Nano-Structures & Nano-Objects 39 (2024) 101253 Contents lists available at ScienceDirect Nano-Structures & Nano-Objects journal homepage: www.elsevier.com/locate/nanoso Nanostructured flame retardants: An overview Jolina Rodrigues , Navinchandra Gopal Shimpi 1, * Laboratory of Materials Science, Department of Chemistry, University of Mumbai, Santacruz (East), Mumbai 400098, India A R T I C L E I N F O A B S T R A C T Keywords: Flame retardants Coatings Thermal insulator Building materials Polymers and plastics Materials or structures at the nanoscale that are designed to prevent or lessen burning are used to make nano­ structured flame retardants. These materials have unique properties and mechanisms that make them highly effective at containing or preventing the spread of fire. A comprehensive description can be found on the clas­ sification of various nanostructured flame-retardant material kinds like metal oxide nanoparticles (NPs), phos­ phorous based NPs, hybrid nanocomposites (NCs), nano-clay, carbon-based NPs and surface modified NPs. By making use of the unique properties and interactions that nanostructured materials provide at the nanoscale, flame retardancy can be improved. Flame retardancy in nanostructured materials is a topic of great interest since it could lead to the creation of safer and more effective materials for a variety of applications. Nanostructured flame retardants find application in polymer plastics, textiles and fabrics, paints and coatings, electronics and electrical devices and building materials for automobiles. Opportunities and challenges for the future emphasize the significance it will be to develop environmentally friendly, sustainable and less dangerous flame-retardant formulations. 1. Introduction to nanostructured flame retardants Nanostructured flame retardants represent a cutting-edge strategy for improving fire safety in a variety of materials and applications. The conventional flame retardants frequently have negative effects on the environment, body and performance of materials. Nanostructured flame retardants provide a possible alternative by utilizing nanotechnology beyond these restrictions. Fundamentally, nanostructured flame re­ tardants are made of materials or structures at the nanoscale that are intended to impede or suppress burning. These substances have a special quality and working that makes them a very efficient to stope or reduce the spread of fire. The potential of nanostructured flame retardants to deliver outstanding fire protection with a reduced use of hazardous chemicals is one of its main advantages. The composition, structure, and interactions of materials with the environment by engineering it at the nanoscale accurately regulated by researchers [1–4]. This degree of control makes it possible to create flame retardants that are both extremely effective and safe for the environment. Many materials such as polymers, textiles, foams, and coatings, can include nanostructured flame retardants without noticeably sacrificing their mechanical or thermal properties. They can be used in a wide sector, including aero­ space, electronics, automotive, and construction because of their adaptability. Nanostructured flame retardants have other advantages beyond just preventing fires, which can extend the lifespan and overall performance of treated materials by boosting their resistance to deteri­ oration, thermal stability and durability. The widespread use of nano­ structured flame retardants is still in its infancy, despite their many benefits. To enable its commercialization and deployment on a larger scale, issues like scalability, cost-effectiveness, regulatory approval and possible health and safety problems must be resolved [5–7]. Finally, the development of nanostructured flame retardants has a great promise for improving fire safety in contemporary materials and applications. These cutting-edge materials have the potential to completely transform how to prevent fires while encouraging sustainability and environmental responsibility with continued research and development [8–23]. 2. Types of nanostructured flame retardants 2.1. Nanostructured metal oxides A well-known class of flame retardants in fire safety applications are nanostructured metal oxides because of their inherent qualities and adaptability. These materials have distinct benefits in terms of flame retardancy, which comprises a wide variety of metal oxides arranged at * Corresponding author. E-mail address: navin_shimpi@rediffmail.com (N.G. Shimpi). 1 ORCID ID: 0000–0003-0291–1804 https://doi.org/10.1016/j.nanoso.2024.101253 Received 26 May 2024; Received in revised form 27 June 2024; Accepted 4 July 2024 Available online 6 July 2024 2352-507X/© 2024 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies. J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 the nanoscale (Fig. 1). Alumina NPs or aluminium oxide (Al2O3) are a powerful flame retardant due to their high melting points and outstanding thermal stability. Alumina NPs create a barrier that pre­ vents heat and oxygen from reaching the substrate, which slower down the burning process over the surface of materials. Alumina NPs which form the char layer functions as a barrier against the spread of heat and flames. Because nanostructured magnesium oxide (MgO) releases water vapor at high temperatures, it naturally has flame-retardant qualities. The release of water vapor dilutes combustible gasses and prevents ignition by cooling surface of the material. Furthermore, the creation of char layers can be accelerated by nanostructured MgO, with strength­ ening the material’s resistance to flame spread and ignition. Flame retardancy is one of the useful qualities of nanostructured zinc oxide (ZnO). ZnO NPs function as excellent flame retardants by lowering the material’s temperature and preventing ignition and flame spread, by absorbing and dissipating heat energy. ZnO NPs can encourage the production of char layers with increasing the resistance of material to fire, additionally through catalytic reactions. TiO2 can be used for flame retardancy as it has excellent photocatalytic qualities. TiO2 NPs have the ability to restrict the spread of flames by catalysing the breakdown of combustible gasses and improving the creation of char layers. Besides this UV stability of materials can be increased using nanostructured TiO2, which can stop degradation and strengthen long-term fire pre­ vention capabilities. For reducing combustion and improving fire safety in a range of materials and applications, each type provides special mechanisms. Novel nanostructured metal oxides are still being investi­ gated, and efforts are being made to maximize their performance in order to improve flame retardancy [24–34]. cylindrical structures known as carbon nanotubes (CNTs). CNTs are useful for increasing fire resistance of materials due to their remarkable mechanical strength, thermal conductivity and flame-retardant quali­ ties. CNTs provide a barrier over the surface of a material used in flame retardant applications which prevents the transmission of heat and ox­ ygen and lowering the flammability. The CNTs materials resistance is strengthen towards ignition and flame spread is slow due to char for­ mation over the surface. A two-dimensional sheet of carbon atoms organized in a hexagonal lattice is called graphene, while graphene oxide (GO) is a derivative of graphene that has functional groups con­ taining oxygen. Graphene and GO are attractive options for flame retardant applications because of their superior mechanical strength, thermal conductivity and barrier qualities. On the surface of the mate­ rial, graphene and GO can form a barrier that inhibits the spread of flames by limiting the amount of heat and oxygen that reaches to the material. These substances