Synergistic flame retardant effect of carbon nanohorns and ammonium polyphosphate as a novel flame retardant system for cotton fabrics

The development of environmentally friendly flame retardants that can achieve high efficiency for textiles at low addition levels is of great significance to human life and environmental protection. Halogen flame retardants have long dominated in flame retardant applications. However, there are increasing calls to ban its use because of the threat they pose to human health and the environment. Herein, this work investigated the potential of a novel carbonaceous nanomaterials-single-walled carbon nanohorns (SWCNHs) coating material for flame retardancy of cotton fabrics. The unique combination of SWCNHs and ammonium polyphosphate (APP) in a single halogen-free nanocoating has a synergistic effect, which endows cotton fabric with prominent fire resistance. When the addition amount of SWCNHs was 0.15 %, the limit oxygen index (LOI) could reach 27.5 ± 0.83 %, and the damage length decreased from 30 ± 0.01 % cm to 6.5 ± 0.06 % cm. SEM results showed that Cotton-APP/SWCNHs (0.15) still displayed well-preserved woven structure after the vertical flammability test. Additionally, the pHRR and THR of Cotton-APP/SWCNHs (0.15) were markedly decreased by 92.22 % and 58.44 %, respectively in the cone calorimeter test. Meanwhile, the flame retardant mechanism analysis confirmed that the incorporation of SWCNHs into the APP coatings promoted the formation of dense and stable graphitized carbon layer on the surface of the cotton fabric, and effectively prevented the generation of combustible volatiles, thus enhancing the flame retardant performance of cotton fabrics. This work provides a new insight into developing carbon nanomaterials for flame retardant polymeric materials and extending the application of SWCNHs.