Brominated Aromatic Flame Retardant Dispersion for Textiles
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Solution Overview
Problem
Existing methods for flame-retarding textiles do not provide sufficient and consistent performance in both NFPA-701 and FMVSS-302 tests, necessitating the development of more effective flame retardant coatings.
Innovation Solution
The use of aqueous flame retardant dispersions containing brominated aromatic polymeric flame retardants, which are applied to textile substrates to achieve enhanced flame retardant performance. These dispersions include water, brominated flame retardants with aromatically-bound bromine, dispersants, wetting agents, and thickeners, with the brominated flame retardants having an average particle size of 20 µm or less and comprising 50 wt% or more of the dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flame retardant coatings are applied to textiles, then some level of fire resistance is achieved, but the performance is insufficient and inconsistent in both NFPA-701 and FMVSS-302 tests
Solution Approach 1:
The patent changes the chemical composition parameters of the flame retardant by using brominated aromatic polymeric compounds with specific bromine content (60-80 wt%) and molecular weight ranges. This chemical parameter modification enables the coating to achieve consistent pass rates in both NFPA-701 and FMVSS-302 tests, resolving the reliability issue of conventional flame retardants that failed to provide consistent performance across different test standards.
Solution Approach 2:
The patent employs composite material formulation by combining brominated aromatic polymeric flame retardants with synergistic agents (such as antimony trioxide, zinc borate, or aluminum hydroxide) in specific ratios. This composite approach creates a synergistic effect that enhances fire resistance effectiveness while maintaining performance consistency across both NFPA-701 and FMVSS-302 test protocols, addressing the harmful factor of insufficient fire protection.
2Reliability
If high concentration of brominated flame retardant is used in the dispersion, then flame retardant performance is improved, but the dispersion stability and ease of application may deteriorate
Solution Approach 1:
The patent introduces dispersants and thickening agents as intermediary substances in the aqueous dispersion formulation. These intermediaries mediate between the high concentration brominated flame retardant particles and the water medium, preventing aggregation and settlement of particles. This enables the dispersion to maintain high flame retardant effectiveness while remaining stable and easy to apply through conventional coating methods, resolving the contradiction between performance and ease of operation.
Solution Approach 2:
The patent optimizes physical parameters of the dispersion including particle size distribution of the brominated flame retardant (controlled through milling or classification), viscosity (adjusted via thickening agents), and pH balance. These parameter modifications enable high concentration formulations to remain stable and pumpable, maintaining both superior flame retardant performance and ease of application through standard coating equipment.
Data Source
AI summary
This invention provides a process for forming aqueous flame retardant dispersions comprising water, a brominated flame retardant containing aromatically-bound bromine, at least one dispersant, at least one wetting agent, and at least one thickener. The brominated flame retardant has an average particle size of about 0.1 µm to about 20 µm. The flame retardant dispersion contains about 25 wt% or more of brominated polymeric flame retardant, based on the total weight of the dispersion. Also provided are processes for forming coating compositions.