encourage the formation of char layer and strengthens the substance’s resistance ability to burning and igniting. CNFs are of fibrous topology useful additives for flame retardance due to high aspect ratios surface area and superior thermal stability. CNFs can promote the development of char layers in flame retardant applications, which serves as an insulating barrier against the spread of heat and flames. Moreover, CNFs can enhance material’s mechanical qualities, enhancing its overall durability and fire resistance. The small carbon particles that are left over after hydrocarbons burn incompletely are what make up carbon black. Since carbon black has a large surface area, good light absorption qualities, and the capacity to encourage char formation, it is frequently employed as a flame-retardant additive. Carbon black is used in flame retardant formulations to absorb heat and infrared radiation which lowering down the material’s temperature and preventing from the spread of flames. Furthermore, carbon black can promote the development of stable char layers, which serve as barriers to prevent further combustion. These carbon-based NPs provide adapt­ able ways to enhance fire safety in a range of materials and applications such as composites, polymers, textiles and coatings. Novel synthesis techniques and optimization approaches are still being investigated in ongoing research to improve the materials flame-retardant qualities and compatibility of matrix [35–44]. 2.2. Carbon-based nanomaterials Another significant class of nanostructured flame retardants are carbon-based nanomaterials, which have special qualities and working principles, which improves fire safety in a variety of applications (Fig. 2). These materials suppress or prevents combustion by taking use of the remarkable thermal stability, large surface area, and distinct structural characteristics of carbon at the nanoscale. Carbon atoms are organized in a special hexagonal lattice to form the Fig. 1. Nanostructured metal oxides as flame retardant. 2 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 Fig. 2. Applications of different carbon-based nanomaterials as flame retardants. 2.3. Nanoclays nanotubes have reduced flammability, improved heat stability and an enhanced char forming process. As flame-retardant additives, nanoclays have a number of benefits which including being naturally abundant, inexpensive, compatible with a wide range of polymers and environ­ mentally benign. Researchers are still creating novel flame-retardant formulations with enhanced fire safety performance for a variety of applications such as plastics, textiles, coatings and building materials, by utilizing the special qualities of nanoclays [45–55]. Nanoclays are another class of nanostructured materials with great potential to flame-retardant applications. These materials are made of layered silicate minerals that have been changed or exfoliated to a create particles to nanoscale. The minerals are featured usually as plate-like due to their special qualities and capacity to improve fire safety in a variety of materials while nanoclays are used frequently as a flameretardant additive (Fig. 3). Montmorillonite (Mmt) is one of the most often utilized nanoclays in flame-retardant application. A naturally occurring clay made up of magnesium and aluminum silicate layers. NCs with enhanced flame-retardant qualities can be created by dispersing montmorillonite particles, which are in nanometric size, within polymer matrix. Mmt NCs show improved char formation with decreased flam­ mability and increased thermal stability upon comparing to neat poly­ mers. Improved flame-retardant effectiveness results from Mmt NPs to broad interface for interactions with polymer chains, which is caused by their high surface area and aspect ratio. Organically altered Mmt nanoclays series known as cloisite clays is created when organic molecules functionalized the interlayer gaps be­ tween two layers. Mmts are improved dispersion and compatibility with polymer matrices. There are benefits of organically modified Mmt which result in more consistent flame-retardant properties such as physical barriers, decreasing heat and mass transport during burning and encouraging the development of char. Hollow lumen is another kind of naturally occurring clay (i.e halloysite) and is rolling or tubular shape. Halloysite nanotubes are useful flame-retardant additives for polymers due to enormous surface area and high aspect ratio. Tubular shape of halloysite nanotubes enables the encapsulation of additives or flame retardants within their lumen which allowing for regulated release during burning. Polymer nanocomposites that contain halloysite 2.4. Phosphorus-based nanocomposites A promising family of flame retardants known as phosphorus-based nanomaterials uses the special qualities of phosphorus compounds to improve fire safety in a variety of materials. These nanomaterials, which have effective flame-retardant qualities, usually contain chemicals or NPs organized at the nanoscale that contain phosphorus (Fig. 4). Polymers that include phosphorus which including phosphoruscontaining polymeric NPs or NCs are frequently utilized as an additive that retard flames. Phosphorus groups are present in these polymers as pendant groups or inside the polymer backbone, and they can react chemically during combustion to produce thermally stable char layers. Gas-phase and condensed-phase mechanisms are used by phosphoruscontaining polymers to prevent the development of flammable gasses and encourage for the formation of char layer over the surface of the material. The flame-retardant efficacy of phosphorus-containing poly­ mers is increased and negative effects on material qualities are reduced through the nanoscale dispersion of these polymers within the matrix. Phosphorus-based NPs have good flame-retardant qualities. Examples of these include phosphorus-containing metal oxides (phosphates, phos­ phides), phosphorus-doped carbon nanomaterials and phosphorusbased quantum dots. These NPs can be distributed throughout Fig. 3. Different types of nanoclays. 3 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 Mechanical qualities, thermal stability, and other required features can be optimized together with flame retardant performance by varying the type, concentration and dispersion of nanofillers and the composition of the polymer matrix. Customizable features allow hybrid NCs to be used in a variety of applications such as electronics, construction materials, automotive components, textiles and coatings. A variety of processing methods such as melt blending, solution mixing, in situ polymerization and layer-by-layer assembly, can be used to create hybrid NCs. To attain consistent dispersion and robust interfacial interactions between various nanomaterials and the polymer matrix, meticulous regulation of pro­ cessing parameters is necessary. Hybrid NCs enhance fire safety through synergistic effects between different nanomaterials by char formation, enhanced thermal stability, improved head shielding, endothermic reactions and catalytic action. The char layer’s structural integrity, resistance to heat, and ability to withstand mechanical stress are all improved by the superior mechani­ cal reinforcement that CNTs provide. On the other hand, stacked sili­ cates improve the insulating qualities of the char layer by forming a barrier to heat and mass transport. In addition to having reflecting qualities that lessen heat absorption, metal oxides function as catalysts for the creation of char. Carbon nanomaterials, such graphene or carbon nanotubes (CNTs), improve the char layer’s mechanical strength and thermal stability. The char layer’s barrier qualities are strengthened with nanoclay, increasing its resistance to heat and gas diffusion. By