Developments in flame retardants for heat and fire resistant textiles—the role of char formation and intumescence

Surface Modification of Ammonium Polyphosphate for Enhancing Flame-Retardant Properties of Thermoplastic Polyurethane

Currently, the development of efficient and environmentally friendly flame-retardant thermoplastic polyurethane (TPU) composite materials has caused extensive research. Ammonium polyphosphate (APP) is used as a general intumescent flame retardant to improve the flame retardancy of TPU. In this paper, we developed a functionalized APP flame retardant (APP-Cu@PDA). Adding only 5 wt% of APP-Cu@PDA into TPU can significantly improve the flame-retardant's performance of the composite material, reflected by a high LOI value of 28% with a UL-94 test of V-0 rating. Compared with pure TPU, the peak heat release rate, total heat release, peak smoke release rate, and total smoke release were reduced by 82%, 25%, 50%, and 29%, respectively. The improvements on the flame-retardant properties of the TPU/5%APP-Cu@PDA composites were due to the following explanations: Cu²⁺-chelated PDA has a certain catalytic effect on the carbonization process, which can promote the formation of complete carbon layers and hinder the transfer of heat and oxygen. In addition, after adding 5% APP-Cu@PDA, the tensile strength and elongation at the break of TPU composites did not decrease significantly. In summary, we developed a new flame-retardant APP-Cu@PDA, which has better flame-retardant properties than many reported TPU composites, and its preparation process is simple and environmentally friendly. This process can be applied to the industrial production of flame retardants in the future.

Facile preparation of uniform polydopamine particles and its application as an environmentally friendly flame retardant for biodegradable polylactic acid

The demand for environmentally benign flame retardants for biodegradable polymers has become particularly necessary due to their inherently “green” nature. This work reports intrinsically non-toxic polydopamine (PDA) particles as an efficient and environmentally friendly flame retardant for polylactic acid (PLA). 5 wt% PDA loading resulted in a 22% reduction in the peak heat release rate, 34.7% increase in the fire performance index, and lower CO2 production compared to neat PLA. A limiting oxygen index (LOI) value of 27.5% and a V-2 rating was achieved in the UL-94 vertical burning test. Highly aggregated amorphous particulate char was formed with the increasing content of PDA, and a significant reduction in evolved pyrolysis gaseous products was achieved for the PLA/PDA composites as compared with control PLA. This work provides important insight into the potential commercial application of PDA alone as an efficiently green, environmentally benign flame retardant for bioplastic PLA.

A Flame-Retardant Phytic-Acid-Based LbL-Coating for Cotton Using Polyvinylamine

Phytic acid (PA), as a natural source of phosphorus, was immobilized on cotton (CO) in a layer-by-layer (LbL) approach with polyvinylamine (PVAm) as the oppositely charged electrolyte to create a partly bio-based flame-retardant finish. PVAm was employed as a synthetic nitrogen source with the highest density of amine groups of all polymers. Vertical flame tests revealed a flame-retardant behavior with no afterflame and afterglow time for a coating of 15 bilayers (BL) containing 2% phosphorus and 1.4% nitrogen. The coating achieved a molar P:N ratio of 3:5. Microscale combustion calorimetry (MCC) analyses affirmed the flame test findings by a decrease in peak heat release rate (pkHRR) by more than 60% relative to unfinished CO. Thermogravimetric analyses (TGA) and MCC measurements exhibited a shifted CO peak to lower temperatures indicating proceeding reactions to form an isolating char on the surface. Fourier transform infrared spectroscopy (FTIR) coupled online with a TGA system, allowed the identification of a decreased amount of acrolein, methanol, carbon monoxide and formaldehyde during sample pyrolysis and a higher amount of released water. Thereby the toxicity of released volatiles was reduced. Our results prove that PA enables a different reaction by catalyzing cellulosic dehydration, which results in the formation of a protective char on the surface of the burned fabric.

