyester, epoxy, and vinyl ester). Environmental degradation and fire retardancy of these composites are potential limitations to their use as infrastructure materials. To enhance their fire retardancy and to protect against environmental degradation, the composites were coated with epoxy resin containing 4 % organoclay (I.28E) and also fabricated by VARTM infusion by infusing the carpet samples with epoxy resin containing 4 % nanoclay. Tests included fire retardancy tests using ASTM D 635 and exposure to moisture and alternating cycle of UV and condensation followed by mechanical testing. The fire retardancy and change in mechanical properties after UV/ moisture exposure of clay-epoxy-carpet composites were compared with baseline samples of carpet composites infused only with epoxy. It was observed that nanoclay coated and clay-epoxy infused carpet composites improved fire retardancy and resisted degradation due to UV and environmental exposure, as evidenced by nearly consistent mechanical properties.