Application of Flame-Retardant Double-Layered Shell Microcapsules to Nonwoven Polyester

Abstract

A microencapsulated flame retardant was used in order to produce a flame retardant nonwoven substrate. Melamine-formaldehyde polymer-shell microcapsules, containing Afflamit ® PLF 280 (resorcinol bis(diphenyl phosphate)) as the core substance, were coated by an outer thermoplastic wall (polystyrene (PS) or poly(methyl methacrylate)), before being applied to a core/sheet-type bi-component PET/co-PET spunbond nonwoven substrate using impregnation. The outer wall of the microcapsules was heated to the softening temperature of the thermoplastic shell in order to be bonded onto the textile fibres. The thermal stability of the microcapsules was examined using thermogravimetric analysis. The textile samples were observed with a scanning electron microscope, and the flame retardancy performance was evaluated using the NF P92-504 standard. The results show that the composition of the outer polymeric shell affected the thermal stability of the microcapsules, since the particles with a PS shell are more stable. Furthermore, the microcapsules were more located at the nonwoven surface without affecting the thickness of the samples. Based on the results of the NF P92-504 test, the flame spread rate was relatively low for all of the tested formulations. Only the formulation with a low content of PS was classified M2 while the others were M3.

An Overview of Carpet Manufacture: Design, Dyeing, Printing and Finishing

“…Recently, a microencapsulated FR was discovered to be useful in producing fire retardancy for a nonwoven substrate. Using the impregnation technique, melamine-formaldehyde polymer shell microcapsules containing resorcinol bis(diphenyl phosphate) were coated by an outer thermoplastic wall (polystyrene or poly(methyl methacrylate)) before being applied to a core/sheet-type bi-component PET/co-PET spunbond on a nonwoven substrate, resulting in improved fibre flame retardancy [42]. Furthermore, Alongi et al published a comprehensive research on the development of water-based flame-retardant coatings for polyester and polyester-cotton blends [43].…”

Bio-Functional Textiles: Combining Pharmaceutical Nanocarriers with Fibrous Materials for Innovative Dermatological Therapies

“…Micro- and nanocapsules are among the most employed carriers employed in textile finishing for a wide range of applications [107,191]. In the context of bio-functional garments, various kinds of core substances and shell materials can be combined in the capsule formation in order to impart health beneficial properties.…”

Potential use of microcapsules in manufacture of fibrous products: A review

“…Other variants having different number of shell layers are shown in Figure . For instance, some double‐walled microcapsules have a two‐layer shell, in which outer thermoplastic layer is used to bond the microcapsules onto the fibers . Systems with three layers are used in very complex microcapsules, for instance, in applications for thermal‐regulating fibrous materials…”