Aqueous polyelectrolyte complex as one pot nanocoating solution to impart antiflammable behavior to various substrates

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current flame retardant materials, such as halogenated compounds and nanoparticles, face issues like environmental toxicity, lack of durability, and inadequate flame suppression, necessitating a more effective fire retardant for substrates like foam and fabric.

Innovation Solution

A method involving a thin film coating with a polyelectrolyte complex, specifically using branched polyethylenimine (BPEI) and poly(sodium phosphate) (PSP), is applied to substrates, creating a nanocoating that imparts flame resistance by preventing ignition and flame spread, even at low concentrations and with a single exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated materials (brominated compounds) are used as flame retardants, then flame suppression capability is improved, but environmental toxicity and harmful effects increase

Engineering Contradiction:

Improveflame suppression capabilityVSAvoidenvironmental toxicity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by replacing halogenated compounds with polyelectrolyte complexes formed from cationic polymers (like polyethylenimine) and anionic polymers (like poly(sodium phosphate)). This substitution maintains flame retardant functionality while eliminating toxic halogenated byproducts, directly resolving the contradiction between flame suppression and environmental safety

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite polyelectrolyte materials formed by complexing cationic and anionic polymers. These composite materials provide effective flame retardancy through intumescence mechanism without the environmental toxicity associated with halogenated compounds, thus resolving the contradiction between performance and environmental harm

Inventive Principle:

Principle #40Composite materials

2Reliability

If nanoparticles are used as flame retardants, then flame suppression is improved, but processing viscosity and modulus of the polymer material increase

Engineering Contradiction:

Improveflame suppressionVSAvoidprocessing viscosity

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the physical state and molecular structure parameters by using soluble polyelectrolyte complexes in aqueous or alcoholic solutions. These solutions have low viscosity and can be easily applied to substrates, unlike nanoparticle suspensions which increase processing viscosity. The polyelectrolyte complexes maintain flame retardant effectiveness while enabling easy processing and application

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs liquid-based application methods (dipping, spraying, or brushing) using aqueous or alcoholic solutions of polyelectrolyte complexes. This liquid formulation approach allows for simple, uniform coating of substrates without the high viscosity problems associated with nanoparticle pastes or suspensions, resolving the contradiction between flame suppression performance and processing ease

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Reliability

If traditional flame retardant coatings are applied, then flame resistance is improved, but coating thickness and weight gain increase

Engineering Contradiction:

Improveflame resistanceVSAvoidcoating weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent forms thin film coatings of polyelectrolyte complexes on substrate surfaces. These thin films provide effective flame retardancy through intumescence without requiring thick coatings, thus minimizing weight gain while maintaining flame resistance. The flexible nature of the polyelectrolyte complex allows it to form uniform thin films that adhere well to substrates like fabric and foam

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent optimizes the concentration and molecular weight parameters of the polyelectrolyte components to achieve maximum flame retardant efficiency at minimal coating thickness. By controlling the stoichiometry of cationic and anionic polymer ratios and selecting appropriate molecular weights, the patent achieves effective flame protection with minimal material deposition, resolving the contradiction between flame resistance and weight gain

Inventive Principle:

Principle #35Parameter changes

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 coating effectively prevents flame spread and ignition on cotton fabric, achieving significant flame suppression with minimal weight gain, outperforming traditional methods in durability and effectiveness, while maintaining the substrate's flexibility and structure.

Implementation Method 1

The coating comprises the cationic material and the anionic material

Methodology Applied

Scientific EffectElectrostatic interaction: Ion Repulsion/Attraction

Data Source

PatentUS9840629B2Aqueous polyelectrolyte complex as one pot nanocoating solution to impart antiflammable behavior to various substrates

Publication Date: 2017.12.12 TEXAS A&M UNIVERSITY

AI summary

A method includes coating a substrate to provide a flame resistant substrate. In an embodiment, the method includes preparing a solution. The solution includes an anionic material, a cationic material, and water. The method further includes exposing the substrate to the solution to produce a coating on the substrate. The coating has cationic material and anionic material.