absorbing heat and releasing water vapor, metal hydroxides help to cool down the substance and postpone ignite [102–107]. The creation of hybrid NCs with precise microstructures and properties suited for particular flame-retardant applications is made possible by advanced fabrication techniques. A possible method for boosting flame retardancy and simultaneously strengthening other material properties is the use of hybrid NCs. Their adaptability, synergistic effects and customized qualities make them excellent choices for dealing with fire safety issues in a range of sectors. For improved flame retardant uses, hybrid NCs are being developed through ongoing materials science and nanotechnology research [63–67]. Advantages of hybrid nanocomposites are enhanced flame retardancy, improved thermal stability, enhanced mechanical properties, lower loading and tailored properties. Hybrid NCs achieve superior flame retardancy through synergistic interactions. Hybrid NCs maintains and enhance the mechanical properties of the base polymers. Hybrid NCs require lower loadings of flame retardancy to achieve the desired level of fire resistance, maintaining the inherent properties of polymer such as transparency, flexibility and processability. Enhanced thermal stability of hybrid NCs makes it more resistant to high tem­ perature and thermal degradation. Hybrid NCs properties can be tailored by adjusting the type and ratio of nanomaterials. Table 1 shows the fire-retardant performance, advantages, disadvantage and applica­ tions of different materials [108–128]. Application of Hybrid Nanocomposites Fig. 4. Various phosphorous nanocomposites as flame retardants. polymer matrices to create NCs with increased fire resistance, Phosphorus-based NPs work in a number of ways which including a as gas-phase flame suppression, catalysis and the creation of protective char coatings. The effective flame-retardant performance of phosphorusbased NPs at low loading levels is attributed to their large surface area and reactivity. Paints, polymer composites and fire-retardant coatings frequently use intumescent flame-retardant solutions that contain phosphorus compounds. Usually, phosphorus-containing compounds, a carbon source, and a blowing agent are combined to form these systems. Intumescent systems go through a complicated chemical reaction when exposed to heat or flame. The result is the formation of a thick, insu­ lating char layer that shields the underlying material from further burning. Improved dispersion, reactivity and efficiency are provided by nanostructured versions of phosphorus-based intumescent flameretardant solutions, which increase fire safety performance. When used as flame retardants, phosphorus-based NPs provide a number of benefits, such as great efficacy, minimal toxicity and material compat­ ibility. They can be used in a variety of applications, including as polymers, textiles, foams, coatings and building materials due to their adaptable methods of action. Novel synthesis techniques and optimi­ zation tactics are still being investigated in order to improve the flameretardant qualities of phosphorus-based NPs and encourage their broad use in fire safety applications [56–62]. 2.5. Hybrid nanocomposites A class of cutting-edge materials known as hybrid NCs combines two or more distinct types of NPs into a single matrix. These materials are very appealing for many applications, including flame retardancy because they have synergistic effects and improved qualities over their individual components. Typically, two or more types of nanofillers such as NPs, nanoclays, carbon- or phosphorus-based nanomaterials, or other functional additives which reinforce a polymer matrix to create hybrid NCs. The integration of various flame-retardant mechanisms, including char formation, gas-phase flame inhibition, heat dissipation and barrier effects is made possible by the mixing of diverse nanomaterials, improving fire safety performance. Compared to separate components, hybrid NCs obtain superior flame-retardant capabilities by utilizing the synergistic interactions between several nanomaterials. For instance, adding phosphorus-based NPs can improve gas-phase flame inhibition and thermal stability, while adding nanoclays to carbon-based nano­ materials can increase mechanical strength and char formation. In comparison to single-component systems, hybrid NCs synergistic effects improve flame retardant efficiency, decrease flammability and increase fire resistance. Depending on the needs of a particular application, hybrid NCs provide the flexibility to modify the material properties. 1. Construction and Building Materials: To improve building fire safety, hybrid nanocomposites are included into structural elements, coat­ ings, and insulating materials. They are perfect for usage in wall coverings, roofing materials and fire-resistant panels because of their enhanced mechanical and flame-retardant qualities. 2. Aerospace and Automotive: High performance in terms of mechan­ ical strength and flame retardancy is required by the automotive and aerospace sectors. To meet strict safety criteria, hybrid nano­ composites are employed in insulation materials, structural parts and interior components. 3. Electrical and Electronic Equipment: Flame-retardant materials are essential in electronics to avoid fires from electrical faults or over­ heating. With hybrid nanocomposites, fire safety is improved in housings, connectors, and circuit boards without sacrificing the functionality of the electronic equipment. 4. Fabrics and Textiles: Textiles that are resistant to flames are crucial for a number of uses, such as draperies, furniture, and protective 4 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 Table 1 Comparison of different materials as flame retardants. Sr No Material Type Fire performance Advantages Disadvantages Applications 1 MOFs Hybrid Nanomaterial Polymer composites, coatings, advanced fire-retardant systems Graphene Oxide 2D Nanomaterial Tendency to restack in polymer matrix, high cost, limited largescale production Coatings, sensors, polymer composites 3 MXenes 2D Nanomaterial Significant resistance transition upon fire exposure, quick firewarning response High cost, complex processing, potential environmental concerns Fire sensors, polymer composites 4 Halogenated Compounds Organic / inorganic LDHs Inorganic Nanomaterial Releases toxic gases during combustion, environmental and health concerns, potential regulatory restrictions Poor dispersion in polymer matrix, may require functionalization to improve compatibility Electronics, textiles, building materials 5 Effective flame retardancy at low cost but associated with toxicity and environmental issues Reduces flammability, enhances thermal stability by forming a protective layer High porosity, tunable structure, effective at low loadings, can act as templates for LDHs High surface area, excellent thermal stability, environmentally friendly, rapid-fire detection High conductivity, rapid fire response, repeatable firewarning capability, high sensitivity Effective at low concentrations, widely used, cost-effective Limited large-scale application, potential for high cost, stability under high temperatures 2 Improved dispersion and compatibility in polymers, enhances flame retardancy through char formation Ultra-fast flame detection, improved flame retardancy through char layer formation 6 Silicon-based Retardants Inorganic Electronics, construction, textiles 7 Nanoclays Inorganic Nanomaterial Can be less effective at lower loadings, higher cost compared to traditional retardants Can aggregate in polymers, requires functionalization to improve compatibility 8 Phosphorusbased Retardants Organic / inorganic May require higher loadings, can affect mechanical properties of polymers Electronics, textiles, automotive, construction Forms protective silica char layer, improves thermal stability and flame retardancy Acts as a physical barrier, improves thermal stability and reduces flammability by promoting char formation Forms protective char layer, disrupts free radical reactions, reduces smoke and toxic gas release Enhanced thermal stability, forms protective char layers, synergistic effects with other materials Thermal stability, low toxicity, environmentally friendly, effective in various polymers High surface area, costeffective, improves mechanical properties, low toxicity Environmentally friendly, less toxic smoke, effective in various polymers Polymer composites, coatings, fire-resistant textiles Polymer composites, coatings, fire-resistant textiles clothes. Hybrid nanocomposites are added to coatings or fibres to increase flame resistance without sacrificing the fabric’s comfort or robustness. 