Breathable Fire-Resistant Fabric With Liquid Barrier Coating
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Solution Overview
Problem
Nylon and polyester fabrics face challenges in achieving both fire-resistant and liquid-barrier properties without compromising their desirable properties like wearability, breathability, and flexibility, as existing fire retardant compositions often melt before ignition, leading to skin burns and reducing fabric performance.
Innovation Solution
A fire-resistant woven fabric is developed using nylon or polyester fibers impregnated with a fluid saturant containing a fire-resistant polymer and oil-water repellent, combined with a polyurethane coating comprising thermally degradable aromatic halogen compounds, antimony oxide, and metal hydroxides, which provides both fire retardant and liquid barrier properties while maintaining fabric breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fire retardant composition is applied to polyester or nylon fabric at high concentration, then fire resistance is improved, but the fabric's wearability, flexibility, and breathability deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the fire retardant treatment by using phosphorus-based compounds (phosphoric acid, phosphorous acid, and their salts) instead of traditional high-concentration coatings. This chemical parameter change allows achieving fire resistance while maintaining fabric flexibility and wearability, as the phosphorus-based agents form protective char layers at lower application concentrations.
Solution Approach 2:
The patent creates a composite treatment system combining multiple phosphorus-based fire retardant agents (phosphoric acid, phosphorous acid, and various phosphorus salts) applied in specific concentration ranges. This composite approach provides synergistic fire protection while preserving the fabric's mechanical properties and breathability better than single-agent high-concentration treatments.
2Reliability
If a fire retardant composition is applied to polyester or nylon fabric, then fire resistance is improved, but liquid barrier properties deteriorate
Solution Approach 1:
The patent optimizes the concentration parameters of fire retardant agents to fall within specific ranges (0.1-5% phosphoric acid, 0.1-5% phosphorous acid, and controlled amounts of phosphorus salts) that provide adequate fire protection without excessive coating thickness. This parameter control prevents the formation of continuous non-porous films, thereby preserving the fabric's liquid barrier properties while maintaining fire resistance.
3Reliability
If traditional fire retardant compositions are applied to polyester or nylon, then self-extinguishing properties are improved, but molten polymer drips increase causing skin burns
Solution Approach 1:
The patent changes the chemical mechanism of fire retardation by using phosphorus-based compounds that promote char formation and reduce polymer melt flow at lower concentrations. The specific parameter ranges of phosphoric acid (0.1-5%), phosphorous acid (0.1-5%), and phosphorus salts create a fire protective char layer that suppresses both flame propagation and molten polymer dripping, thereby reducing skin burn hazards while maintaining self-extinguishing properties.
4Reliability
If both fire retardant and water repellant compositions are applied to fabric, then fire resistance and liquid barrier properties are improved, but breathability deteriorates
Solution Approach 1:
The patent merges the fire retardant and water repellant treatment steps into a single combined application process. The phosphorus-based fire retardant composition is applied concurrently with or integrated into the water repellant treatment, allowing both functionalities to be achieved in one coating operation. This combined approach maintains breathability better than sequential heavy coatings because the phosphorus-based agents work at lower concentrations and form more porous protective layers.
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 solution effectively enhances fire resistance and liquid barrier properties without sacrificing the fabric's feel, drape, and breathability, ensuring self-extinguishing, low smoke, and minimal burning with reduced molten polymer drips, while maintaining durability and resistance to laundering and chemicals.
Implementation Method 1
a fluid saturant impregnates the fabric and covers the surfaces of the fibers
Implementation Method 2
a layer of fire resistant polyurethane covers at least one surface of the fabric substrate
Implementation Method 3
a thermally degradable aromatic halogen containing compound
Implementation Method 4
an antimony oxide or barium metaborate monohydrate; and a metal hydroxide or mineral hydride
Implementation Method 5
an oil and water repellent composition, such as a combination of fluoroalkyl acrylate copolymer and thiourea formaldehyde
Implementation Method 6
Breathability in barrier fabrics may be desirable because it allows moisture vapor to egress out of the garment while preventing liquids from ingressing into the fabric
Data Source
AI summary
The present invention is directed to a fabric composed of nylon or polyester fibers and having both liquid barrier properties and fire retardant properties without sacrificing many of the desirable properties of the fabric. In particular, the present invention helps overcome many of the disadvantages associated with prior art fabrics by providing a fabric having feel and drape of a textile fabric while having good fluid barrier characteristics and fire retardant characteristics. In one embodiment, the invention is also directed to a breathable nylon or polyester fabric having liquid barrier and fire retardant properties. The present invention also provides methods of making such fabrics.