key: cord-0951078-ynr336rf authors: Wang, Xingguo; Wang, Wenjia; Wang, Shuheng; Yang, Yufan; Li, Hongfei; Sun, Jun; Gu, Xiaoyu; Zhang, Sheng title: Self-intumescent polyelectrolyte for flame retardant poly (lactic acid) nonwovens date: 2020-10-02 journal: J Clean Prod DOI: 10.1016/j.jclepro.2020.124497 sha: 6da87ba5d9469c4a19503ea267dc54c9687d910c doc_id: 951078 cord_uid: ynr336rf The demand for eco-friendly poly (lactic acid) (PLA) nonwovens grows at a high rate in the past several decades, however, only a little attention has been received for flame retardant PLA nonwoven fabrics. In this work, a novel halogen-free self-intumescent polyelectrolyte tris (hydroxymethyl)-aminomethane polyphosphate (APTris) was synthesized by reacting ammonium polyphosphate with tris (hydroxymethyl) aminomethane, and was then used to improve the fire resistance of PLA nonwovens via a dip-nip process. The flammability characterization indicated the limiting oxygen index value was increased to 30.0% from 18.3%, and the damaged area in the vertical burning test was reduced by about 87.0% by the presence of APTris. The cone calorimeter test results revealed that the peak heat release rate and total heat release of the treated sample were decreased by 41.0% and 28.2% respectively compared with that of the control PLA nonwoven sample. The char residue was increased to 12.3 from 1.7 wt. % at 800 °C. It is suggested that the dense char barrier formed at the presence of APTris prevents heat, smoke, and gas transfer, and hence enhance thermal dilatability and flame retardancy of PLA nonwovens. This simple sustainable halogen-free treatment has great potential to produce cleaner commercialized flame-retardant PLA nonwovens. With the depletion of fossil resources and deterioration of the environment, bio-based and biodegradable materials have been drawn more and more attention. Poly (lactic acid) (PLA), which is derived from renewable resources (e.g., rice, corn, wheat, etc.), can be biodegradable to generate H 2 O and CO 2 (Iwata, 2015; Murariu and Dubois, 2016) , and has become one of the most widely used biodegradable materials. Compared with petroleum-based polymers, the production of PLA requires 25-55% less energy and consumes carbon dioxide, which doesn't cause environmental damage and pollution (Farah et al., 2016) . PLA fabrics are also considered as an ideal J o u r n a l P r e -p r o o f candidate to substitute petroleum-based chemical fabrics. PLA nonwovens grow at a high rate in the several decades (Wang et al., 2007) , and it is widely applied in the textile industry, such as upholstery backings, needle punched carpets, agricultural textiles, furniture fabrics, linings, and geotextile products (Cheng et al., 2016a) . Unfortunately, PLA nonwovens are unsuitable in many commercial cases for its intrinsic flammability (Parma et al., 2014) . PLA is flammable with a very low limited oxygen index (LOI) of 18~19%, and the key challenge for flame retardant PLA is the severe molten dripping. Although intensive efforts have been made on the flame-retardant PLA thermoplastics, the research on flame-retardant PLA nonwovens are rarely reported so far. Therefore, it is necessary to develop high value-added biodegradable flame-retardant PLA nonwovens in the textile industry (Cheng et al., 2019; Shahid ul et al., 2013) . The halogen-containing flame retardants were widely applied in the textiles industry (Kemmlein et al., 2009; Qi et al., 2014) , however, these halogenated compounds usually exist the harm of bioaccumulation in the environment and generate toxic gases during combustion to cause serious environmental pollution and health problems (Liu et al., 2020) . Therefore, halogen flame retardants are restricted more and more in many countries (Veen and Boer, 2012) . It has been demonstrated that P/N containing flame retardants are efficient additives to reduce the fire hazard of PLA thermoplastics (Bourbigot and Fontaine, 2010; Wang, X. et al., 2019) , and are more environmentally friendly than halogen-containing flame retardants. The introduction of phytic acid (PA) into PLA nonwovens by a pad-dry-cure process (Cheng et al., 2016b) increased the LOI value of PLA/45%PA sample by 37.3% in comparison with that of the control PLA nonwoven sample, but hardly reduced the damaged