Multifunctional coating for polyester/spandex fabrics with carbon black/melamine polyphosphate/aluminum diethylphosphinate dispersion: flame retardancy and antistatic protection

The development of sustainable, multifunctional polyester/spandex (T/S) protective fabrics is of increasing importance for advanced textile applications. In this study, a stable and multifunctional dispersion comprising melamine polyphosphate (MPP), aluminum diethylphosphinate (ADP), and carbon black (CB) was prepared via zirconia bead-assisted grinding and subsequently applied to T/S fabrics using a roll-bake coating process with the aid of polyacrylate adhesive. The coated T/S fabrics were systematically evaluated for color characteristics, antistatic performance, flame retardancy, combustion behavior, and underlying flame-retardant mechanisms. The results revealed that the coated T/S fabrics exhibited stable black coloration and excellent antistatic property, with minimal impact on tensile strength and air permeability. Furthermore, the coated T/S fabrics demonstrated self-extinguishing behavior, with a significantly reduced damaged length of about 7.1 cm and no molten dripping. The limiting oxygen index reached 27.5%, indicating enhanced flame resistance. They also displayed significantly suppressed heat release capacity. Mechanistically, MPP and ADP promoted the formation of a stable char layer through acid catalysis and carbonization, while releasing phosphorus-containing radicals and inert gases that disrupted flame-propagating reactions and reduced local oxygen concentration, effectively inhibiting combustion.