5. Packaging Materials: Packaging materials profit from hybrid nano­ composites’ improved flame retardancy, particularly if they are utilized to convey flammable or dangerous commodities. These materials shield the contents from damage and stop a fire from spreading. 6. Consumer Goods: To improve fire safety, hybrid nanocomposites are used into a variety of consumer goods, including toys, appliances, and furniture. The increased flame retardancy assist in adhering to safety standards and lower the possibility of accidents involving fires. [102–107] 2.6. Surface-modified nanoparticles Chemically tailored surface features of nanoscale particles, known as surface-modified NPs, enhance their dispersion, compatibility and functioning in a range of applications including flame retardancy. Usually, these NPs are made of a core material (such as clay, metal oxide or carbon-based substance) that has been functionalized or coated with organic or inorganic molecules to modify the surface characteristics (Fig. 5). To provide NPs certain characteristics, functional groups or coatings are affixed to their surface. Numerous chemical and physical techniques such as grafting processes, covalent bonding, adsorption, layer-by-layer assembly and surface coating can be used to produce functionalization. Functional groups containing silanes, surfactants, polymers, compounds containing phosphorus and other organic or inorganic molecules are frequently employed for surface modification. Surface-modified nanoparticles are more effective as flame-retardant additives because of their increased compatibility and dispersion in­ side polymer matrices. Functionalized surfaces improve the mechanical and flame-retardant qualities of polymers by dispersing particles more uniformly and reducing agglomeration. Higher NP loadings can be Fig. 5. Technique for surface modification of nanoparticles. incorporated without sacrificing material qualities thanks to improved dispersion and compatibility, which increases flame retardancy even more. Surface modification makes it possible to add particular func­ tional groups or additions to NPs, giving them flame retardant charac­ teristics. For instance, functional groups containing phosphorus can strengthen gas-phase flame suppression and encourage the development of char, whereas coatings based on carbon can increase thermal stability and char strength. Surface-modified NPs with tailored flame-retardant mechanisms can efficiently suppress ignition, limit the propagation of flames and improve the creation of protective char layers during burning. Beyond flame retardancy, surface-modified nanoparticles can be designed to have other uses. For instance, additional advantages like microbiological resistance, UV protection and increased durability can 5 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 be obtained by functionalizing NPs with antimicrobial agents, UV sta­ bilizers or antioxidants. When adding various functions to flame retar­ dant formulations, multifunctional NPs provide an economical and spatially efficient way to do so while reducing the need for extra addi­ tives. Customizing and optimizing the properties of NPs in accordance with particular application needs is made possible via surface modifi­ cation. Researchers can customize surface-modified NPs to obtain desired flame-retardant performance, compatibility with different polymers and compatibility with other additives by choosing the right surface modifiers and functional groups. Tailored surface-modified NPs provide adaptability and flexibility to tackle a range of flame-retardant issues in different sectors. A flexible and efficient method for improving flame retardancy in polymers, textiles, coatings and other materials is to use surface-modified NPs. Significant gains in fire safety performance are made possible by their optimized surface qualities, improved dispersion and compatibility, which also provide further features to satisfy the needs of contemporary applications. The creation of surfacemodified NPs for improved flame-retardant applications is still being advanced by ongoing research [68–72]. 4. Applications of nanostructured flame retardants 4.1. Polymers and plastics Because nanostructured flame retardants can increase fire safety without sacrificing the mechanical, thermal or processing qualities of the materials. Hence, they are widely used in polymers and plastics (Fig. 6). Polymers and plastics used in building materials such as structural composites, cable coatings and insulating foams, contain nanostructured flame retardants. These components are necessary to increase the in­ frastructures and buildings fire resistance, lower the chance of a fire spreading and increase occupant safety. Nanostructured flame re­ tardants are frequently incorporated into the polymers and resins used in printed circuit boards, connections and casings. Flame retardant polymers, especially in high-temperature and high-voltage applications, reduce the risk of fire initiation or propagation, ensuring the safety and dependability of electronic goods. Interior trim, upholstery, dashboard materials and wiring insulation are examples of the polymers and plastics that contain nanostructured flame retardants. By decreasing the chance of fires and limiting the spread of flames in the case of an acci­ dent or electrical breakdown, these materials increase the fire safety of automobiles. Fabrics and textiles used in clothing, furniture, curtains and protective gear are treated with flame-retardant polymers that contain nanostructured additives. Nanostructured flame retardants are ideal for a variety of applications in residential, commercial and in­ dustrial environments because they improve fabrics’ fire resistance without sacrificing comfort, style, or durability. To increase fire safety during storage, shipping and handling, nanostructured flame retardants are incorporated into polymers and plastics used in packaging materials such as films, bottles, containers and trays. Packaging materials that are flame retardant prevent the spread of flames and lower the danger of fire mishaps, especially in areas where flammable goods are carried or kept. Polymers and plastics used in cabin interiors, seating materials, struc­ tural panels and electrical insulation all contain nanostructured flame retardants. Nanostructured flame retardants enhance fire safety in polymer and plastic products by char formation, heat shielding, catalytic action and endo thermic decomposition without compromising the mechanical, thermal or processing properties of the materials. During combustion, nanostructured flame retardants promote the formation of char layer which is in stable form on the surface of polymer and plastic. The pro­ duced char layer acts as barrier which protects the underlying material from oxygen & heat slowing down the degradation process and reducing the