Fire Retardant Textile Coatings Requirements, Challenges, Solutions ECC on fire retardant coatings 13&14/3/212 - Berlin
Outline Centexbel: company presentation Fire retardant textile research Flame retardants extrusion Flame retardants coating Conclusions
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 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
Floor covering EU classification EN 1351-1 EN 11925-2 ignitability all floor covering: textile, wood, resilient (PVC), cork
Floor covering EU classification EN 1351-1 EN 9239-1 Reaction at fire all floor covering: textile, wood, resilient (PVC), cork
Transportation
Smoke density chamber density & toxicity
LOI Cone calorimeter
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
R&D on finishing/coating/dyeing Material functionalisation FR Material substitution X-FR Surface modification Surface protection Durable coating/finishing/dyeing techniques
Flame retardants in textiles Requirements Challenges Some solutions
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
Curtains current status
Different methods, same end use M1, M2 (FR) Classifications not interchangeable Type B,C (UK) B1 (GE)
Curtains the future?
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 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
Solutions Fire retardant textile research Addition of flame retardants during extrusion Use of flame retardants in coating
Flame retardants coating FR hotmelts FR UV-curable coatings
Flame retardants coating FR hotmelts FR UV-curable coatings
FR hotmelts Cornet project functionalised hotmelts In cooperation with Aitex (ES) & ITV (DE) 28-211
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
Compounding FR hotmelts Substantial increase in viscosity visc. @ 14 C visc. @ 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
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
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 g/m² 2% of FR1 => PASS Viscose mattress ticking With coating of 15 g/m² and 3 g/m² 2% of FR1 => PASS
FR testing FR Flame test - ISO 12952 3/4 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 coating of 15 g/m² Even 4% of FR1 => FAIL With coating of 3 g/m² 2% of FR1 => PASS
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
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
UV curable coatings Substraat 1 % Oligomer Monomer diluent Photo-initiator water based Water (evaporation) Oligomer Thickener Photo-initiator
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
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 % 1 2 3 2 % 1 2 3 3 % 1 2 3 4 % 1 2 3 Add-on: 25g/m²
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%
WB FR UV-curable coatings Concentration FR additive Flame application time (s) 1 2 1 1 2 15 1 2 2 1 2 3 1 2 4 1 2 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
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
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 243556-2 Partners: ENSAIT, IVGT, TEXCLUBTEC, DEVAN, INCA, CENTEXBEL, UPTEX, IQAP, MECACORP, WEBER, CREPIM, SANDER, LUXILON, TRISIT, CLUBTEX
INTIMIRE Evolution in the strict CE regulation and standards for fire retardant products: regulations for materials used in railway transport: ST EN 45545 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 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)
Future actions FR4Tex - Fire-retardant textiles in 215: reconciliating regulations, ecology and economy? Environmental impact Regulations / REACH Eco-labels
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
Outline Centexbel: company presentation Fire retardant textile research Flame retardants coating Conclusions
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.
Fire Retardant Textile Coatings Requirements, Challenges, Solutions ECC on fire retardant coatings 13&14/3/212 Berlin Myriam.vanneste@centexbel.be