Durable and Nonflammable Crew Clothing Utilizing Phosphorus-based Fire-Retardant Materials

Protecting astronauts and spacecraft from the great threat of heat and fire is essential for the success of space programs. The ability to provide astronauts with safe yet comfortable clothing that suits their individual preferences and improves their overall well-being in space would be a significant benefit to the National Aeronautics and Space Administration (NASA). Current inherently flame retardant (FR) fibers may meet NASA’s needs in terms of flame protection, but they do not offer the comfort, breathability, or ease of customization desirable in everyday clothing. Heavy, harsh, or unappealing colored fabrics can result in noncompliance, imperiling crew safety and mission success. To meet these needs for safety, comfort and personalization in clothing, InnoSense LLC (ISL) has developed and evaluated laundering durable fire-retardant white and dyed fabrics (FREFAB). FREFAB fabrics consist of commonly used breathable and comfortable polyester (PET) and spandex materials modified with nontoxic phosphorus-based FR treatments. We have established highly effective FR formulations and FR treatment processes for polyester fabrics and spandex materials demonstrating durable attachment of the FR materials via covalent bonding. The FR treated fabrics show minimum weight gain (≤3±0.15%) and their integrity remains unchanged. The FR treated fabrics demonstrate low char lengths (≤4±0.20 inches for polyesters and ≤5±0.25 inches for spandex), low mass loss (≤2 ±0.10%), and no afterflame (burn propagation), melting, or dripping after vertical flame tests in both 20% and 34% oxygen environments. Tests were conducted according to ASTM D6413 and NASA guidelines. FR treated fabrics also demonstrate effective performance and durability after 25 laundry cycles for the polyester fabrics, and 10 laundry cycles for spandex. The development of FREFAB has broad implications for apparel, protective clothing, tents, transportation gear, curtains, drapes, upholstery, bedding and carpets used by NASA, firefighters and industry.