Thermal and Calorimetric Evaluations of Some Chemically Modified Carbohydrate-Based Substrates with Phosphorus-Containing Groups

In the present article, we report on the chemical modifications of some carbohydrate-based substrates, such as potato starch, dextran, β-cyclodextrin, agar agar and tamarind, by reacting with diethylchlorophosphate (DECP), in dispersions in dichloromethane (DCM), in the presence of triethylamine (TEA) as the base. The modified substrates, after recovery and purification, were analyzed for their chemical constitutions, thermal stabilities and calorimetric properties using a variety of analytical techniques. These included: solid-state ³¹P NMR, inductively coupled plasma-optical emission spectroscopy (ICP-OES), thermogravimetric analysis (TGA) and pyrolysis combustion flow calorimetry (PCFC). The unmodified counterparts were also subjected to the same set of analyses with a view to serving as controls. Phosphorus analyses, primarily through ICP-OES on the recovered samples, showed different degrees of incorporation. Such observations were optionally verified through solid-state ³¹P NMR spectroscopy. The thermograms of the modified substrates were noticeably different from the unmodified counterparts, both in terms of the general profiles and the amounts of char residues produced. Such observations correlated well with the relevant parameters obtained through PCFC runs. Overall, the modified systems containing phosphorus were found to be less combustible than the parent substrates, and thus can be considered as promising matrices for environmentally benign fire-resistant coatings.

Sulfur-Based Copolymeric Polyamidoamines as Efficient Flame-Retardants for Cotton

The polyamidoamine derived from N,N'-methylenebisacrylamide (M) and glycine (G), M-G, has been shown to be an effective flame-retardant (FR) for cotton in horizontal flame spread tests (HFST), extinguishing the flame at 5% add-on. Its activity was attributed to its intrinsic intumescence. In vertical flame spread tests (VFST), M-G failed to extinguish the flame even at 30% add-on. Conversely, in VFST, the polyamidoamine derived from M and cystine (C), M-C, inhibited cotton combustion at 16% add-on, but in HFST failed to extinguish the flame below 12% add-on. Its activity was ascribed to the release of sulfur-containing volatiles acting as radical scavengers. In this work, the FR effectiveness of M-Gm-Cn copolymers with different G/C ratio was compared with that of the M-G and M-C homopolymers and of M-G/M-C blends of the same compositions. In HFST, both copolymers and blends extinguished the flame. In particular, M-G50-C50 and (M-G/M-C)50/50 extinguished the flame, even at 7% add-on. In VFST, the copolymers with ≥50% M-C units, similar to M-C, inhibited cotton combustion at 16% add-on. At the same add-on, the M-G/M-C blends failed to extinguish the flame. It may be concluded that, in contrast to blends, copolymers combined the merits of both homopolymers in all tests.

On the Origin of Alkali-Catalyzed Aromatization of Phenols

To gain an insight of the chemistry in the alkali-promoted aromatization of oxygen-containing heavily aromatic polymers or biomass; thermal degradations of sodium phenolates with different substituents have been investigated. The -ONa group strongly destabilizes the phenolates. The thermal stability of phenolates is largely in parallel with bond strengths of Ar substituents. De-substituents and the removal of aromatic hydrogens are dominant reactions in the main degradation step. CO is formed only at a very late stage. This degradation pattern is completely different from that of phenol. To account for this distinctive decomposition; a mechanism involving an unprecedented formation of an aromatic carbon radical anion generated from the homolytic cleavage of Ar substituent (or Ar–H) in keto forms has been proposed. The homolytic cleavage of Ar substituent (or Ar–H) is facilitated by the strong electron-donating ability of the oxygen anion. A set of free-radical reactions involved in the alkali-catalyzed aromatization have been established.

Recent Advances in Bio-Based Flame Retardant Additives for Synthetic Polymeric Materials

It would be difficult to imagine how modern life across the globe would operate in the absence of synthetic polymers. Although these materials (mostly in the form of plastics) have revolutionized our daily lives, there are consequences to their use, one of these being their high levels of flammability. For this reason, research into the development of flame retardant (FR) additives for these materials is of tremendous importance. However, many of the FRs prepared are problematic due to their negative impacts on human health and the environment. Furthermore, their preparations are neither green nor sustainable since they require typical organic synthetic processes that rely on fossil fuels. Because of this, the need to develop more sustainable and non-toxic options is vital. Many research groups have turned their attention to preparing new bio-based FR additives for synthetic polymers. This review explores some of the recent examples made in this field.

