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.

The Potential for Bio-Sustainable Organobromine-Containing Flame Retardant Formulations for Textile Applications-A Review

This review considers the challenge of developing sustainable organobromine flame retardants (BrFRs) and alternative synergists to the predominantly used antimony III oxide. Current BrFR efficiencies are reviewed for textile coatings and back-coatings with a focus on furnishing and similar fabrics covering underlying flammable fillings, such as flexible polyurethane foam. The difficulty of replacing them with non-halogen-containing systems is also reviewed with major disadvantages including their extreme specificity with regard to a given textile type and poor durability.The possibility of replacing currently used BrFRs for textiles structures that mimic naturally occurring organobromine-containing species is discussed, noting that of the nearly 2000 such species identified in both marine and terrestrial environments, a significant number are functionalised polybrominated diphenyl ethers, which form part of a series of little understood biosynthetic biodegradation cycles.The continued use of antimony III oxide as synergist and possible replacement by alternatives, such as the commercially available zinc stannates and the recently identified zinc tungstate, are discussed. Both are effective as synergists and smoke suppressants, but unlike Sb₂0₃, they have efficiencies dependent on BrFR chemistry and polymer matrix or textile structure. Furthermore, their effectiveness in textile coatings has yet to be more fully assessed.In conclusion, it is proposed that the future of sustainable BrFRs should be based on naturally occurring polybrominated structures developed in conjunction with non-toxic, smoke-suppressing synergists such as the zinc stannates or zinc tungstate, which have been carefully tailored for given polymeric and textile substrates.

Multifunctional modification of cotton using layer-by-layer finishing with chitosan, sodium lignin sulphonate and boric acid

Functionally modified fabrics produced using sustainable techniques are in huge demand in today's world. In the present work, cotton fabric was modified using layer-by-layer two-stage finishing method using a solution of chitosan in citric acid (CS) and sodium lignin sulphonate (SLS) with boric acid (BA), thus granting several performance traits like wrinkle-free, antibacterial, flame retardant, UV protection and antioxidant properties. The finished fabric was evaluated for several textile properties like tensile strength, bending length, crease recovery, whiteness index and functional properties like antibacterial activity, UV protection, flame retardancy and antioxidant properties under standard conditions. The finished cotton showed an increase in CRA, antibacterial activity in the range 70-89%, UPF in the excellent range, much higher LOI values with a decrease in heat release and antioxidant activity of higher than 93%. The novel method of multifunctional finishing of cotton by layer-by-layer technique is explored.

Sol-Gel and Layer-by-Layer Coatings for Flame-Retardant Cotton Fabrics: Recent Advances

Surface-engineered coatings for the fire protection of cotton are being increasing used thanks to the ease of application of the coatings and their effectiveness in preventing flame propagation and improving resistance to irradiative heat flux exposure. Two main approaches have been extensively investigated, namely sol-gel derived coatings and layer-by-layer assemblies. These approaches are both capable of providing treated fabrics with outstanding flame-retardant features. Notwithstanding, according to the composition of the sol-gel recipes and the type of deposited layers, it is possible to design multifunctional (for example hydrophobic and electrically conductive) treatments. This review aims at discussing recent advances with respect to both strategies, highlighting current limitations, open challenges, and possible advances.

Chitosan-based flame retardant coatings for polyamide 66 textiles: One-pot deposition versus layer-by-layer assembly

Chitosan (CS) and phosphorylated chitosan (PCS) were deposited onto the polyamide 66 (PA66) fabric surfaces along with poly-acrylate sodium (PAS) via 'one pot' and layer by layer (LbL) assembly methods in preparing flame retardant coatings. Subsequently, to stabilize the deposited coatings, some of the fabric samples were treated under the UV-irradiation and additionally, a thermal treatment was also carried out for the remaining fabric samples. The LbL assembled fabrics showed a better homogeneity in the coating structure over the one pot deposited fabrics as appeared in scanning electron microscopy (SEM). Nonetheless, the LbL treated fabric sample (i.e., PA66-10BL-UV) with a higher weight gain% exhibited a greater improvement in limiting oxygen index (LOI) (i.e., 23%), and a reduced peak heat release rate (pHRR) (i.e., 25%). Yet more, only the LbL assembled and thermally cross-linked fabric sample could able to retain the flame retardant behavior in the vertical burning test even after 5 washing cycles.

Synergistic Effects and Mechanism of Modified Silica Sol Flame Retardant Systems on Silk Fabric

The nano-silica sol was prepared by sol-gel method, and the boric acid, urea, cyanoguanidine, melamine cyanurate (MCA), 1-hydroxyethane 1,1-diphosphonic acid (HEDP), and 6H-dibenz (C,E) (1,2) oxaphosphorin-6-oxide (DOPO) were added to the silica sol to modify the flame retardant through physical doping and chemical bonding. According to the formula proposed by Lewin, the calculation of flammability parameters were obtained by the limiting oxygen index meter, the micro calorimeter, the vertical burner, and the thermogravimetric analyzer proved that there was a synergistic or additive effect between the B/N/P flame retardant and the silica sol. Fourier transform infrared (FT-IR) spectrum, scanning electron microscopy, and pyrolysis gas chromatography-mass spectrometry were used to characterize the morphology, structure, and pyrolysis products of treated silk fabric and residues after combustion. The results show that the flame retardancy of silica-boron sol is mainly caused by endothermic reaction and melt covering reaction. Silicon-nitrogen sol acts as a flame retardant through endothermic reaction, release of gases, and melting coverage. Silicon-phosphorus sol achieves flame retardancy by forming an acid to promote formation of a carbon layer and melting coverage. Silica sol and other flame retardants show excellent flame retardanty after compounding, and have certain complementarity, which can balance the dosage, performance, and cost of flame retardants, and is more suitable for industrial development.