release of flammable gases. Clay and hydroxides lead to the forma­ tion of physical barrier when exposed to heat. This formed barrier re­ flects heat away from the material and slow down the temperature which rise within polymer and plastics. As metal oxide acts as catalyst, formation of non-flammable gases leads to reducing the combustion of volatile gases. Polymer and plastics decompose exothermically leading to absorbing heat and lowering temperature of polymer and plastics. Hence ignition is delayed and combustion process is slow. [102–107]. By reducing the chance of fire starting and spreading, these materials guarantee the fire safety and dependability of aircraft, especially in enclosed spaces where controlling fires can be difficult. Nanostructured flame retardants are incorporated into polymers and plastics used in medical equipment and devices, including housings, tubing and surgical instruments, to improve fire safety in hospital environments. Flame retardant materials ensure patient safety and regulatory compliance by preventing the igniting of medical devices during surgical operations, sterilizing processes and other medical procedures. All things consid­ ered, nanostructured flame retardants are essential for improving fire safety in a variety of polymer and plastics industrial applications. They also help to build safer and more environmentally friendly materials for a broad range of end uses [68–74]. 3. Mechanisms of flame retardancy in nanostructured materials Because it could lead to the development of safer and more effective materials for a range of applications, flame retardancy in nanostructured materials is a topic of great interest. Enhancing flame retardancy can be accomplished by utilizing the special qualities and interactions that nanostructured materials offer at the nanoscale. Nanostructured mate­ rials ability to withstand flames is a result of multiple mechanisms. During combustion, heat and gasses can’t pass through physical barriers made of nanostructured materials. For example, a network of scattered NPs or nanofibers within a polymer matrix might limit the passage of oxygen and heat transmission, so limiting the spread of flames. By lowering the concentration of flammable components below the neces­ sary level for sustained combustion, nanostructured additives can dilute the flammable components present in a material. Scattered throughout a polymer matrix, NPs can effectively suppress combustion by lowering the fuel-to-air ratio. When flammable gasses are produced during com­ bustion, some NPs with catalytic capabilities aid in their breakdown. For instance, metal oxide NPs can impede combustion by catalysing the breakdown of volatile organic molecules and carbonaceous wastes. When exposed to heat or flames, nanostructured materials can help a protective char coating form. By acting as a thermal insulator, this layer of char prevents further deterioration of the underlying material. By encouraging cross-linking reactions or producing a more cohesive and stable char structure, NPs can improve the creation of char. When combustion products interact with NPs distributed in a polymer matrix, inert gasses are produced that put out the flame. The radical chain re­ actions that maintain combustion are broken by this gas-phase quenching mechanism. When different kinds of nanostructured addi­ tives are used, flame retardancy can be increased beyond what can be accomplished with each component alone. For instance, compared to each additive alone, a combination of NPs that encourage char forma­ tion and NPs that accelerate gas-phase reactions can give better flameretardant qualities. Materials with nanostructures may also physically interact with flames, changing their behaviour and intensity. For example, distributed carbon nanotubes inside a polymer matrix have the ability to entangle with soot particles, disrupting the flame structure and ultimately causing flame suppression. The study of nanostructured materials’ flame retardancy is still in its early stages, with goals of developing novel materials with improved fire safety characteristics as well as comprehending the underlying principles [59–67]. 6 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 Fig. 6. Polymers and plastics in flame retardation. 4.2. Textiles and fabrics used to make industrial workwear, safety vests and firefighting suits. Because flame retardant textiles lower the chance of burns and other heat-related injuries, they offer workers in dangerous circumstances vital protection. In order to comply with vehicle safety regulations, nanostructured flame retardants may be used in the carpets, headliners, and seating materials used in automobile interiors. Automotive textiles treated with flame retardants increase the safety of cars against fire by lowering the possibility of fires starting from electrical problems, ciga­ rette ignition, or other sources. To improve fire resistance, materials used to make hiking boots, sportswear and outerwear may contain nanostructured flame retardants. For outdoor enthusiasts and athletes, flame-retardant textiles increase safety by lowering the chance of burns from unintentional fires or heat-related sources. Nanostructured flame retardants are essential for enhancing the fire safety of textiles and fabrics in a variety of applications, guaranteeing adherence to safety laws and guidelines and shielding people and property from fire threats [75–79]. The textile and fabric industry makes widespread use of nano­ structured flame retardants to improve the fire safety of a variety of fabrics used in clothing, upholstery, home furnishings, and protective gear. To increase fire resistance, materials used for workwear, uniforms and apparel are treated with nanostructured flame retardants. Flame-retardant fabrics offer an additional layer of defence against unintentional fires, lowering the possibility of burns or other injuries for wearers in a variety of settings including military operations, fire­ fighting and industrial sites. Nanostructured flame retardants are frequently utilized in fabrics used for upholstery, drapes and furnishings in homes, businesses and hospitality environments. By lowering the chance of a fire starting and preventing flames from spreading quickly within enclosed spaces, flame retardant textiles improve the fire safety of furniture and interior décor. In order to comply with fire safety standards and regulations, textiles and materials used in bedding, mat­ tresses, pillows and bedding accessories may incorporate nano­ structured flame retardants (Fig. 7). By lowering the possibility of fires brought on by bed smoking, electrical problems or other ignition sour­ ces, flame retardant mattress materials increase customer safety. In residential, commercial and institutional settings, flame-retardant draperies, curtains and window treatments provide an additional layer of protection against fire dangers. In the event of a fire, flame-retardant drapes and curtains prevent the spread of flames, giving residents plenty of time to safely evacuate and reducing property damage. Nano­ structured flame retardants are frequently employed in the materials 4.3. Coatings and paints In order to improve fire safety and shield surfaces from ignition and flame propagation, nanostructured flame retardants are used in a variety of coatings and paints. For usage on interior and exterior surfaces, including walls, ceilings, and facades, architectural coatings include nanostructured flame retardants (Fig. 8). In residential, commercial and industrial buildings, flame retardant coatings help stop flames from spreading, minimizing property damage and improving occupant safety. To increase fire resistance, intumescent coatings with nanostructured flame retardants are applied to structural elements including steel beams, columns, and walls. Intrinsic char coatings expand and create an insulating layer during a fire, shielding the underlying substrate from heat and flame and preventing structural collapse. Fig. 7. Applications of textiles and fabrics. Fig. 8. Various applications of paints and coatings. 