Layer-by-layer deposition of a TiO2-filled intumescent coating and its effect on the flame retardancy of polyamide and polyester fabrics

Use of intumescent flame-retardant systems in epoxy adhesives for debonding purpose

This work investigates the use of intumescent flame-retardant additives as a new debonding solution to disassemble bonded aluminum substrates. Melamine polyphosphate (MPP) or ammonium polyphosphate (APP) was incorporated into an epoxy adhesive joint as both an acid source and a swelling agent with this stimulus responsive behavior being triggered by heating. The ability of the system containing intumescent additives to swell and foam under heat radiation was efficiently exploited to provide enough local pressure to induce porosities and cracks at the interface, facilitating the disassembling of bonded aluminum substrates. Several aluminum/intumescent-epoxy/aluminum laminates were assembled and tested to assess the influence of the MPP and APP content on the mechanical strength of the joints. The structural, morphological, mechanical, and thermal properties of these modified epoxy resins and assemblies with aluminum substrates were studied using Scanning Electron Microscopy (SEM), a pull-off test, Differential Scanning Calorimetry (DSC), and Thermogravimetric Analysis (TGA). The ability of the intumescent-modified joints to support temperature-controlled debonding was evaluated using an oven. The lower debonding temperatures found were comparable to laminates with unmodified epoxy joint systems. Our patented debonding on-demand technology, based on an intumescent flame-retardant system, represents a promising treatment for multi-material structures and will enable products to be recycled at the end of their service life.

Micro crystalline cellulose aided surface modification and deposition of green polyelectrolytes for the improved hydrophilicity and flame retardancy of polyamide 66 fabric

In this work, microcrystalline cellulose (MCC) treated polyamide 66 (PA66) textiles were coated with green and naturally abundant polysaccharides specifically, chitosan (CS) and sodium alginate (SA) together with phytic acid (PA) via layer by layer (LbL) deposition. The prime focus of such treatment was to intensify both the hydrophilic and flame retardant properties of PA66 fabric substrates. Subsequently, the prepared coatings were further subjected to cross-linking modification by dipping them into the barium (Ba) salt solution. Obtained results indicated that the MCC-modified PA66 exhibited a water contact angle (WCA) value of 00 and revealed a drop in peak heat release rate (pHRR) up to 31 % with complete suppression of melt-dripping. Meanwhile, the Ba-ion-induced cross-linking treatment further escalated this reduction up to 36 % by adding enhanced thermal stability, improved char quality along better wash durability of as prepared coatings. In addition, the combined modification of PA66 textiles with MCC and Ba-ion handed a superb enhancement of physical properties like tensile strength by ca. 50 % compared to the pure PA66. Thus, this MCC-assisted surface modification paves the way for a new kind of greener treatment of PA66 textiles in attaining superior hydrophilic and flame retardant properties of the same.

Advanced Flame-Retardant Methods for Polymeric Materials

Most organic polymeric materials have high flammability, for which the large amounts of smoke, toxic gases, heat, and melt drips produced during their burning cause immeasurable damages to human life and property every year. Despite some desirable results having been achieved by conventional flame-retardant methods, their application is encountering more and more difficulties with the ever-increasing high flame-retardant requirements such as high flame-retardant efficiency, great persistence, low release of heat, smoke, and toxic gases, and more importantly not deteriorating or even enhancing the overall properties of polymers. Under such condition, some advanced flame-retardant methods have been developed in the past years based on "all-in-one" intumescence, nanotechnology, in situ reinforcement, intrinsic char formation, plasma treatment, biomimetic coatings, etc., which have provided potential solutions to the dilemma of conventional flame-retardant methods. This review briefly outlines the development, application, and problems of conventional flame-retardant methods, including bulk-additive, bulk-copolymerization, and surface treatment, and focuses on the raise, development, and potential application of advanced flame-retardant methods. The future development of flame-retardant methods is further discussed.

Layer-by-Layer Self-Assembly Coating for Multi-Functionalized Fabrics: A Scientometric Analysis in CiteSpace (2005-2021)

Surface-engineered coatings have been increasingly applied to functionalize fabrics due to the ease of deposition of the coatings and their effectiveness in endowing the fabric with abundant properties. Among the surface modification methods, layer-by-layer (LbL) self-assembly has emerged as an important approach for creating multifunctional surfaces on fabrics. In this review, bibliometric analysis with the visualization analysis of LbL self-assembly coatings on fabrics was performed on publications extracted from the Web of Science (WOS) from 2005 to 2021 based on the CiteSpace software. The analysis results showed that research on LbL self-assembly coatings on fabrics has attracted much attention, and this technique has plentiful and flexible applications. Moreover, research on the LbL self-assembly method in the field of functionalization of fabrics has been summarized, which include flame retardant fabric, antibacterial fabric, ultraviolet resistant fabric, hydrophobic fabric and electromagnetic shielding fabric. It was found that the functionalization of the fabric has been changing from singularity to diversification. Based on the review, several future research directions can be proposed. The weatherability, comfort, cost and environmental friendliness should be considered when the multifunctional coatings are designed.

