Surface Coating for Flame-Retardant Behavior of Cotton Fabric Using a Continuous Layer-by-Layer Process

Cotton's exceptional softness, breathability, and absorbency have made it America's best-selling textile fiber; however, cotton textiles are generally more combustible than their synthetic counterparts. In this study, a continuous layer-by-layer self-assembly technique was used to deposit polymer clay nanocoatings on cotton fabrics to enhance their flame retardancy. Alternating layers of positively charged branched polyethylenimine (BPEI) with urea and diammonium phosphate and negatively charged clay nanoparticles were continuously applied to the fabrics in a single process without rinsing. The morphology and flame-retardant properties of the coated fabrics were characterized using scanning electron microscopy (SEM) and a variety of flammability tests. The treated fabrics exhibited improved thermal stability, as evidenced by increased ignition times and lower heat release rates. The results of this study show that flame-retardant nanocoatings can be readily applied to textile fabrics using a continuous process that is ideal for commercial and industrial applications.