Evidence that microplastics aggravate the toxicity of organophosphorus flame retardants in mice (Mus musculus)

This study was performed to reveal the health risks of co-exposure to organophosphorus flame retardants (OPFRs) and microplastics (MPs). We exposed mice to polyethylene (PE) and polystyrene (PS) MPs and OPFRs [tris (2-chloroethy) phosphate (TCEP) and tris (1,3-dichloro-2-propyl) phosphate (TDCPP)] for 90 days. Biochemical markers and metabolomics were used to determine whether MPs could enhance the toxicity of OPFRs. Superoxide dismutase (SOD) and catalase (CAT) increased (p < 0.05) by 21% and 26% respectively in 10 μg/L TDCPP + PE group compared to TDCPP group. Lactate dehydrogenase (LDH) in TDCPP + MPs groups were higher (18%-30%) than that in TDCPP groups (p < 0.05). Acetylcholinesterase (AChE) in TCEP + PE groups were lower (10%-19%) than those in TCEP groups (p < 0.05). These results suggested that OPFR co-exposure with MPs induced more toxicity than OPFR exposure alone. Finally, in comparison to controls we observed that 29, 41, 41, 26, 40 and 37 metabolites changed significantly (p < 0.05; fold-change > 1.2) in TCEP, TCEP + PS, TCEP + PE, TDCPP, TDCPP + PS and TDCPP + PE groups, respectively. Most of these metabolites are related to pathways of amino acid and energy metabolism. Our results indicate that MPs aggravate the toxicity of OPFRs and highlight the health risks of MP co-exposure with other pollutants.

Thermal stability of PMMA–LDH nanocomposites: decoupling the physical barrier, radical trapping, and charring contributions using XAS/WAXS/Raman time-resolved experiments

In-depth understanding of the thermal stability of polymer–clay nanocomposites requires the use of advanced time-resolved techniques combined with multivariate data analysis, as well as the preparation of layered nanofillers with well-defined composition. The layered double hydroxide (LDH) compounds Zn₂Al(OH)₆·nH₂O, Zn₂Al_0.75Fe_0.25(OH)₆·nH₂O, ZnCuAl(OH)₆·nH₂O, and ZnCuAl_0.5Fe_0.5(OH)₆·nH₂O were prepared, each designed to specifically identify the physical barrier, radical trapping, and char formation contributions to the thermal stability of the PMMA–LDH nanocomposites. The unique combination of conventional methods (TG, DSC, and Raman spectroscopy) and synchrotron radiation techniques (XAS and WAXS), applied during PMMA–LDH heating, revealed the synergetic (of iron) and antagonist (of copper) effects of the LDH layers transformations on the three main endothermic steps of mass loss of the polymer. The diffusion barrier effect was proved by the downshift of the PMMA thermal decomposition temperature caused by the decrease of the LDH edifice thermostability when divalent cations were substituted in the LDH (passing from PMMA–Zn₂Al(OH)₆·nH₂O to PMMA–ZnCuAl(OH)₆·nH₂O). For PMMA–Zn₂Al_0.75Fe_0.25(OH)₆·nH₂O, a cooperative contribution of iron reduction, stabilisation of layered edifice, and radical trapping effects was observed for the thermal stability of the nanocomposite. LDH also acted as a diffusion barrier to the efflux and evaporation of depolymerized species, favouring the charring which exerts an additional contribution to thermal stability of the PMMA–LDH nanocomposites.

Thermal stability of polymer-double layered hydroxides nanocomposites: concurrent contributions from physical barrier, char formation and radical trapping.

Hybrid films of chitosan, cellulose nanofibrils and boric acid: Flame retardancy, optical and thermo-mechanical properties

Chitosan (CS), cellulose nanofibrils (CNF) and boric acid, the latter of which was used as flame retardant, were combined in transparent, hybrid films that were produced by solvent casting. The flammability and the thermal stability of the films were studied with respect to the loading of the inorganic component. Chitosan films displayed fire retardancy properties, which were enhanced in the presence of boric acid. CNF films, in contrast to those from chitosan, were readily flammable; however, when combined with boric acid (30w%), they became self-extinguishing. Most remarkably, bicomponent films comprising CNF and chitosan, displayed better fire retardancy than that of neat CS films. Moreover, boric acid improved the thermal stability of the bicomponent films. The tensile strength and Young's modulus of CS, CNF and CS-CNF films improved at intermediate boric acid addition, although a negative effect on elongation was observed.

