Composite Yarn with Functionalized Particles for Fire-Safe Textiles
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Solution Overview
Problem
Current composite yarns used for sunblinds and solar protection textiles face challenges in achieving high fire performance, particularly in meeting Euroclass Bs2d0 or Bs3d0 standards, while being easy to manufacture and environmentally friendly, with existing solutions often resulting in stiffness and increased costs due to the use of toxic materials and high volatile organic compounds (VOCs).
Innovation Solution
A composite yarn is developed with a continuous multifilament core yarn and a matrix containing functionalized particles with a median size of less than 40 μm, dispersed throughout the inter-filament interstices, which reduces the yarn's titer and mass per unit area, and uses a lower content of fire-retardant filler, allowing for improved fire performance and reduced VOC emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high content of fire-retardant filler is used to improve fire performance, then fire resistance is enhanced, but the composite yarn becomes stiffer and more difficult to manipulate
Solution Approach 1:
The patent changes the particle size parameter of the fire-retardant filler, using fine particles with median size of 5-40 μm instead of conventional larger particles. This parameter change allows achieving fire performance requirements with lower overall filler content (5-20 wt%), thereby maintaining the flexibility and manipulability of the composite yarn while ensuring fire safety compliance.
2Reliability
If conventional fire-retardant fillers are used to meet fire standards, then fire resistance is achieved, but toxic materials and high VOC emissions result
Solution Approach 1:
The patent employs a composite filler system combining fine inorganic particles (silica, alumina, titanium oxide) with organic fire-retardant compounds (phosphonates, phosphinates, phosphates). This composite material approach achieves effective fire resistance while using environmentally friendly components that do not emit toxic VOCs, replacing conventional toxic fire-retardant chemicals.
3Ease of operation
If fine particles are used to improve fire performance with lower filler content, then flexibility is maintained, but manufacturing precision is required
Solution Approach 1:
The patent specifies a controlled particle size range with median diameter of 5-40 μm for the fire-retardant filler particles. This precise parameter control ensures that particles are fine enough to disperse uniformly and provide effective fire protection at low concentrations (5-20 wt%), maintaining yarn flexibility while avoiding agglomeration issues that would compromise manufacturing quality.
Data Source
AI summary
A process for manufacturing a composite yarn comprising a continuous multifilament core yarn incorporated in a matrix, comprising at least one step of depositing, by coating or extrusion, a matrix comprising a polymer material and a reinforcing filler formed from functionalized particles, onto a core yarn. A composite yarn obtained by such process. A textile comprising at least one such composite yarn.