Layer-by-Layer Deposition: A Promising Environmentally Benign Flame-Retardant Treatment for Cotton, Polyester, Polyamide and Blended Textiles

A detailed review of recent developments of layer-by-layer (LbL) deposition as a promising approach to reduce flammability of the most widely used fibers (cotton, polyester, polyamide and their blends) is presented. LbL deposition is an emerging green technology, showing numerous advantages over current commercially available finishing processes due to the use of water as a solvent for a variety of active substances. For flame-retardant (FR) purposes, different ingredients are able to build oppositely charged layers at very low concentrations in water (e.g., small organic molecules and macromolecules from renewable sources, inorganic compounds, metallic or oxide colloids, etc.). Since the layers on a textile substrate are bonded with pH and ion-sensitive electrostatic forces, the greatest technological drawback of LbL deposition for FR finishing is its non-resistance to washing cycles. Several possibilities of laundering durability improvements by different pre-treatments, as well as post-treatments to form covalent bonds between the layers, are presented in this review.

Macro and micro thermal investigation of nanoarchitectonics-based coatings on cotton fabric using new quaternized starch

Implementation of a new cationizing reagent and its incorporation onto the backbone of starch was performed successfully, confirmed from the remarkable micro- and macro anti-flammable properties. The morphologies and localized compositional analysis of the modified starch-based LBL coatings on the cotton surface were carried out using LV-SEM and EDX: highly uniform coating layers and uptake of solution species for intermediate implant reagent concentrations were confirmed. The subject samples were further analyzed through thermogravimetric analysis (TGA), microcombustion experiments (MCC), flame testing (VFT) and afterburn measurements. The peak range of the degradation was highly improved from the lower range to the higher range (329.92–394.48 °C), together with significant mass residue for TBAB-0.7–17.02%. Moreover, a significant decrease in the absolute heat loss (THR ∼ 30%), heat dissipation competence (HRC ∼ 27.86%), and peak heat output (PHRR ∼ 23%) was achieved for a TBAB loading of ∼0.7 g. The results were further confirmed from the increase in the limiting oxygen index (LOI) to a higher rate of ∼23.2, improved structural integrity and higher quality of char obtained in the VFT and after-burn analysis.

Schematic diagram of the cationization of starch, LBL layering and resistance against flame.

LBL generated fire retardant nanocomposites on cotton fabric using cationized starch-clay-nanoparticles matrix

In this work, starch-clay-TiO₂-based nanocomposites were deposited on cotton fabric through layer-by-layer (LBL) process and their effect on the flame retardancy, inhibition of pyrolysis and combustion processes were discussed in details. Polyelectrolyte solutions/suspensions of cationized starch and VMT (vermiculite)/TiO₂ nanoparticles were used to deposit these nanocomposites in the form of multi-layered coatings (5, 7, 10 and 15 bilayers). Uniform fabric coverage and presence of electrolytes was imaged by scanning electron microcopy (LV-SEM), attenuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR) and EDX characterizations. The greatest pyrolysis reduction was found for the StVT-7 sample (7 bilayers); ~30% and 21%, based on microscale combustion calorimetry (MCC) and thermogravimetric analysis (TGA). When using MCC, the improved values of the PHRR ~ 193 W/g, THR ~ 10.7 kJ/g), HRC ~ 390 J/g∙K and LOI ~ 22.2% were found for the StVT-7 sample which was strongly supported by the UL-94 test.

Flame-Retardant Wood Composites Based on Immobilizing with Chitosan/Sodium Phytate/Nano-TiO2-ZnO Coatings via Layer-by-Layer Self-Assembly

Composite coatings of inorganic nanomaterials with polyelectrolytes are promising materials for wood modification. Endowing wood with flame retardancy behavior can not only broaden the range of applications of wood, but also improve the safety of wood products. In this work, chitosan/sodium phytate/TiO2-ZnO nanoparticle (CH/SP/nano-TiO2-ZnO) composite coatings were coated on wood surface through layer-by-layer self-assembly. The morphology and chemical composition of the modified wood samples were analyzed using scanning electron microscopy and energy dispersive spectrometry. The thermal degradation properties and flame retardancy of the samples treated with different assembly structures were observed by thermogravimetric analysis, limiting oxygen test, and combustion test. Due to the presence of an effective intumescent flame retardant system and a physical barrier, the CH/SP/nano-TiO2-ZnO coatings exhibited the best flame retardant performance and required only approximately six seconds for self-extinguishing. The coated samples had a limiting oxygen index of 8.4% greater than the original wood.