Hairy cellulose nanocrystalloids: a novel class of nanocellulose

Nanomaterials have secured such a promising role in today's life that imagining the modern world without them is almost impossible. A large fraction of nanomaterials is synthesized from environmentally-dangerous elements such as heavy metals, which have posed serious side-effects to ecosystems. Despite numerous advantages of synthetic nanomaterials, issues such as renewability, sustainability, biocompatibility, and cost efficiency have drawn significant attention towards natural products such as cellulose-based nanomaterials. Within the past decade, nanocelluloses, most remarkably nanocrystalline cellulose (NCC) and nanofibrillated cellulose (NFC), have successfully been used for a wide spectrum of applications spanning from nanocomposites, packaging, and mechanical and rheological property modifications, to chemical catalysis and organic templating. Yet, there has been little effort to introduce fundamentally new polysaccharide-based nanomaterials. We have been able to develop the first kind of cellulose-based nanoparticles bearing both crystalline and amorphous regions. These nanoparticles comprise a crystalline body, similar to conventional NCC, but with polymer chains protruding from both ends; therefore, these particles are called hairy cellulose nanocrystalloids (HCNC). In this article, we touch on the philosophy of HCNC synthesis, the striking superiority over existing nanocelluloses, and applications of this novel class of nanocelluloses. We hope that the emergence of hairy cellulose nanocrystalloids extends the frontiers of sustainable, green nanotechnology.

Key Role of Reinforcing Structures in the Flame Retardant Performance of Self-Reinforced Polypropylene Composites

The flame retardant synergism between highly stretched polymer fibres and intumescent flame retardant systems was investigated in self-reinforced polypropylene composites. It was found that the structure of reinforcement, such as degree of molecular orientation, fibre alignment and weave type, has a particular effect on the fire performance of the intumescent system. As little as 7.2 wt % additive content, one third of the amount needed in non-reinforced polypropylene matrix, was sufficient to reach a UL-94 V-0 rating. The best result was found in self-reinforced polypropylene composites reinforced with unidirectional fibres. In addition to the fire retardant performance, the mechanical properties were also evaluated. The maximum was found at optimal consolidation temperature, while the flame retardant additive in the matrix did not influence the mechanical performance up to the investigated 13 wt % concentration.

Flame-Retardant Paper from Wood Fibers Functionalized via Layer-by-Layer Assembly

The highly flammable character of cellulose-rich fibers from wood limits their use in some advanced materials. To suppress the flammability and introduce flame-retardant properties to individual pulp fibers, we deposited nanometer thin films consisting of cationic chitosan (CH) and anionic poly(vinylphosphonic acid) (PVPA) on fibers using the layer-by-layer (LbL) technique. The buildup of the multilayer film was investigated in the presence and absence of salt (NaCl) using model cellulose surfaces and a quartz crystal microbalance technique. Fibers were then treated with the same strategy, and the treated fibers were used to prepare paper sheets. A horizontal flame test (HFT) and cone calorimetry were conducted to evaluate the combustion behavior of paper sheets as a function of the number of bilayers deposited on fibers. In HFT, paper made of fibers coated with 20 CH/PVPA bilayers (BL), self-extinguished the flame, while uncoated fibers were completely consumed. Scanning electron microscopy of charred paper after HFT revealed that a thin shell of the charred polymeric multilayer remained after the cellulose fibers had been completely oxidized. Cone calorimetry demonstrated that the phosphorus-containing thin films (20 BL is ∼25 nm) reduced the peak heat release rate by 49%. This study identifies a unique and highly effective way to impart flame-retardant characteristic to pulp fibers and the papers made from these fibers.

Novel Multifunctional Organic-Inorganic Hybrid Curing Agent with High Flame-Retardant Efficiency for Epoxy Resin

A novel multifunctional organic-inorganic hybrid was designed and prepared based on ammonium polyphosphate (APP) by cation exchange with diethylenetriamine (DETA), abbreviated as DETA-APP. Then DETA-APP was used as flame-retardant curing agent for epoxy resin (EP). Curing behavior, including the curing kinetic parameters, was investigated by differential scanning calorimetry (DSC) and X-ray photoelectron spectroscopy (XPS). The flame retardance and burning behavior of DETA-APP cured EP were also evaluated. The limiting oxygen index (LOI) value of DETA-APP/EP was enhanced to 30.5% with only 15 wt % of DETA-APP incorporated; and the UL-94 V-0 rating could be easily passed through with only 10 wt % of the hybrid. Compared with DETA/EP, the peak-heat release rate (PHRR), total heat release (THR), total smoke production (TSP), and peak-smoke production release (SPR) of DETA-APP/EP (15 wt % addition), obtained from cone calorimetry, were dropped by 68.3, 79.3, 79.0, and 30.0%, respectively, suggesting excellent flame-retardant and smoke suppression efficiency. The flame-retardant mechanism of DETA-APP/EP has been investigated comprehensively. The results of all the aforementioned studies distinctly confirmed that DETA-APP was an effective flame-retardant curing agent for EP.

