Phosphorus Flame Retardants for Textiles

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Novecare 18/06/2006 CHALLENGING BOUNDARIES

Phosphorus Flame Retardants for Textiles



Summary

18/06/2006 Novecare CHALLENGING BOUNDARIES

Introduction

• How Do Textiles Burn?

• The Action of a Phosphorus Flame Retardant

• Flame Retardant Selection

• Classification of Textile Flame Retardants

• “Inherent” Flame Retardant Fibres

• Methods of Application

• Flammability Standards and Testing

• HSE Considerations

• Conclusions



Introduction


Stenter

Winch Dyeing

machine

•Flame retardants are prevalent in many aspects of our lives

•In upholstered furniture

•Curtaining•Car seating

•The work place

•Transportation



How Do Textiles Burn?


Fire

Oxygen+

Textile (fuel)

+ =

Ignitionsource





Stenter

•Cellulose decomposes (in oxygen) to tarry

depolymerization products, notably levoglucosan

• Then to volatile combustible products such as alcohols,aldehydes, ketones and hydrocarbons

•Flammable gases ignite

•After flaming, the carbonised residue slowly oxidises(smoulders) until it has been consumed

Winch Dyeing

machine





Thermal degradation of Cellulose

O

CH2OH

OH

OH

O

O

O

OH

OH

O

CH2OH

3500C O

HO

OH

OH

O

CH2

Levoglucosan



Summary


• Introduction


• The Action of a Phosphorus Flame Retardant• Flame Retardant Selection


• “Inherent” Flame Retardant Fibres• Methods of Application



• Conclusions




The Action of a Phosphorus Flame Retardant

There are Potentially Four ways of Disrupting Combustion

• Removal of heat or application of cooling. Achievedby treating the material with heat absorbing materials.

• Increase in pyrolysis temperature i.e. glass fibre,

aramids, carbon fibres• Elimination of oxygen from combustion zone i.e.

halogens

• Prevent evaporation i.e. form char - Phosphorus





Stenter

Winch Dyeing

machine

• Application of ignition source

• Formation of phosphorus pentoxide and phosphoricacid

• Dehydration of cellulose occurs

• Dehydration reduces the temperature of

decomposition (275-325°C as opposed to 375°C for untreated cotton)

• Evolution of levoglucosan inhibited

• Flammable tars and gases reduced, char increased• Formation of protective layer of char





Synergistic Effect of Nitrogen

• Nitrogen catalyzes the cellulose phosphorylation• The retention of phosphorus in the char may be aided

by nitrogen

• Release of nitrogen gas which dilutes the flammablegases and reduces flaming

• Higher levels of nitrogen may allow lower levels of phosphorus in the flame retardant



Summary


• Introduction




•“Inherent” Flame Retardant Fibres




• Conclusions



Flame Retardant Selection


• Application

• Application method

• Performance requirements

• Fabric composition

• Fabric construction, weight

• Fabric must still behave like untreated material

COST



Summary


• Introduction




•“Inherent” Flame Retardant Fibres




• Conclusions



Classification of Textile Flame Retardants


• Phosphorus containing flame retardants

O

P OR 3R 1O

OR 2

P

R 1

O

O

O R 2

R 3

P

R 1

O

O

O R 2

R 3

Phosphate Phosphonium Phosphonate

R 2

P R 4R 1

R 3

Cyclic





• Another method of classifying textile FRs isaccording to

• their durability to washing:

• Durable Resistant to 50 or more washes

• Semi-Durable Resistant to a water soak

• Non-Durable Resistant to no washing





• Dialkylphosphonopropionamide

• Co-reacted with an amino resin and an acid curing catalyst

• Pad, dry, heat cure followed by alkali wash

H2C CHCONH2 + (CH3O)2P O

H(CH3O)2P

O

CH2CH2CNH2

O

(CH3O)2PO

CH2CH2CNHCH2OH

O

HCHO

Durable Flame Retardants (Top Treatments)





Durable Flame Retardants (Top Treatments)

• Tetrakis(hydroxymethyl)phosphonium

chloride marketed under the PROBAN® trademark by Rhodia and is availableonly under licence

• Applied to cotton and cotton syntheticblends by pad, dry, ammonia cure and

hydrogen peroxide oxidation• Durable to repeated washing

(HOCH2)3P+CH2 NHCNHCH2P+(CH2OH)3

OCL

-CL-

NH3

NHCH2PCH2 NHCNHCH2PCH2 NH

CH2

NH

CH2

NHCH2PCH

2 NHCNHCH

2PCH

2 NH

CH2

NH

CH2

O

O

O2H2C P CH2

CH2

O





Flame Retardants for Polyester fabrics (Top Treatments)

• Cyclic Phosphonate Ester based

products may be used• Applied by pad, dry, heat cure

process

• Durable to washing

• Phosphorus FR’s lower themelting point of polyester fabricsallowing the fabric to melt awayfrom the ignition source moreeasily