7 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 To prevent and control the spread of flames, paints that are fireproof are made with nanostructured flame retardants and are used in high-risk areas including kitchens, labs and electrical rooms. These paints mini­ mize fire damage and lower the chance of ignite by adding an extra layer of fire protection to cabinets, walls, doors and other surfaces. To increase fire safety, nanostructured flame retardants are applied to industrial coatings used in chemical plants, oil refineries and manufacturing fa­ cilities. Flame retardant coatings lower the risk of accidents and guar­ antee regulatory compliance by shielding machinery, equipment and infrastructure from fire threats. To improve fire resistance in maritime situations, marine coatings with nanostructured flame retardants are applied to ships, boats, offshore platforms, and marine structures. By preventing fires brought on by electrical malfunctions, gasoline leaks or other ignition sources, flame retardant marine coatings lower the chance of mishaps and safeguard marine assets. To increase fire safety in crucial applications, nanostructured flame retardants are added to specialized coatings used in the electronics, automotive and aerospace sectors. Flame retardant speciality coatings ensure dependability and perfor­ mance in harsh situations by preventing fire dangers from harming delicate parts, electronics and valuable assets. The use of nanostructured flame retardants is essential in passive fire protection systems, which include barriers, coatings and seals that resist flames and stop them from spreading. These systems minimize fire damage and safeguard people and property by providing vital fire protection for infrastructure, buildings and transportation networks. All things considered, nano­ structured flame retardants improve the fire safety of paints and coatings in a variety of applications by offering strong defence against flame propagation, ignition and fire-related damage. They are useful additives for enhancing fire resistance in a variety of situations due to their adaptability, effectiveness and compatibility with various coating for­ mulas [80–85]. gadgets, including laptops, tablets, cell phones and appliances, use plastics, polymers and coatings that contain nanostructured flame re­ tardants. Flame retardant materials improve customer safety and prod­ uct reliability by shielding electronic equipment from fire threats brought on by electrical faults, external heat sources, or failed batteries. All things considered, nanostructured flame retardants are essential for improving the fire safety of electronics and electrical equipment, guar­ anteeing adherence to safety guidelines and standards while lowering the danger of fires and safeguarding people and property [86–91]. 4.5. Building materials There are many uses for nanostructured flame retardants in building materials to improve fire safety and shield buildings from potential fire threats. For thermal and acoustic insulation in buildings, nanostructured flame retardants are added to insulation materials such foams, boards and blankets. Flame-retardant insulating materials lower the danger of fire propagation and improve occupant safety by preventing fires from spreading within building cavities. To increase fire resistance, nano­ structured flame retardants are incorporated into structural materials such wood composites, engineered lumber and concrete additives. By halting the development of fires in building assemblies, flame-retardant structural elements buy crucial time for evacuation and firefighting operations (Fig. 9). Paints, coatings, wall coverings and ornamental finishes applied to a building’s interior surface contain nanostructured flame retardants. Interior finishes with flame retardants make walls, ceilings and parti­ tions less combustible, which inhibits the spread of flames and lessens the amount of interior structure damage caused by fire. To increase fire resistance, nanostructured flame retardants are added to outside clad­ ding materials such siding, facades and rainscreen systems. The use of flame-retardant cladding materials shields building inhabitants from potential danger by preventing flames from starting and spreading on a building’s outside. To improve fire resistance, nanostructured flame retardants are added to roofing materials such as coatings, shingles and membranes. Flame retardant roofing materials lower the danger of ignition and restrict the spread of fire within buildings by preventing flames brought on by outside heat sources such as nearby building fires or wildfires. To increase fire resistance and containment, nanostructured flame retardants are added to the materials used to create fire doors, partitions, and obstacles. Critical fire protection in buildings is provided by flame-resistant fire doors and partitions, which isolate fire threats and stop fires from spreading to adjacent areas. To improve fire safety in outdoor contexts, materials for exterior decking, balconies, and outdoor constructions are treated with nanostructured flame retardants. Flameretardant decking materials limit the spread of fire to nearby vegeta­ tion and structures and lessen the chance of outdoor fires brought on by activities like smoking or grilling. All things considered, nanostructured flame retardants are essential for enhancing the fire safety of construc­ tion materials, guaranteeing adherence to rules and specifications and shielding inhabitants, assets and infrastructure from fire risks [92–98]. 4.4. Electronics and electrical devices Since the possibility of fire might present serious operational and safety problems, nanostructured flame retardants are essential for improving the fire safety of electronics and electrical devices. To in­ crease the fire resistance of PCBs, nanostructured flame retardants are incorporated into the resin systems. Flame retardant PCB materials lower the possibility of harm to electronic components and guarantee the dependability of electronic devices by preventing flames brought on by electrical faults, overheating or short circuits. Plastics, resins and coatings used in electrical enclosures, housings and cabinets contain nanostructured flame retardants. Flame retardant materials lower the danger of fires in commercial, residential and industrial environments by shielding wiring systems, control panels and electrical equipment from fire threats. Plastics and polymers used in electrical and electronic systems as connectors, terminals, and junction boxes have nano­ structured flame retardants. Flame-retardant materials provide the safety and dependability of electrical connections in a variety of appli­ cations by preventing fires brought on by overheating or arcing at connection points. Polymers used to make power cables, wire insulation, and cable jackets contain nanostructured flame retardants. By prevent­ ing fires brought on by overload situations, electrical faults or external heat sources, flame retardant materials preserve the functionality and integrity of electrical wiring systems. Lithium-ion and other recharge­ able batteries electrolytes, separators and battery casings are made of materials that incorporate nanostructured flame retardants. Flame retardant battery components improve safety in portable gadgets, elec­ tric cars and stationary applications by lowering the risk of thermal runaway, fires and explosions in battery packs and energy storage sys­ tems. To increase