ZnO Microstructures as Flame-Retardant Coatings on Cotton Fabrics

In this study, we report a unique strategy that utilizes ZnO and ZnS microparticles and rods as fire-retardant materials when coated onto cotton fabrics. ZnO and ZnO/ZnS microparticles or rods were grown or adsorbed to the surface of cotton fibers. Properties such as heat release rate, total smoke release, and mass loss rate of the materials were tested using a cone calorimeter. ZnO and ZnO/ZnS rods were able to reduce the heat release rate and total smoke release from 118 kW/m² and 18.3 m²/m² to about 70.0 kW/m² and 6.00 m²/m², respectively. The maximum average rate of heat emission and fire growth rate index, which is used to evaluate the fire spread rate, the size of the fire, and the propensity of fire development, were improved with these coatings and indicate that there are potential applications of these materials as fire retardants.

Improving the Flame Retardant Efficiency of Layer by Layer Coatings Containing Deoxyribonucleic Acid by Post-Diffusion of Hydrotalcite Nanoparticles

This work deals with the use of hydrotalcite nanoparticle post-diffusion in layer by layer (LbL) coatings with the aim of improving their flame retardant action on cotton. The selected LbL components, which encompass polydiallyldimethylammonium chloride and deoxyribonucleic acid, aim at the deposition of an intumescent coating. Infrared spectra pointed out a super-linear growth of the investigated assembly, indicating the ability to deposit thick coatings while maintaining a relatively low deposition number. A post-diffusion process, performed by exposing the LbL-treated fabrics to two different concentrations of hydrotalcite water suspensions (0.1 or 1 wt %), was carried out to improve the fireproofing efficiency of these coatings. Coatings treated with the lowest concentration suspension partially swelled as a consequence of their structural rearrangements while the use of the highest concentration led to nanoparticle aggregates. Horizontal flame spread tests were used for assessing the achieved flame retardant properties. The post-diffusion performed at the lowest hydrotalcite concentration lowers the minimum number of Bi-Layers required for obtaining cotton self-extinguishment while samples treated with the highest concentration showed detrimental effects on the performances of treated fabrics. This behavior is ascribed to the effects of hydrotalcite particles on the intumescence of LbL coatings, as evidenced by the morphological analyses of post-combustion residues.

Synthesis of polymeric dyes based on UV curable multifunctional waterborne polyurethane for textile coating

Novel UVPDs based on multifunctional waterborne polyurethane have been synthesized to overcome the drawbacks of polymeric dyes and polyurethane coatings.

Citric acid based durable and sustainable flame retardant treatment for lyocell fabric

Pyrovatex CP New, is a commonly used organophosphorus based flame retardant (FR) reagent for cellulosic materials. However, it has a drawback of high formaldehyde release when used with methylated melamine (MM) based cross-linker, a known carcinogenous compound. In the present approach, a durable and sustainable flame retarding recipe formulation for lyocell fabrics is developed using citric acid (CA) as a cross-linker. The FR finish was applied by pad-dry-cure process. The treated fabrics were characterized for surface morphology, elemental analysis, TG analysis, char study and FT-IR spectroscopy. Furthermore, flame retardancy, washing durability, formaldehyde release and breaking strength were also assessed, and compared with the conventional MM based FR recipe. The fabric samples treated with 400gL(-1) of FR with either 40 or 80gL(-1) of CA demonstrate flame retardancy even after 10 washing cycles. Furthermore, a 75% reduction in formaldehyde release is achieved. Higher char yield and lower decomposition temperature are found compared to untreated and FR+ MM treated lyocell. Such an improved sustainable recipe formulation can be used for lyocell fabric without any health risk in apparel wear.

Ultra-Fast Layer-by-Layer Approach for Depositing Flame Retardant Coatings on Flexible PU Foams within Seconds

In this letter, we are presenting a novel approach for the deposition of layer-by-layer (LbL) coatings capable of conferring flame retardant properties to flexible polyurethane foams exploiting subsecond deposition times. The process yields nanoscale coatings able to reduce by 33% one of the main fire safety parameters, namely the heat release rate peak, with a total treatment time of only 2.5 s. This new approach turned out to be three to 4 orders of magnitude faster than conventional LbL treatments. Such results make it possible for the exploit of LbL as a competitive, efficient and ecofriendly technology at industrial scale.

A wash-durable polyelectrolyte complex that extinguishes flames on polyester–cotton fabric

Polyester–cotton (PECO) blends were rendered flame retardant by depositing a stable polyelectrolyte complex as a wash-durable coating.