The Influence of Arc-Flash and Fire-Resistant Clothing on Thermoregulation during Exercise in the Heat

We evaluated the effect of arc-flash and fire-resistant (AFR) clothing ensembles (CE) on whole-body heat dissipation during work in the heat. On 10 occasions, 7 males performed four 15-min cycling bouts at a fixed rate of metabolic heat production (400 W) in the heat (35°C), each separated by 15-min of recovery. Whole-body heat loss and metabolic heat production were measured by direct and indirect calorimetry, respectively. Body heat storage was calculated as the temporal summation of heat production and heat loss. Responses were compared in a semi-nude state and while wearing two CE styles: (1) single-piece (coveralls) and (2) two-piece (workpant + long-sleeve shirt). For group 1, there was one non-AFR single-piece CE (CE1STD) and three single-piece CE with AFR properties (CE2AFR, CE3AFR, CE4AFR). For group 2, there was one non-AFR two-piece CE (CE5STD) and four two-piece CE with AFR properties (CE6AFR, CE7AFR, CE8AFR, CE9AFR). The workpants for CE6AFR were not AFR-rated, while a cotton undershirt was also worn for conditions CE8AFR and CE9AFR and for all single-piece CE. Heat storage for all conditions (CE1STD: 328 ± 55, CE2AFR: 335 ± 87, CE3AFR: 309 ± 95, CE4AFR: 403 ± 104, CE5STD: 253 ± 78, CE6AFR: 268 ± 89, CE7AFR: 302 ± 70, CE8AFR: 360 ± 36, CE9AFR: 381 ± 99 kJ) was greater than the semi-nude state (160 ± 124 kJ) (all p ≤ 0.05). No differences were measured between single-piece uniforms (p = 0.273). Among the two-piece uniforms, heat storage was greater for CE8AFR and CE9AFR relative to CE5STD and CE6AFR (all p ≤ 0.05), but not CE7AFR (both p > 0.05). Differences between clothing styles were measured such that greater heat storage was observed in both CE1STD and CE2-4AFR relative to CE5STD. Further, heat storage was greater in CE2AFR and CE4AFR relative to CE6AFR, while it was greater in CE4AFR compared to CE7AFR. Body heat storage during work in the heat was not influenced by the use of AFR fabrics in the single- or two-piece uniforms albeit less heat was stored in the two-piece uniforms when no undershirt was worn. However, heat storage was comparable between clothing styles when an undershirt was worn with the two-piece uniform.

Cotton flame retardancy: state of the art and future perspectives

This paper reviews the most significant achievements in cotton flame retardancy merging past experience and current efforts.

Few durable layers suppress cotton combustion due to the joint combination of layer by layer assembly and UV-curing

In the last five years, Layer by Layer (LbL) assembly has proven to be one of the most innovative solutions for conferring flame retardancy to fabrics.

Assessment of health implications related to processing and use of natural wool insulation products

This paper discusses possible health implications related to dust particles released during the manufacture of sheep's wool-based non-woven insulation material. Such insulation may replace traditional synthetic insulation products used in roofs, wall cavities, etc. A review of the literature concerning organic dusts in general and sheep's wool fiber summarizes dust exposure patterns, toxicological pathways and the hazards imposed by inhalation and explosion risk. This paper highlights a need for more research in order to refrain from overgeneralizing potential pulmonary and carcinogenic risks across the industries. Variables existing between industries such as the use of different wool types, processes, and additives are shown to have varying health effects. Within the final section of the paper, the health issues raised are compared with those that have been extensively documented for the rock and glass wool industries.

Ultrasound-promoted coating of silk yarn with different morphology of magnesium hydroxide nanostructures

The growth of magnesium hydroxide nanostructures on silk yarn was achieved by sequential dipping steps in alternating bath of magnesium nitrate and potassium hydroxide under ultrasound irradiation. The effects of ultrasound irradiation, concentration, pH and sequential dipping steps on growth of the Mg(OH)(2) nanostructures have been studied. Morphology of the nanostructures, depending on pH and with decreasing pH from 13 to 8, changed from nanoparticle to nanoneedle. Results show a decrease in the particles size as the concentration and sequential dipping steps increased. The physicochemical properties of the nanostructures were determined by powder X-ray diffraction (XRD), scanning electron microscopy (SEM) and wavelength dispersive X-ray (WDX).