fire resistance, polymers, lenses and housings for LED lighting systems are coated with nanostructured flame retardants. Flame-retardant materials ensure safety and dependability in indoor and outdoor lighting applications by preventing fires caused by overheating or electrical faults in LED luminaires and lighting fixtures. Consumer 4.6. Automotive components In many automotive components, nanostructured flame retardants are used to improve fire safety and reduce the likelihood of vehicle fires (Fig. 10). Plastics, textiles and foams used for interior trim, upholstery and seating materials all contain nanostructured flame retardants. Flame-retardant materials lower the risk of fires caused by electrical problems, smoking materials, or other ignition sources by preventing fires from starting and spreading inside vehicles. Plastics, polymers and coatings used for instrument clusters, control surfaces and dashboard panels contain nanostructured flame retardants. By lowering the combustibility of interior surfaces, flame retardant dashboard materials improve passenger safety by reducing the likelihood of fires. Polymers and coatings used for electrical wiring insulation, 8 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 Fig. 9. Application of building materials in various fields. nanostructured flame retardants on human health and the environment. To fully comprehend their long-term impacts such as toxicity, bio­ accumulation, and environmental persistence, more research is required. It is crucial to create environmentally safe and sustainable flame-retardant formulations that employ fewer dangerous chemicals and have a less environmental impact. It is essential to develop standardized testing procedures and legal criteria in order to assess the safety and efficacy of nanostructured flame retardants. To develop comprehensive guidelines and regulations for the use of nanostructured flame retardants in various applications, re­ searchers, industry stakeholders and regulatory bodies must work together. Maximizing compatibility and performance between nano­ structured flame retardants and host materials such as polymers, textiles and coatings remains a difficult task. To improve flame retardant effectiveness without compromising material qualities, research is required to optimize the dispersion, stability and interaction of nano­ structured flame retardants inside host materials. Nanostructured flame retardants must have scalable synthesis pathways and affordable pro­ duction techniques in order to be widely used in commercial applica­ tions. In order to produce nanostructured flame retardants on a wide scale with consistent quality and performance, research efforts should concentrate on creating cost-effective and efficient production proced­ ures. The investigation of the multifunctional characteristics and syn­ ergistic impacts of nanostructured flame retardants is a topic of great interest. It is necessary to conduct research to determine whether nanostructured flame retardants can offer additional features beyond flame retardancy such as mechanical strengthening, UV resistance or antibacterial qualities. To comprehend the structure-property correla­ tions and performance processes of nanostructured flame retardants, it is essential to advance characterisation methods. In order to understand the behaviour and interactions of flame-retardant materials at the nanoscale, research endeavours ought to concentrate on the develop­ ment of sophisticated analytical techniques, including spectroscopy, microscopy and computer modelling. To solve a variety of fire safety concerns, it is imperative to tailor nanostructured flame retardants for particular applications and industries. The goal of research should be to create flame retardant formulations and techniques that are applicationspecific and suited to the particular needs and performance standards of many industries, including textiles, electronics, automotive, and con­ struction (Fig. 11). In general, resolving these issues and investigating fresh avenues for investigation would support the ongoing development and application of nanostructured flame retardants, resulting in enhanced fire safety and sustainability in a range of sectors. Researcher, industry partner and regulatory agency collaboration is essential to promoting innovation and guaranteeing the secure and efficient appli­ cation of nanostructured flame-retardant technology. Fig. 10. Flame retardants in automotive components. connections and harnesses incorporate nanostructured flame retardants. The dependability and security of automotive electrical systems are ensured by flame-resistant wiring insulation materials, which stop electrical fires brought on by overload situations, short circuits and other electrical failures. To foam cushions, padding and headrests used in car seats and interior parts, nanostructured flame retardants are applied. In the case of a fire or collision, the occupants of vehicles will be better protected by flame retardant foam materials which lessen the flammability of the interior. Plastics, composites and coatings used in housings, shrouds and coverings for engines all contain nanostructured flame retardants. Flame-resistant materials used in engine compart­ ments reduce the possibility of fires resulting from engine problems, fluid leaks or hot components, protecting vehicle propulsion systems and guaranteeing their dependability. Plastics, composites and coatings used on exterior body panels, like bumpers, fenders and hoods, contain nanostructured flame retardants. Flame-retardant body panel materials lessen a vehicle’s exterior’s combustibility, which helps to contain flames and lessens the amount of damage that fires cause to nearby structures and automobiles. The plastics, polymers and coatings used in electronic enclosures, connectors and sensors in automobiles incorpo­ rate nanostructured flame retardants. Vehicle electronics and control systems are reliable and safe because flame retardant materials shield wiring systems and electronic components from fire threats. In general, nanostructured flame retardants are essential for enhancing the fire safety of automotive parts, guaranteeing adherence to safety guidelines and standards and shielding people, property and infrastructure from the risk of fire in cars [99–101]. 5. Challenges and future directions Although there is great promise for improving fire safety in a variety of applications with nanostructured flame retardants, there are a num­ ber of obstacles as well as chances for additional study and improve­ ment. It is crucial to address the possible negative effects of 6. Commercialization and recent progress Recent developments in nanostructure flame-retardant materials are based on a number of creative strategies, such as the creation of novel 9 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 including hydrothermal synthesis, sol-gel and chemical vapor deposi­ tion needs improvement. For flame retardant effectiveness to be consistent, nanoparticles must be homogenous in size, shape and dis­ tribution. Inconsistent characteristics are resulted from differences in the shape or size of the particles. Because of their high surface energy, nanoparticles have a tendency to clump together, which makes it diffi­ cult to achieve uniform dispersion in the polymer matrix. It is necessary to apply efficient dispersion procedures, such as high-shear mixing, sonication or the use of surfactants. Maintaining the mechanical prop­ erties of the composite requires that the nanoparticles and the polymer matrix be compatible. Modifying the surface of nanoparticles enhances their ability to interact with polymers. High-quality nanomaterial pro­ duction can be prohibitively expensive. To make NFRs commercially viable, large-scale production