Flame-retardant finishes durable

Nondurable Finishes. Flame-retardant finishes that are not durable to launderiag and bleaching are, ia general, relatively iaexpensive and efficient (23). In some cases, a mixture of two or more salts is more effective than either of the components alone. For example, an add-on of 60% borax (sodium tetraborate) is required to prevent fabric from burning, and boric acid is iaeffective as a flame retardant even at levels equal to the weight of the fabric. However, a mixture of seven parts borax and three parts boric acid imparts flame resistance to a fabric with as Utde as 6.5% add-on. 

The following sections will discuss some of the more important test methods in use for fabrics with durable press, flame-retardant, soil release, repellent, UV protective, antimicrobial, anti-insect, anti-felting, hand building and weighting finishes. 

Melamine—Formaldehyde Resins. The most versatile textile-finishing resins are the melamine—formaldehyde resins. They provide wash-and-wear properties to ceUulosic fabrics, and enhance the wash durability of flame-retardant finishes. Butjiated melamine —formaldehyde resins of the type used in surface coatings may be used in textile printing-ink formulations. A typical textile melamine resin is the dimethji ether of ttimethjiolmelamine [1852-22-8] which can be prepared as follows ... 

Incorporation of chitosan as well as increasing its concentration in the finishing formulation improved the durability and flame retardancy property. -The enhancement in the aforementioned properties was attributed to its synergetic effects as well as to the enhancement in the extent of phosphorylation... 

Phosphonomethylated Ethers. A phosphoms-containing ether of ceUulose can be prepared by the reaction of cotton ceUulose with chioromethylphosphonic acid [2565-58-4] ia the presence of sodium hydroxide [1310-73-2] by the pad-dry-cure technique (62). Phosphoms contents of between 0.2 and 4.0% are obtained. This finish is durable but has high ion-exchange properties and is flame resistant only as the ammonium salt. DurabUity on medium weight fabrics is obtained with chi oromethylph osph onic diamide. This finish has never penetrated the flame retardant market (63). 

Ammonia—Gas-Cured Flame Retardants. The first flame-retardant process based on curing with ammonia gas, ie, THPC—amide—NH, consisted of padding cotton with a solution containing THPC, TMM, and urea. The fabric was dried and then cured with either gaseous ammonia or ammonium hydroxide (96). There was Httle or no reaction with cellulose. A very stable polymer was deposited in situ in the cellulose matrix. Because the fire-retardant finish did not actually react with the cellulose matrix, there was generally Httle loss in fabric strength. However, the finish was very effective and quite durable to laundering. 

This provides a durable finish which, unlike many other flame retardants, can withstand repeated (50—100) launderiags without a loss of efficiency. An added advantage is that the feel of the cloth (hand) is Htde effected. Principal markets are ia the treatment of iadustrial protective clothing, military uniforms, and, ia Europe, for furnishings. These products are available from Albright Wilson Ltd. and Cytec Industries Inc. 

Ozone is being investigated for shrinkage prevention (182). Wool and blends of wool, cotton, and polyester have been finished to provide improved flame-retardant, durable-press, and shrinkage properties (183,184). Fabrics of these types are often used for uniforms or protective clothing (185). 

Early Durable Finishes. Early studies lo produce durable flame retardants for cellulose were based on treatment wilh inorganic compounds containing antimony and titanium. 

Flame relardanls are used in smolder-resistant upholstery fabric, combination flame retardant-durable press performance, flame-retardant treatments for wool, thermoplastic fibers (Tris. decabromodiphenyl oxide-polyacrylate finishes. Antihlu/e 19. nylon finishes), polyester-cotton fiber blends (THPOH-ummonju-Tris finish, decabromodiphenyl oxide-polyacrylate finish. THPC-amide-polytv illy I bromide) finish, THPOH-NHi and Fyrol 76. LRC-UX) finish, phusphonium salt-urea precondcn-satej. cotton-wool blends, and core-yam fabric,... 

