3D Crimp PET Multifilament With Phosphorus Flame Retardancy
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Solution Overview
Problem
Conventional methods for flame retardancy in polyethylene terephthalate fibers, such as bromine-based compounds, face issues with durability, environmental pollution, and the generation of carcinogenic substances, while phosphorus-based alternatives require optimization for effective flame retardancy and toughness in 3-D crimp polyethylene terephthalate multifilaments.
Innovation Solution
Incorporating a phosphorus-based flame retardant within a specific concentration range into a polyethylene terephthalate polymer, combined with a steam jet- or air jet-type texturing process, to produce a 3-D crimp polyethylene terephthalate multifilament with enhanced flame retardancy and toughness, characterized by a specific stress-strain curve and limited oxygen index.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bromine-based flame retardant is used to achieve flame retardancy, then flame retardant effect is improved, but polymer is discolored and lightfastness deteriorates
Solution Approach 1:
The patent changes the chemical composition parameter by replacing bromine-based flame retardant with phosphorus-based flame retardant (specifically phosphite esters of glycolic acid or phosphonates). This substitution fundamentally alters the chemical mechanism of flame retardancy while avoiding the harmful side effects of bromine compounds, including discoloration and lightfastness deterioration.
Solution Approach 2:
The patent employs phosphorus-based flame retardants that are more environmentally friendly and stable compared to bromine-based alternatives. These compounds provide lasting flame retardancy without generating carcinogenic substances, effectively replacing short-lived, harmful bromine compounds with more sustainable options.
2Reliability
If bromine-based flame retardant is used to achieve flame retardancy, then flame retardant effect is improved, but carcinogenic substances such as dioxin and benzofuran are generated
Solution Approach 1:
The patent fundamentally changes the chemical composition by substituting phosphorus-based flame retardants for bromine-based ones. This parameter change eliminates the generation of carcinogenic substances like dioxin and benzofuran that are associated with bromine compound decomposition, while maintaining effective flame retardancy through alternative chemical mechanisms.
Solution Approach 2:
The patent converts the harmful byproducts of bromine-based flame retardancy into beneficial outcomes by using phosphorus-based alternatives. The decomposition products of phosphorus-based flame retardants are non-carcinogenic and environmentally friendly, effectively turning a harmful process into a beneficial one.
3Object-affected harmful factors
If phosphorus-based flame retardant is used to achieve flame retardancy, then environmental friendliness is improved, but flame retardant effectiveness and toughness require optimization
Solution Approach 1:
The patent optimizes the concentration parameter of phosphorus-based flame retardant within the range of 0.05 to 5 wt% based on phosphorus atom content. This precise parameter control ensures sufficient flame retardant effectiveness while maintaining the environmental benefits of phosphorus-based compounds. The specific concentration range balances flame retardancy, toughness, and environmental friendliness.
Solution Approach 2:
The patent creates a composite system by combining phosphorus-based flame retardant with polyethylene terephthalate polymer through copolymerization. This composite approach integrates the flame retardant properties into the polymer structure, ensuring both effectiveness and durability while maintaining environmental compatibility.
4Reliability
If post-process flame retardation treatment is applied to fibers, then flame retardancy is achieved, but durability of fiber deteriorates and environmental pollution occurs
Solution Approach 1:
The patent applies preliminary action by incorporating phosphorus-based flame retardant into the polymer during the copolymerization process, before fiber formation. This pre-integration ensures the flame retardant is permanently bonded within the polymer structure, providing lasting durability without requiring subsequent post-process treatments that could damage the fiber.
Solution Approach 2:
The patent uses phosphorus-based flame retardant as an intermediary that is chemically integrated into the polymer structure during copolymerization. This intermediary approach creates a permanent bond between the flame retardant and polymer, ensuring long-term durability and eliminating the need for separate post-treatment steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting 3-D crimp polyethylene terephthalate multifilament exhibits improved flame retardancy, toughness, and bulkiness, with elongation capabilities and tensile strength that absorb impact energy effectively, while minimizing strain and weight, and maintaining excellent physical properties.
Implementation Method 1
using a steam jet- or air jet-type texturing process
Implementation Method 2
contains a phosphorus-based flame retardant of 0.05 to 5 wt % based on a phosphorus atom
Data Source
AI summary
Disclosed is a 3-D crimp polyethylene terephthalate multifilament (BCF) having a stress-strain curve that (a) it elongates less than 5.0% when subjected to an initial stress of 1.0 g/d, (b) it has an initial modulus of 20 to 60 g/d, (c) it elongates at least 20% when subjected to a stress region of 1.0 to 2.5 g/d and (d) it elongates from a tensile strength of at least 3.0 g/d to the tensile strength at break. The BCF has improved physical properties such as excellent flame retardancy, high toughness, improved crimp uniformity and improved compressive elasticity modulus.