Fire Retardant Textile Coatings Requirements, Challenges, Solutions

ECC on fire retardant coatings – 13&14/03/2012 - Berlin

www.centexbel.be

Outline

Centexbel: company presentation

Fire retardant textile research

Flame retardants extrusion

Flame retardants coating

Conclusions

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Testing Research

Certification Consultancy

collective centre of competence

• 800 Belgian textile producers

• 100 associated national and

international companies

Activities & services of Centexbel

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Testing

burning behaviour ignitability

flame propagation

smoke density & toxicity

microbiological analysis anti-microbial effect

biodegradability

barrier effects

chemical analysis hazardous substances

extraction

VOC determination

physical testing abrasion

colour fastness

antistatic properties

Certification

GuT

Öko-Tex

Made in Green

CE-labelling

CertiPUR

Consultancy … and more

patent cell

in-company training

technological consultancy

standardisation

Activities & services of Centexbel

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Floor covering

EN 11925-2 ignitability

all floor covering: textile, wood, resilient (PVC), cork …

EU classification

EN 13501-1

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Floor covering

EN 9239-1 Reaction at fire

all floor covering: textile, wood, resilient (PVC), cork …

EU classification

EN 13501-1

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Transportation

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Smoke density chamber

density

&

toxicity

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LOI Cone calorimeter

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Functional Thermoplastic Textiles compounding, extrusion –

(bio-)polymers, (nano-)functionalisation

Research domains

Textile Functionalisation & Surface modification coating, finishing & laminating, dyeing

Human Health, Safety & Security medical and bio-functional textiles, cosmeto-textiles,

personal risk assessment & safety,

thermo-physiological comfort,…

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R&D on finishing/coating/dyeing

Material functionalisation FR

Material substitution X-FR

Surface modification

Surface protection

Durable coating/finishing/dyeing techniques

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Flame retardants in textiles

Requirements

Challenges

Some solutions

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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

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Curtains – current status

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Different methods, same end use

M1, M2 (FR)

Type B,C (UK)

B1 (GE)

Classifications not

interchangeable

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Curtains – the future?

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Challenges

Harmonised standards

Environmental impact

Regulations / REACH

ban penta-BDE & octa-BDE,

others classified as hazardous substances,

HBCD (communication needed >0.1wt%),

American market 2013: phase out of deca-BDE

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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”

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Solutions

Fire retardant textile research

Addition of flame retardants during extrusion

Use of flame retardants in coating

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Flame retardants coating

FR hotmelts

FR UV-curable coatings

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Flame retardants coating

FR hotmelts

FR UV-curable coatings

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FR hotmelts

Cornet project “functionalised hotmelts”

In cooperation with Aitex (ES) & ITV (DE)

2008-2011

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FR hotmelts

Compounding

PPA= Licocene 2602 (Clariant)

FR1= Exolit AP 423 (Clariant) – 10 to 40%

Process parameters

Characterisation compounds

Application

Influence add-on: 15 & 30g/m²

FR behaviour

Mattress ticking

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Compounding FR hotmelts

Substantial increase in viscosity

visc. @ 140°C visc. @ 160°C

PPA 19,62 10,62

19,46 10,72

PPA + 20%FR1 24,91 15,57

24,42 14,61

PPA + 30%FR1 47,61 32,82

47,34 32,91

PPA + 40%FR1 76,39 55,55

79,66 57,18

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Compounding FR hotmelts

Melting & crystallisation temperatures affected:

40% FR:

