Development of sustainable flame-retardant bio-based hydrogel composites from hemp/wool nonwovens with chitosan-banana sap hydrogel

Flame retardant (FR) finishing is crucial for developing protective textiles, traditionally relying on halogen, phosphorus, and phosphorus-nitrogen chemistries, which have limitations like toxicity and fabric stiffening. Innovative approaches such as nanotechnology, plasma treatments, and natural resource-based finishes are being explored to achieve sustainable FR textiles. This study presents the development and comprehensive characterization of hydrogel composites made from nonwoven fabrics composed of various hemp/wool blends (70/30, 80/20, and 90/10). The nonwoven fabrics were treated with a chitosan hydrogel incorporating banana sap to enhance their properties. Scanning electron microscope (SEM) examined the surface morphology and structural integrity of the composites, while Fourier transform infrared spectroscopy (FTIR) identified chemical interactions and functional groups. Differential scanning calorimeter (DSC) revealed thermal properties, water absorbency tests demonstrated hydrophilicity, mechanical testing assessed tensile strength, and vertical flammability tests evaluated fire resistance. SEM and FTIR revealed a successful coating of chitosan hydrogel with banana sap inclusions onto the hemp/wool nonwoven fabric, forming a composite structure. DSC analysis suggests higher chitosan content and hemp fiber ratio (like 70/30) lead to increased thermal stability of hydrogel composites. Higher chitosan concentrations in the hydrogel significantly improve the flame-retardant properties of hemp/wool nonwoven fabrics by reducing char length and enhancing protective char layer formation, with banana sap further promoting charring. These results indicate that the developed composite can be effectively used in flame-retardant textiles.