length in the vertical burning test. Other research reported (Cheng et al., 2016a ) that cyclic phosphonate ester improved the flame retardancy of PLA nonwovens by gas-phase mechanism, and the LOI value was increased by 33.1%, but the performance of microscale combustion and vertical burning test was not satisfactory. A mixture of phosphonate esters was used to enhance the fire performance of PLA nonwovens (Avinc et al., 2012) , after complex drying and curing J o u r n a l P r e -p r o o f procedure, the treated fabrics could pass the criteria of NFPA 701 after washing. The sheath/core configuration bicomponent PLA containing intumescent flame retardants were prepared by melt spinning to fabricate PLA nonwovens by thermal bonding (Maqsood and Seide, 2019) . The obtained PLA/APP5/PES10/KL3 nonwovens showed a 46.0% reduction in pHRR and a 34.5% increase in residual mass compared pure PLA nonwovens, the LOI value of that increased to 30.4% from 19.3%. However, the preparation process which involves high temperature spinning and bonding, is complex and toilsome. In summary, the effective and feasible way for flame-retardant PLA nonwovens is still under seeking. Polyelectrolytes are long chain compounds with ionizable groups in their repetitive molecular units, which have been widely used as porous materials on environmental remediation, tissue engineering, and catalyst (Zhang et al., 2018) . Polyelectrolytes are prepared by ionic reaction in aqueous solution, which is convenient, efficient, and eco-friendly (Christophe et al., 2004) . In recent years, polyelectrolytes have attracted extensive attention in the flame-retardant application. Some bio-based materials including phytic acid, chitosan, casein, and polyethyleneimine have been frequently selected to match each other as anionic or cationic (Holder et al., 2017) . For examples, the chitosan/phytic acid (Zhang et al., 2014) was used to improve the flame retardancy of vinyl acetate copolymer (EVA), and showed excellent intumescent effect to promote the EVA composite to form a compact char layer. Polyethyleneimine and oxidized sodium alginate were alternately coated on polyester-cotton blend fabrics by the layer-by-layer assembly (Pan et al., 2018 ), which enabled the fabrics self-extinguish after being ignited. Guanidine sulfamate (GSM) was added in intumescent polyelectrolyte to improve the flame retardancy of polyester fabrics by the LBL technique (Jordanov et al., 2019) . In our previous work, phytic acid, casein, and ammonium polyphosphate were combined to form core-shell bio-polyelectrolyte PC@APP, and the presence of only 5% PC@APP significantly decreased the peak heat release rate of PLA composites (Jin et al., 2019) . Overall, polyelectrolytes have been used to enhance the fire resistance of PLA plastic, so it is possible to improve the flame retardancy of PLA nonwoven fabrics by J o u r n a l P r e -p r o o f polyelectrolyte coating. In this work, a novel polyelectrolyte of tris(hydroxymethyl) aminomethane polyphosphate (APTris) was designed and prepared based on the acid-base equilibrium theory. A high phosphorus-containing ammonium polyphosphate (APP) was chosen as anionic, and a polyhydroxy compound tris (hydroxymethyl)-aminomethane was selected as a guest compound with opposite charge. APTris coating was then introduced onto the surface of PLA nonwovens by a convenient pressure leaching and heat cure process. The combustion behavior and thermal stability of treated PLA nonwovens were comprehensively evaluated, and the mechanism of APTris in improving the flame-retardancy of the fabrics was discussed. The strategy of coating single self-instrument polyelectrolyte provides an efficient, low cost way to enhance the fire safety of PLA nonwovens. The synthesis of water soluble APTris doesn't involve any toxic solvents, and involved raw materials are readily available at reasonable prices, and the dip-nip technology for flame retardant finishing of PLA nonwovens is efficient, low cost, and suitable for commercialization. To the best of our knowledge, the application of polyelectrolytes to endow flame retardancy of PLA nonwovens has not been reported so far, this work should be one of the few to focus on the flame retardancy of bio-based PLA nonwovens. Hydrosoluble ammonium polyphosphate (APP, 10