Wool Wool, though not as flammable as cotton, still needs flame retardation for specific applications, e.g., carpets, upholstered furniture in transport, etc. Ammonium phosphates and polyphosphate, boric acid-borax, and ammonium bromide can be successfully used in nondurable FR finishes for wool. Various commercial products have been reviewed by Horrocks.3 The most successful durable treatment for wool is Zirpro, developed by Benisek, which involves exhaustion of negatively charged complexes of zirconium or titanium onto positively charged wool fibers under acidic conditions at 60°C. The treatment can be applied to wool at any processing stage from loose fiber to fabric using exhaustion techniques. 

In commercial use, easy-care and durable press finishes are frequently combined with other finishes to provide additional properties such as water and oil repellency, flame retardancy, soil release and the like. Often the combination of another finish with the cellulose crosslinking finish will result in a more durable effect from the first finish. Combination with pigment printing is very common because of similar chemistry to cellulose crosslinking agents and binders and the similar application conditions. 

Environment, toxicity With durable flame retardancy, formaldehyde emission during curing and after finishing, phosphorous compounds in the waste water Antimony oxide and organic halogen donators (DBDPO and HCBC) are discussed as problems (for example possibility of generating polyhalo-genated dioxins and furanes)... 

Although inorganic salts can provide excellent flame-retardant properties for cellulose, reasonable laundering durability must be incorporated into any finish destined for apparel use. The most successful durable flame retardants for cellulose are based on phosphorous- and nitrogen-containing chemical systems that can react with the fibre or form crosslinked structures on the fibre. The key ingredient of one of these finishes is tetrakis(hydroxymethyl)phosphonium chloride (THPC), made from phosphine, formaldehyde and hydrochloric acid (Fig. 8.11). THPC reacts with urea to form an insoluble structure on cellulose in a pad-dry-cure process (Fig. 8.12). 

A variation on the THPC-urea system was developed to produce finishes with less stiffness and fibre damage (Proban process). A precondensate is prepared by the careful reaction of THPC with urea. This precondensate is padded onto the fabric and the fabric is dried to a specific moisture content ( 15 %). The fabric is then exposed to ammonia vapours in a special reaction chamber, followed by oxidation with hydrogen peroxide (Fig. 8.13). The polymer that forms is primarily located in the lumen of the cotton fibre. The final finish provides durable flame retardancy to cotton with much improved fabric properties. It is important to note... 

Another approach to durable flame retardant finishes for polyester is the use of highly brominated chemicals as topical finishes. One particularly useful material is hexabromocyclododecane (HBCD, Fig. 8.19). To achieve durable flame retardancy, fabric padded with 8 % of a dispersion of this water insoluble material must be heated above 190 °C or 375 °F to form a film of the flame retardant on the fibre surface."... 

There are also serious side effects to fabric physical properties from flame-retardant finishing that must be recognised, often caused by the high application levels of the flame retardants. Harsh hand, loss of tensile suength and colour effects (fabric yellowing and dye shade changes) are common problems with durable flame-retardant finishes for cotton. The combination with other finishes, such as softeners, easy-care and repellent finishes, must be carefully tested. The flame retardancy of the multi-purpose finish is more often reduced than it is acceptable. 

Most flame-retardant finished textiles are excluded from the Oko-Tex Standard 100 label. In all cases, the durability of the finish is often a problem. It is the responsibility of the fabric finisher to address these issues if commercial flame-retardant fabrics are to be produced. An alternative for the fabric designer without most of the named problems is the use of flame-resistant modified fibres, but... 

Permanent antistatic fmishes, based on crosshnked polyamines and polyglycols, need an alkaline catalyst. Therefore the one-bath combination with finishes, which need acid catalysis, is difficult but not impossible. Examples of acid-catalysed fmishes are the easy-care and durable press fmishes, durable hydrophylic silicone softeners and elastomeric finishes, also fluorocarbon-based repellency and some flame-retardant finishes. High finish effects result from a two-bath application with of the easy-care finish first followed by the surface-related antistatic finish. 

A resinous flameproof product which provides flame retardancy to polyester fabrics and blends. The flame retardant properties are durable to many launderings. A mild after-wash following drying of treated fabrics will provide a soft flame retardant finish. 

A semi-durable flame retardant application especially suited for wool, wool/nylon, wool/polyester blends. Laundering will remove this finish. 

---