Purpose The purpose of this paper is to investigate the potential use of the layer-by-layer (LbL) assembly as an intumescent flame retardant for polyester, cotton and their blended fabrics. Design/methodology/approach In this study, polyester (PET), cotton and their blends were applied with the flame retardant coating via the LbL assembly technique. The flame retardancy, melt dripping, thermal properties and morphology of coated polyester fabrics were then examined. Findings The scanning electron micrograph of uncoated and coated fabrics revealed that the LbL assembly coating on the fabric surface was successful. The assessment of the flame retardancy and thermal properties of the coated fabrics showed that the after-flame time and melt dripping during the vertical burning test decreased. The char residue at temperatures ranging from 450 to 800°C during thermogravimetric analysis was enhanced as compared with the uncoated fabric. Furthermore, the morphology of the char residual of coated fabrics was rougher and bulkier than the uncoated fabrics, suggesting the typical behavior of intumescence. Social implications The LbL technique generally uses much fewer chemicals, thus making this flame retardant finishing much more environmentally friendly. It is also expected that these fabrics will show better touch characteristics. These fabrics may be tested for their comfort compared to that of conventional coating to enable their use on an industrial scale. Originality/value This work demonstrated the ability to apply an effective intumescent coating on polyester, cotton and blend fabric. In order to maintain fabric handle property, the Lbl coating technique is also employed.
Intumescent coatings consisting of branched-polyethyleneimine (BPEI) and ammonium polyphosphate (APP) solution were successfully applied on polyester fabrics by the layer-by-layer assembly technique to enhance the flame retardant and anti-dripping properties of polyester fabrics. The surface morphology of fabrics revealed that the coatings thoroughly covered the fabrics. The assessment of the vertical burning test of thin material (UL-94 rating VTM 0) indicated that the flame retardancy of coated polyester fabrics was improved significantly as compared with the uncoated fabric. The self-extinguishing ability and anti-dripping behaviors of coated polyester fabrics were also enhanced markedly. The improvement of flame retardancy depends on the number of coating layers and the amount of APP. However, after washing, the flame retardancy decreases to some extent. The morphology of char exhibits the typical structure of intumescent char on coated fabrics. The assessment of mechanical properties revealed that the intumescent coating via layer-by-layer assembly did not deteriorate the strength of the fabric. The increasing number of coated layers leads to the slight increase of the breaking force of the fabric; however, the increasing number of layers and the increasing amount of prepared APP lead to increased rigidity of the fabrics.
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