Tm increased with 5°C

Tc increased with 10°C

Hotmelt process parameters need to be selected

that can tackle the increase in viscosity, melt &

crystallisation temperatures

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Application FR hotmelts

Slot-die coater

Width: 45 cm

Temperature: up to 200°C

Speed: 0,5 – 30 m/min

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FR testing

FR – Cigarette test – ISO 12952 1/2

Visc/PP mattress ticking

With coating of 15 g/m² and 30 g/m²

20% of FR1 => PASS

Viscose mattress ticking

With coating of 15 g/m² and 30 g/m²

20% of FR1 => PASS

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FR testing

FR – Flame test - ISO 12952 3/4

Visc/PP mattress ticking

With coating of 15 g/m²

Even 40% of FR1 => FAIL

With coating of 30 g/m²

Even 40% of FR1 => FAIL

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FR testing

FR – Flame test - ISO 12952 3/4

Viscose mattress ticking

With coating of 15 g/m²

Even 40% of FR1 => FAIL

With coating of 30 g/m²

20% of FR1 => PASS

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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

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FR UV-curable coatings

IWT national research project “functionalisation

of UV-curable coatings for textile applications”

In cooperation with

Flamac

University College Ghent (TO2C)

2009-2010

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UV curable coatings

100 %

Oligomer

Monomer diluent

Photo-initiator

water based

Water (evaporation)

Oligomer

Thickener

Photo-initiator

Substraat

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100% UV-curable FR coatings

Halogene free FR additives: 10, 20, 30, 40%

CTF2000:

Addiflam PN21 HF powder – phospor based

Addiflam - ceramic powder; intumiscent

CHT:

Apyrol PP 46 CRC 03 non aqua – antimony &

polyphosphate

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100% FR UV-curable coatings Cotton

Concentration

FR additive

Flame

application

time (s)

Duration of flaming (s)

Addiflam PN 21

HF

Addiflam CRC 03

non aqua

Apyrol PP 46 U

V

10 % 1

2

3

0

0

0

0

0

0

0

20 % 1

2

3

0

0

0

0

0

0

0

30 % 1

2

3

0

0

0

0

0

0

0

40 % 1

2

3

0

0

0

0

0

0

0

EN ISO 6940

Add-on: 25g/m²

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WB FR UV-curable coatings

Halogene free FR additives:

Research grades Devan Chemicals:

UVcoat2_P1: organofosphate; 10-40%

UVcoat2_P2: phospor & nitrogen based; 15-30%

UVcoat2_P3: fosphate based; 10-40%

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WB FR UV-curable coatings

Concentration

FR additive

Flame

application

time (s)

Duration of flaming (s) UV

UVCOAT2_P1 UVCOAT2_P2 UVCOAT2_P3

0 1

2

43,5

38,0

43,5

38,0

43,5

38,0

10 1

2

0

38,2

50,5

7,7

15 1

2

54,8

43,9

20 1

2

0

29,4

47,5

0

30 1

2

0

28,5

40 1

2

0

1,5 (*)

0

0

EN ISO 6940

Add-on: 27g/m²

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Conclusion FR UV-curable coating

Flame retardant UV-curable coatings are feasible 100% UV curable coatings:

large potential

10% of FR passes the flame test!

Water based:

40% of FR is needed

Further research needed to confirm good results of flame retardant 100% UV curable

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Participation in FP7 project

Intimire

INTUMESCENT MATERIALS WITH

IMPROVED FIRE RETARDANT AND

FLAME RESISTANT PROPERTIES FOR

BUILDING and TRANSPORT APPLICATIONS

Partners:

ENSAIT, IVGT, TEXCLUBTEC, DEVAN, INCA,

CENTEXBEL, UPTEX, IQAP, MECACORP, WEBER,

CREPIM, SANDER, LUXILON, TRISIT, CLUBTEX

Project supported by European Commission under Seventh Framework Programme

Grant agreement n° 243556-2

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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 60013

evolution of the automotive fire test standard

FMVSS 302

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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)

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Future actions

FR4Tex - Fire-retardant textiles in 2015:

reconciliating regulations, ecology and economy?

Environmental impact

Regulations / REACH

Eco-labels

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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

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Outline

Centexbel: company presentation

Fire retardant textile research

Flame retardants coating

Conclusions

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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&14/03/2012 – Berlin

Myriam.vanneste@centexbel.be