Fire Retardant Textile Coatings Requirements, Challenges, Solutions. ECC on fire retardant coatings 13&14/03/ Berlin

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1 Fire Retardant Textile Coatings Requirements, Challenges, Solutions ECC on fire retardant coatings 13&14/3/212 - Berlin

2 Outline Centexbel: company presentation Fire retardant textile research Flame retardants extrusion Flame retardants coating Conclusions

3 Activities & services of Centexbel Testing collective centre of competence 8 Belgian textile producers 1 associated national and international companies Research Certification Consultancy

Activities & services of Centexbel Testing burning behaviour ignitability flame propagation smoke density & toxicity physical testing abrasion colour fastness antistatic properties chemical analysis

4 Activities & services of Centexbel Testing burning behaviour ignitability flame propagation smoke density & toxicity physical testing abrasion colour fastness antistatic properties chemical analysis hazardous substances extraction VOC determination microbiological analysis anti-microbial effect biodegradability barrier effects Certification GuT Öko-Tex Made in Green CE-labelling CertiPUR Consultancy and more patent cell in-company training technological consultancy standardisation

5 Floor covering EU classification EN EN ignitability all floor covering: textile, wood, resilient (PVC), cork

6 Floor covering EU classification EN EN Reaction at fire all floor covering: textile, wood, resilient (PVC), cork

7 Transportation

8 Smoke density chamber density & toxicity

9 LOI Cone calorimeter

10 Research domains Functional Thermoplastic Textiles compounding, extrusion (bio-)polymers, (nano-)functionalisation Human Health, Safety & Security medical and bio-functional textiles, cosmeto-textiles, personal risk assessment & safety, thermo-physiological comfort, Textile Functionalisation & Surface modification coating, finishing & laminating, dyeing

11 R&D on finishing/coating/dyeing Material functionalisation FR Material substitution X-FR Surface modification Surface protection Durable coating/finishing/dyeing techniques

12 Flame retardants in textiles Requirements Challenges Some solutions

13 Requirements Depend on the market (country) reflected in the variety of standards Depend on the application Key issues with textiles Density - air entrapped in the textile Wash resistance

14 Curtains current status

15 Different methods, same end use M1, M2 (FR) Classifications not interchangeable Type B,C (UK) B1 (GE)

16 Curtains the future?

17 Challenges Harmonised standards Environmental impact Regulations / REACH ban penta-bde & octa-bde, others classified as hazardous substances, HBCD (communication needed >.1wt%), American market 213: phase out of deca-bde

Challenges Eco-Labels (Oeko-Tex, European

class IV (no specific FR rules) class II

18 Challenges Eco-Labels (Oeko-Tex, European Ecolabel, ) Der Blaue Engel mattresses: no halogenated organic compounds Oeko-Tex Use of flame retardants limited mattresses: class IV (no specific FR rules) class II (direct skin contact): only use of FR white-list

19 Solutions Fire retardant textile research Addition of flame retardants during extrusion Use of flame retardants in coating

20 Flame retardants coating FR hotmelts FR UV-curable coatings

21 Flame retardants coating FR hotmelts FR UV-curable coatings

22 FR hotmelts Cornet project functionalised hotmelts In cooperation with Aitex (ES) & ITV (DE)

23 FR hotmelts Compounding PPA= Licocene 262 (Clariant) FR1= Exolit AP 423 (Clariant) 1 to 4% Process parameters Characterisation compounds Application Influence add-on: 15 & 3g/m² FR behaviour Mattress ticking

24 Compounding FR hotmelts Substantial increase in viscosity 14 C 16 C PPA 19,62 1,62 19,46 1,72 PPA + 2%FR1 24,91 15,57 24,42 14,61 PPA + 3%FR1 47,61 32,82 47,34 32,91 PPA + 4%FR1 76,39 55,55 79,66 57,18

25 Compounding FR hotmelts Melting & crystallisation temperatures affected: 4% FR: Tm increased with 5 C Tc increased with 1 C Hotmelt process parameters need to be selected that can tackle the increase in viscosity, melt & crystallisation temperatures

26 Application FR hotmelts Slot-die coater Width: 45 cm Temperature: up to 2 C Speed:,5 3 m/min

FR testing FR Cigarette test ISO 12952 1/2 Visc/PP mattress ticking With coating of 15 g/m² and 3

27 FR testing FR Cigarette test ISO /2 Visc/PP mattress ticking With coating of 15 g/m² and 3 g/m² 2% of FR1 => PASS Viscose mattress ticking With coating of 15 g/m² and 3 g/m² 2% of FR1 => PASS

28 FR testing FR Flame test - ISO /4 Visc/PP mattress ticking With coating of 15 g/m² Even 4% of FR1 => FAIL With coating of 3 g/m² Even 4% of FR1 => FAIL

