Blending alginate fibers with polyester fibers for flame-retardant filling materials: Thermal decomposition behaviors and fire performance

Abstract

Abstract Polyester fibers are often applied as filling materials; however, they are flammable and exhibit melt-dripping. In this work, to prepare fibers with high flame retardancy, inherently flame-retardant alginate fibers were blended with polyester fibers, without using any toxic chemicals. The blended fibers with 20\xa0wt.% alginate fibers achieved quick self-extinguishing without any melt-dripping in the vertical flame test and a test according to Pennsylvania Stuffed Toy Regulations. During the cone calorimetry test, the blended materials with 50\xa0wt.% alginate fibers showed a remarkable decrease in heat and smoke release, compared with the blend with 20\xa0wt.% alginate fiber and polyester fibers. Moreover, the alginate fibers could decompose prematurely and then delay the weight loss of polyester components when the natural/synthetic blends were subjected to heating. Also, they exhibited flame-retardant activities both in the vapor phase by the fuel dilution of non-flammable gases and in the condensed phase by forming calcium-enriched residues that were incompatible with polyester melts. Given their ease of preparation and high flame retardancy, the blended fibers have the potential for applications as filling materials of children s toys, furniture, and clothing.