Flame Retardant Polyamide Fibers for Space Crew Clothing

NASAs vision is to eventually establish human outpost stations on the Moon and explore Mars and other destinations further out of the Lower Earth Orbit (LEO). During these space missions, astronauts need to be protected inside space vehicles and space habitats with an atmosphere of 36% oxygen at a pressure of 8.2 psi. To address this need, intrinsically flame-retardant (FR) halogen-free polyamide fibers and fabrics were developed for space crew clothing during the Phase I project. FR polymers were melt spun into multi-filament yarns and knitted into flexible FR textile fabrics. The knitted FR fabrics demonstrated a V-0 grade in the standard UL-94 testing. In the proposed Phase II effort, the FR polyamide polymer developed in the Phase I effort will be optimized to improve the FR property and scaled-up for producing close-to-skin garments for crews in future space missions. In Phase I, intrinsically flame-retardant (FR) halogen-free polyamide fibers and fabrics were developed for space crew clothing and for use in spacecraft cabins in an atmosphere of 36% oxygen at a pressure of 8.2 psi.  The value of this innovation is a comfortable, durable FR fiber and fabrics designed for extended space flight. The thermal stability of the FR polymer was evaluated using thermogravimetric methods. The melting and recrystallization temperatures were measured using differential scanning calorimetry. Microscale Combustion Calorimetry (MCC) analysis demonstrated >50% reduction of heat release capacity in the FR polymers compared to neat polymer resins indicating their potential in the production of FR polyamide fibers. FR polymers were melt spun into multi-filament yarns and knitted into flexible FR textile fabrics.  The knitted FR fabrics demonstrated a V-0 grade in standard UL-94 testing. In  Phase II, the FR polyamide polymer developed in the Phase I will be optimized to improve the FR property and scaled-up for producing close-to-skin garments for space missions. The objective of the Phase II effort is to fine-tune, expand, and scale-up the FR polyamide polymer and the melt spin production of multifilament yarns. This will be followed by the building of a prototype inner garments (T-shirts, and socks) along with system level testing at NASA JSC and White sands fire testing facilities.  Work plan includes the following tasks: Materials Procurement Optimization of Precursors Synthesis and FR-Polyamide High Pressure Synthesis Multifilament Yarn Production Physical properties of FR-Yarns Production of knitted fabrics Physical properties of knitted fabrics Biocompatibility & Toxicity Testing (EPA’s ‘Six-Pack’ Testing) Fabrication of inner garments, Deliverables and Cost Evaluation Phase II Report and Phase III Commercialization Planning

The ultimate value of this innovation is comfortable, durable FR textiles for extended space flight. The new next-to-the-skin flame-retardant fabrics can be used in NASA programs like the lunar Human Landing System (HLS), Orion, Gateway, and Artemis. The FR fabrics developed in this project will allow the astronauts to function in the oxygen-rich atmosphere such as habitats, pressurized rovers, and other space vehicles. Flame retardant Nylon polymers can be used in electrical devices, construction materials, and textiles. Textile products  include panel fabric, Upholstery, Wallcoverings, Bedspreads, blankets, Window screens, Drapery, and Mattresses. MMI's FR Nylon can be extended to other markets, including plastic products, electronics, wire and cables, and lithium batteries in transportation. 

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