must concentrate on economical synthesis techniques and raw material sources. Costs can be decreased by achieving economies of scale in production, but doing so necessitates large investments in industrial infrastructure and technology. It is necessary to address the possible health concerns connected to the handling and production of nanomaterials. It is essential to follow safe production procedures, appropriate handling guidelines, and compre­ hensive environmental impact evaluations. It is imperative that laws governing the usage and disposal of nanomaterials be followed. Guidelines set forth by regulatory agencies like OSHA, EPA, and REACH must be adhered to in order to safeguard the environment and maintain worker safety. Production efficiency and scalability can be improved by employing methods like large-scale chemical vapor deposition (CVD) and continuous flow reactors. Improving dispersion and lowering agglomeration can be achieved by adding nanoparticles immediately into the polymerization process. The dispersion and compatibility of nanoparticles with the polymer matrix can be enhanced by coating them with either organic or inorganic coatings. Better integration and per­ formance can result from functional groups added to the surface of nanoparticles, which will improve their interaction with the polymer. By combining various nanomaterials, such as metal oxides and carbon nanotubes, hybrid nanocomposites can maximize their synergistic ef­ fects and enhance their overall mechanical and flame-retardant quali­ ties. Creating optimal formulations that strike a balance between processability, performance and cost is essential to making NFRs prac­ tical for use in industrial settings [102–107]. Fig. 11. Schematic representation of challenges and future directions of flame retardants. nanocomposites, metal-organic frameworks (MOFs) and twodimensional (2D) nanomaterials. Utilizing graphene oxide, environ­ mentally safe flame-retardant coatings have been created. These coat­ ings provide lightning-fast flame detection and are capable of sending out a fire alert in an instant of seconds. With the creation of a shielding char layer after combustion, the integration of GO with polymers im­ proves flame retardancy. MXene-based two-dimensional materials can detect fires quickly when paired with polymers like polyethylene glycol (PEG) or polyvinyl pyrrolidone (PVP). When exposed to fire, MXenebased sensors exhibit a notable resistance transition that are utilized to create effective fire-warning systems. Layered double hydroxides, or LDHs, are created from MOFs and function as powerful flame retardants. These substances create char layers that shield the underlying material from burning, improving the thermal stability of polymer composites and lowering flammability. MOFs are incorporated into polymers via processes including solution casting and melt compounding, which im­ proves the MOFs’ dispersion and strengthens their flame-retardant qualities. Compared to conventional materials, these composites have improved mechanical performance and flame retardancy. Excellent re­ sults have been observed when reduced graphene oxide (rGO) and LDHs are combined in epoxy nanocomposites. These hybrids have better flame retardancy and smoke suppression because they combine the flameretardant qualities of LDHs with the high surface area and thermal conductivity of graphene. To achieve synergistic effects, researchers have experimented with different mixtures of nanomaterials with con­ ventional flame retardants. For example, combining polymers with molybdenum disulfide (MoS2) has produced composites that have improved heat stability and flame retardancy. Achieving homogeneous dispersion of nanoparticles inside the polymer matrix is one of the main problems. Novel approaches are being investigated to solve this prob­ lem, such as functionalizing the nanomaterials or utilizing sophisticated mixing processes. One of the main priorities is creating flame-retardant materials that are safe for human health, the environment, and both. Scientists are attempting to fulfil these needs by employing non-toxic and sustainable materials. To sum up, advancements in nanostructure flame retardant materials are resulting in the creation of flame re­ tardants that have become more efficient, adaptable and eco-friendly. These developments have a great deal of potential to increase fire safety in a variety of environments [108–128]. The large-scale production and industrialization of nanostructured flame retardants involves several challenges, scaling up its production requires technical, economic and regulatory factors. It is challenging to scale up complicated synthesis procedures from the lab to industrial scales when producing nanomaterials. For mass production, techniques 7. Conclusion To sum up, nanostructured flame retardants are a viable way to improve fire safety in a range of applications such as electronics, building materials, polymers, textiles, coatings and automobile com­ ponents. These cutting-edge materials provide practical ways to mitigate fire dangers and lower the chance of ignition, flame spread and firerelated damage by taking use of the special qualities and interactions at the nanoscale. We have looked at the various methods, uses and po­ tential future developments of nanostructured flame retardants in this overview. Nanostructured flame retardants provide a variety of ap­ proaches to improve fire resistance while lowering health and envi­ ronmental risks, from gas-phase flame inhibition and smoke suppression to physical barrier development and char enhancement. The field of nanostructured flame retardants continues to progress despite obstacles like compatibility, standardization, cost, scalability and health and environmental concerns. We can fully realize the promise of nano­ structured flame retardants to enhance fire safety across industries and safeguard people, property and the environment by tackling these issues and looking into new avenues for innovation. In order to spur innova­ tion, create standards and laws, and hasten the commercialization of nanostructured flame retardants, cooperation between researchers, in­ dustry players, and regulatory bodies will be essential in the future. Nanostructured flame retardants are expected to become more signifi­ cant in the global creation of safer and more sustainable environments for people and communities as a result of ongoing research, 10 J. Rodrigues and N.G. Shimpi Nano-Structures & Nano-Objects 39 (2024) 101253 development, and application. [14] J. Rodrigues, S. Jain, N. Shimpi, Performance of 1D tin (Sn) decorated spherical shape ZnO nanostructures as an acetone gas sensor for room and high temperature, Mater. Sci. 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[31] Georgiana Amariei, Martin Lahn Henriksen, Pernille Klarskov, Mogens Hinge, Quantification of aluminium trihydrate flame retardant in polyolefins via in-line hyperspectral imaging and machine learning for safe sorting, ISSN 1386-1425, Spectrochim. Acta Part A: Mol. Biomol. Spectrosc. Volume 311 (2024) 123984, https://doi.org/10.1016/j.saa.2024.123984. [32] Dang Khoa Vo, Trung Dieu Do, Binh T. Nguyen, Cong Khanh Tran, Tuan An Nguyen, Dang Mao Nguyen, Lam H. Pham, Trong Danh Nguyen, ThanhDanh Nguyen, DongQuy Hoang, Effect of metal oxide nanoparticles and aluminum hydroxide on the physicochemical properties and flame-retardant behavior of rigid polyurethane foam, ISSN 0950-0618, Constr. Build. Mater. CRediT authorship contribution statement Jolina Rodrigues: Writing – original draft, Visualization, Valida­ tion, Software, Resources, Project administration, Methodology, Inves­ tigation, Funding acquisition, Formal analysis, Data curation, Conceptualization. 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