C

CH3OH3CP

O O P

CH3

OCH3

O

x

2-x





Non-Durable Flame Retardants (Top Treatments)

• Non-durable APP’s used

• End-uses include furnishings, filter fabrics, disposable protective clothing

(NH4.PO 3)n (HPO3)n + nNH3

H 3PO4

Degradation of APP





Non-Durable Flame Retardants (Top Treatments)

• Need for more sophisticated flame retardants for higher processing

speeds and more demanding applications• Phosphonates generally have higher thermal stability than APP’s

allowing higher processing speeds

• Flame Retardants capable of being processed at temperatures of over

130ºC have been developed by Rhodia and marketed under theAMGARD® trademark

• Some of the AMGARD® products are based on phosphonate chemistrywhich generally have higher thermal stability than APP’s





Semi-Durable Flame Retardants

• Used for items not normally washed but may be subjected to water soak

or dry cleaning• Ammonium polyphosphates may be used

• End uses include upholstery and curtains



Summary


• Introduction




• Inherent Flame Retardant Fibres




• Conclusions



“Inherent” Flame Retardant Fibres


• Phosphorus containing FR additive can be incorporated into the spinning

dope during manufacture of viscose fibres• Polyester fibres can also be given FR properties by inclusion of

phosphonic acid based derivative



“Inherent” Flame Retardant Fibres


C

O

P

OCH3

CH3

S

O P

O

C

O CH3

CH3

S

Viscose spinning bath additive for flame retardant rayon

Cl

OCH2

P

O

Cl

OCH2

CP

O

OCH2

OCH2

Spirocyclic pentaerythritol di(phosphate acid monochloride additive for

polyester



Summary


• Introduction








• Conclusions



Methods of Application


Drying AreaMangle Rollers

Pad

MangleStenter

Fabric rollFabric roll





Pad trough

Padding

(full

impregn

ation) Fabric

Mangle rollers

Lick

Roll

Low

viscosity

paste

Fabric

Knife or

squeegee

Foam or

pasteFabric

Screen coating (back-coating)

Mesh -screen

Steel

support

roller





Paste FabricKnife

Steel

roller

Steel

roller

Knife

over air

(Back-coating)

PasteSteel roller

Fabric

Knife

Knife over

roll

(Back-coating)





Pad Mangles





Stenter

Drying

f





Textile Coating Machines

M th d f A li ti





Winch Dyeing

Machine

Wet Processing (Dyeing) machines

Jig Dyeing machine

Jet Dyeing Machine






Wet Processing (Dyeing) machines

Continuous Wash Ranges



Summary


• Introduction








• Conclusions

Flammability Standards and Testing





• Standards and testing are vital in ensuring that the flammabilityperformance of a fabric is satisfactory for a specific end-use

• Flammability testing must be carried out in accredited test laboratoriesusing recognised flammability test methods

• There are a range of national and international flammability standards






Protective Clothing (woven & or knitted) for use in the European Community

EN 533: 1997 Index 3, EN 531: 1995 para 6.2.2 EN 470: Part 1: 1995 para 6.1

after 50 washes at 75°C (according to EN 10528 Standard wash).

UK Sheeting & Blankets

BS7175 Ignition sources 0, 1 & or 5 when tested on top of & or below the test

fabric, after 200 washes at 74°C.

UK Curtaining

BS 5867 Part 2 Type B after 50 washes at 74°C.

Mattress Ticking

BS 7175 Ignition sources 0, 1& or 5 when tested on top of & or below the test

fabric, after 3 washes at 74°C.

UK Upholstery

BS 5852 Part 1 Ignition sources 0 & 1 after a water

soak treatment BS 5651.






EN 532 standard for work wear






BS 7175 on Continental quiltsCrib 5 test






EN 348 standard for work wear






DOC FF3-71 standard for children’s sleepwear

Summary



Summary


• Introduction





• Methods of Application• Flammability Standards and Testing


•Conclusions

HSE Considerations




• In recent years all chemicals are coming under increased scrutiny,especially halogen containing flame retardants

• Further pressure from REACH proposals (the Registration, Evaluationand Authorisation of Chemicals) in the EU due to become operationalin spring 2007

• High customer expectation in terms of safety of chemical finishes

• Ecolabels such as Öko-Tex (or Blue Angel) whereby the endorsement

confers safe toxicological and environmental profiles of the relevantchemicals

Conclusions




• Ever increasing pressure on chemical manufacturers to produce finishes

which have a good tox and environment profile, and are cost andperformance effective

• General move away from halogen containing flame retardants

• Challenge for the future will be to develop more efficient flame retardant

finishes in terms of application and also performance• Also multi-function finishes for textiles where flame retardantperformance is imparted along with other properties, e.g. antimicrobial,soil/stain resist

• Reference: R Padda and G Lenotte, General Trends in Textile Flame Retardants, Speciality Chemicals Magazine, 2005, 43-44.




Phosphorus Flame Retardants for Textiles

Text of Phosphorus Flame Retardants for Textiles

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Phosphorus Flame Retardants for Textiles

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