Enzymatic Modification of Polyamide for Improving the Conductivity of Water-Based Multilayer Nanocoatings

Enzymatic modification, using a protease from Bacillus licheniformis (Subtilisin A), was carried out on polyamide 6.6 (PA6.6) fabric to make it more amenable to water-based nanocoatings used to impart electrical conductivity. The modified PA6.6 fibers exhibit a smoother surface, increased hydrophilicity due to more carboxyl and amino groups, and larger ζ-potential relative to unmodified polyamide. With its improved hydrophilicity and surface functionality, the modified textile is better able to accept a water-based nanocoating, composed of multiwalled carbon nanotubes (MWCNT) stabilized by sodium deoxycholate (DOC) and poly(diallyldimethylammonium chloride) (PDDA), deposited via layer-by-layer assembly. Relative to unmodified fabric, the enzymatically modified fibers exhibit lower sheet resistance as a function of PDDA/MWCNT-DOC bilayers deposited. This relatively green technique could be used to impart a variety of useful functionalities to otherwise difficult-to-treat synthetic fibers like polyamide.

Investigation of Flame Retardant Flexible Polyurethane Foams Containing DOPO Immobilized Titanium Dioxide Nanoparticles

In this work, a multi-functional nanoparticle (TiO₂-KH570-DOPO) has been successfully synthesized through the attachment of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO)-methacryloxy propyl trimethoxyl silane on the surface of titanium dioxide (TiO₂). Supercritical carbon dioxide was used as the solvent in order to increase the grafting level. The chemical structure of TiO₂-KH570-DOPO was fully characterized using Fourier transform infrared spectra, thermogravimetric analysis and transmission electron microscopy. The modified TiO₂ was incorporated into flexible polyurethane foam (FPUF). The fire performance of FPUF blends was evaluated using microscale combustion calorimetry. Peak heat release rate and total heat release values were reduced from 657.0 W/g and 28.9 kJ/g for neat FPUF sample to 519.2 W/g and 26.8 kJ/g of FPUF specimen containing 10 wt % of TiO₂-KH570-DOPO. Analysis of thermal stability and the observation of char formation suggests that TiO₂-KH570-DOPO is active in the condensed phase.

Surface Coating for Flame Retardancy and Pyrolysis Behavior of Polyester Fabric Based on Calcium Alginate Nanocomposites

A polyester fabric, coated with calcium alginate and nano-calcium borate composites (CAB-PL), was fabricated by a post-cross-linking method, with remarkable improvement of flame retardancy and thermal stability, as compared with the original polyester fabric (PL). The mechanical properties of CAB-PL and PL were studied, and characterizations and tests including Fourier transform infrared spectrum (FTIR), scanning electron microscopy (SEM), limiting oxygen index (LOI), cone calorimetry (CONE) and thermogravimetric analysis (TGA) were employed to evaluate the flame retardancy and thermostability. The test results of CAB-PL showed excellent mechanical strength and anti-dripping properties. In comparison with PL, TGA results indicate that the presence of surface-coated composites produced more char residue and can effectively inhibit the heat transmission, and the LOI value of CAB-PL was improved from 25 to 33. Moreover, CONE results show that 88.65% reduction of total smoke release (TSR) values was induced by the presence of CAB. In addition, the possible pyrolysis mechanisms for CAB-PL have been proposed based on the results of pyrolysis-gas chromatography⁻mass spectrometry (Py-GC-MS) analysis. The combined results can provide useful information for understanding the flame retardant mechanisms of alginates as well. In summary, polyester fabric was upgraded by coating it with the calcium alginate/nano-calcium borate, thus achieving extraordinary flame retardancy and thermal stability for various applications within the textile industry.

Recent Advances in the Design of Water Based-Flame Retardant Coatings for Polyester and Polyester-Cotton Blends

Over the last ten years a new trend of research activities regarding the flame retardancy of polymeric materials has arisen. Indeed, the continuous search for new flame retardant systems able to replace the traditional approaches has encouraged alternative solutions, mainly centred on nanotechnology. In this context, the deposition of nanostructured coatings on fabrics appears to be the most appealing and performance suitable approach. To this aim, different strategies can be exploited: from the deposition of a single monolayer consisting of inorganic nanoparticles (single-step adsorption) to the building-up of more complex architectures derived from layer by layer assembly (multi-step adsorption). The present paper aims to review the application of such systems in the field of polyester and polyester-cotton blend fabrics. The results collated by the authors are discussed and compared with those published in the literature on the basis of the different deposition methods adopted. A critical analysis of the advantages and disadvantages exhibited by these approaches is also presented.

Nanomaterials for Functional Textiles and Fibers

Nanoparticles are very interesting because of their surface properties, different from bulk materials. Such properties make possible to endow ordinary products with new functionalities. Their relatively low cost with respect to other nano-additives make them a promising choice for industrial mass-production systems. Nanoparticles of different kind of materials such as silver, titania, and zinc oxide have been used in the functionalization of fibers and fabrics achieving significantly improved products with new macroscopic properties. This article reviews the most relevant approaches for incorporating such nanoparticles into synthetic fibers used traditionally in the textile industry allowing to give a solution to traditional problems for textiles such as the microorganism growth onto fibers, flammability, robustness against ultraviolet radiation, and many others. In addition, the incorporation of such nanoparticles into special ultrathin fibers is also analyzed. In this field, electrospinning is a very promising technique that allows the fabrication of ultrathin fiber mats with an extraordinary control of their structure and properties, being an ideal alternative for applications such as wound healing or even functional membranes.