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