One-Pot Synthesis of Silicone-Urethane Hybrid Foam and Comparison of Flame Retardant, Rheological, and Mechanical Properties with Polyurethane Foam.

This study presents the design and fabrication of silicone-urethane hybrid foam (SUF) to improve fire safety in transportation seating. Tin(II) 2-ethylhexanoate (Sn(OCT)) was used to catalyze reactions between bifunctional isocyanates, polyols, and vinyl-terminated PDMS, enabling simultaneous curing and foaming. Sn(OCT) effectively facilitated both the foaming and gelation processes of silicone and urethane chemistries. The resulting SUF demonstrated a 44.55% reduction in peak heat release rate (PHRR) compared to UF, due to the PDMS network's synergistic flame-retardant and barrier effects. Additionally, the crosslinked PDMS structure maintained strong mechanical integrity. This study offers a simple and effective approach for producing SUF with enhanced fire safety.