Multilayer Semipermeable Fabrics with Electrospun Nanofiber Membranes for Chem-Bio Protection and Flame Retardancy

High Resolution Image Download MS PowerPoint Slide Protective fabrics that combine chem-bio (CB) protection, flame retardancy, and thermal comfort are critical for high-risk applications. However, achieving this combination for lightweight and breathable materials remains a significant challenge. This study reports the development of a breathable multifunctional nylon/cotton blend (50:50) (Nyco) fabric with an electrospun thermoplastic polyurethane (TPU) membrane for enhanced chem-bio protection and flame retardancy. The composite membrane was fabricated by electrospinning a TPU solution containing a zirconium-based metal–organic framework (MOF) along with tannic acid, a nonhalogenated flame retardant onto a phosphoric acid-treated Nyco fabric. The samples were investigated by analyzing their morphology, thermal stability, chemical resistance, flammability, air permeability, and particle filtration efficiency. Morphological analysis showed electrospun nanofibers (0.2–0.4 μm diameter) with well-dispersed MOF particles of about 0.5–5 μm. Thermal analysis demonstrated reduced degradation temperatures with enhanced char formation (up to 29.53%), providing an effective thermal barrier necessary for enhanced thermal stability. Flammability tests confirmed improved flame resistance of the composite membranes, showing shorter char lengths (6 in.) and reduced after-flame times (5 s), compared to untreated samples. Cone calorimetry further demonstrated enhanced fire performance with the optimized composite reducing the peak heat release rate and total heat release by up to 23% and 24%, respectively. Chemical resistance testing using the nerve agent simulant dimethyl methyl phosphonate (DMMP) demonstrated the fabric’s superior chemical protective capabilities. The integration of MOFs resulted in extended breakthrough times (5.2 min, 10-fold) due to the presence of the electrospun membrane layer and MOFs’ high surface area and reactivity contributing to the effective adsorption of DMMP. These results demonstrate a clear and systematic improvement in chemical resistance relative to untreated control Nyco. The air permeability (4.07 L m –2 s –1 ) and particle filtration efficiency (99.99%) tests revealed an optimized balance between breathability and protective performance, ensuring protection without compromising comfort. The results highlight the potential of these advanced materials for protective clothing applications in high-risk environments, offering a unique combination of lightweight design, durability, and multifunctionality, making them promising candidates for military, emergency response, and industrial safety applications.