FR testing FR Flame test - ISO 12952 3/4 Viscose mattress ticking With

29 FR testing FR Flame test - ISO /4 Viscose mattress ticking With coating of 15 g/m² Even 4% of FR1 => FAIL With coating of 3 g/m² 2% of FR1 => PASS

30 Conclusion - FR hotmelt FR additives can be compounded using the same settings as the pure PP hotmelt Processing: take into account changes in viscosity, melting & crystallisation behaviour Flame retardancy influenced by % FR Coating layer thickness (add-on) Type of substrate

31 FR UV-curable coatings IWT national research project functionalisation of UV-curable coatings for textile applications In cooperation with Flamac University College Ghent (TO2C) 29-21

32 UV curable coatings Substraat 1 % Oligomer Monomer diluent Photo-initiator water based Water (evaporation) Oligomer Thickener Photo-initiator

33 1% UV-curable FR coatings Halogene free FR additives: 1, 2, 3, 4% CTF2: Addiflam PN21 HF powder phospor based Addiflam - ceramic powder; intumiscent CHT: Apyrol PP 46 CRC 3 non aqua antimony & polyphosphate

34 1% FR UV-curable coatings Cotton EN ISO 694 Concentration FR additive Flame application time (s) Addiflam PN 21 HF Duration of flaming (s) Addiflam CRC 3 non aqua Apyrol PP 46 U V 1 % % % % Add-on: 25g/m²

35 WB FR UV-curable coatings Halogene free FR additives: Research grades Devan Chemicals: UVcoat2_P1: organofosphate; 1-4% UVcoat2_P2: phospor & nitrogen based; 15-3% UVcoat2_P3: fosphate based; 1-4%

36 WB FR UV-curable coatings Concentration FR additive Flame application time (s) Duration of flaming (s) UVCOAT2_P1 UVCOAT2_P2 UVCOAT2_P3 43,5 38, 38,2 29,4 1,5 (*) 43,5 38, 54,8 43,9 28,5 43,5 38, 5,5 7,7 47,5 UV EN ISO 694 Add-on: 27g/m²

37 Conclusion FR UV-curable coating Flame retardant UV-curable coatings are feasible 1% UV curable coatings: large potential 1% of FR passes the flame test! Water based: 4% of FR is needed Further research needed to confirm good results of flame retardant 1% UV curable

Commission under Seventh Framework Programme Grant agreement n 243556-2 Partners: ENSAIT, IVGT,

38 Participation in FP7 project Intimire INTUMESCENT MATERIALS WITH IMPROVED FIRE RETARDANT AND FLAME RESISTANT PROPERTIES FOR BUILDING and TRANSPORT APPLICATIONS Project supported by European Commission under Seventh Framework Programme Grant agreement n Partners: ENSAIT, IVGT, TEXCLUBTEC, DEVAN, INCA, CENTEXBEL, UPTEX, IQAP, MECACORP, WEBER, CREPIM, SANDER, LUXILON, TRISIT, CLUBTEX

39 INTIMIRE Evolution in the strict CE regulation and standards for fire retardant products: regulations for materials used in railway transport: ST EN novel standards of upholstered furniture: norm NF D 613 evolution of the automotive fire test standard FMVSS 32

INTIMIRE Requirements flame retardant upholstery fabrics Exclusive use of fabrics with a low rate of heat release Avoid the use of fabrics that spread the fire to other elements with burning droplets

40 INTIMIRE Requirements flame retardant upholstery fabrics Exclusive use of fabrics with a low rate of heat release Avoid the use of fabrics that spread the fire to other elements with burning droplets No release of toxic gas Limitation at the minimum rate the smoke Use of fabrics capable to prevent ignition of the underneath layers (foam, or stuffing) even at intense flames (e.g. in railway application against vandalism using flames)

41 Future actions FR4Tex - Fire-retardant textiles in 215: reconciliating regulations, ecology and economy? Environmental impact Regulations / REACH Eco-labels

42 Traject FR4Tex Alternative FR products are currently developed not halogenated halogenated, but with reduced impact on the environment Focus on replacement of halogenated FR products Evaluation of synergetic effects

43 Outline Centexbel: company presentation Fire retardant textile research Flame retardants coating Conclusions

44 Conclusions Centexbel has an extensive fire lab for a variety of tests Centexbel has done a lot of efforts regarding research on fire retardant textiles Due to the importance of these textiles and this functionality Centexbel keeps investigating in research on new technologies and materials Goal is to provide the textile companies possibilities to put FR textiles on the market, even in the most critical markets.

45 Fire Retardant Textile Coatings Requirements, Challenges, Solutions ECC on fire retardant coatings 13&14/3/212 Berlin

EU flammability standards and ENFIRO

EU flammability standards and ENFIRO Pim Leonards Institute for Environmental Studies, VU University Amsterdam Email: pim.leonards@vu.nl EU research project FP7: 226563 Life Cycle Assessment of Environment-Compatible