This paper aims at updating the progress on the phosphorus-based flame retardants specifically designed and developed for fibers and fabrics (particularly referring to cotton, polyester and their blends) over the last five years. Indeed, as clearly depicted by Horrocks in a recent review, the world of flame retardants for textiles is still experiencing some changes that are focused on topics like the improvement of its effectiveness and the replacement of toxic chemical products with counterparts that have low environmental impact and, hence, are more sustainable. In this context, phosphorus-based compounds play a key role and may lead, possibly in combination with silicon- or nitrogen-containing structures, to the design of new, efficient flame retardants for fibers and fabrics. Therefore, this review thoroughly describes the advances and the potentialities offered by the phosphorus-based products recently developed at a lab-scale, highlighting the current limitations, open challenges and some perspectives toward their possible exploitation at a larger scale.

The latest techniques used to prove, describe and analyze the gas phase activity of a fire retardant used in polymeric materials are briefly reviewed. Classical techniques, such as thermogravimetric analysis or microscale combustion calorimetry, as well as complex and advanced analytical techniques, such as modified microscale combustion calorimeter (MCC), molecular beam mass spectroscopy and vacuum ultra violet (VUV) photoionization spectroscopy coupled with time of flight MS (TOF-MS), are described in this review. The recent advances in analytical techniques help not only in determining the gas phase activity of the flame-retardants but also identify possible reactive species responsible for gas phase flame inhibition. The complete understanding of the decomposition pathways and the flame retardant activity of a flame retardant system is essential for the development of new eco-friendly-tailored flame retardant molecules with high flame retardant efficiency.

Organophosphorus compounds containing P-C bonds are increasingly developed as flame retardant additives due to their excellent thermal and hydrolytic stability and ease of synthesis. The latest development (since 2010) in organophosphorus flame retardants containing P-C bonds summarized in this review. In this review, we have broadly classified such phosphorus compounds based on the carbon unit linked to the phosphorus atom i.e., could be a part of either an aliphatic or an aromatic unit. We have only considered those published literature where a P-C bond was created as a part of synthetic strategy to make either an intermediate or a final organophosphorus compound with an aim to use it as a flame retardant. General synthetic strategies to create P-C bonds are briefly discussed. Most popular synthetic strategies used for developing P-C containing phosphorus based flame retardants include Michael addition, Michaelis–Arbuzov, Friedels–Crafts and Grignard reactions. In general, most flame retardant derivatives discussed in this review have been prepared via a one- to two-step synthetic strategy with relatively high yields greater than 80%. Specific examples of P-C containing flame retardants synthesized via suitable synthetic strategy and their applications on various polymer systems are described in detail. Aliphatic phosphorus compounds being liquids or low melting solids are generally applied in polymers via coatings (cellulose) or are incorporated in the bulk of the polymers (epoxy, polyurethanes) during their polymerization as reactive or non-reactive additives. Substituents on the P atoms and the chemistry of the polymer matrix greatly influence the flame retardant behavior of these compounds (condensed phase vs. the gas phase). Recently, aromatic DOPO based phosphinate flame retardants have been developed with relatively higher thermal stabilities (>250 °C). Such compounds have potential as flame retardants for high temperature processable polymers such as polyesters and polyamides. A vast variety of P-C bond containing efficient flame retardants are being developed; however, further work in terms of their economical synthetic methods, detailed impact on mechanical properties and processability, long term durability and their toxicity and environmental impact is much needed for their potential commercial exploitations.

This review provides insight into recent studies related to thermal degradation, smoke and toxicity production and their reduction strategies for polyurethane-based materials.