Discontinuous Adhesive Composite Textile for Flame Retardancy
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Solution Overview
Problem
Current flame retardant treatments for fabrics often result in materials with poor hand, drape, and pliability, and may not meet stringent flammability standards, particularly in European Union and International Maritime Organization regulations, while temporary solutions lack durability and permanent solutions compromise on texture and feel.
Innovation Solution
A multilayer composite material is developed, comprising a film layer, a fibrous material layer, and a discontinuous adhesive region layer, which allows for improved flame retardancy without compromising hand or pliability, by decoupling the production of the substrate from the treatment process and using a non-acrylic binder and phase change materials to enhance flexibility and wash durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame retardant chemical treatments are applied to fabrics, then flame retardancy is improved, but hand, drape, and pliability deteriorate
Solution Approach 1:
The fabric structure is segmented into multiple layers (textile fabric substrate, film layer, fibrous material layer) with each layer serving specific functions. The flame retardant properties are concentrated in the film layer while the textile fabric substrate maintains natural hand and drape characteristics, thus resolving the contradiction between flame retardancy and tactile comfort.
Solution Approach 2:
The invention uses a composite material structure combining textile fabric, film, and fibrous layers. This composite approach allows the fabric to achieve flame retardancy through the film layer while the textile substrate preserves the natural hand, drape, and pliability, thus resolving the contradiction between safety requirements and comfort properties.
2Strength
If continuous adhesive layers are used to laminate film and fabric, then bonding strength is improved, but flexibility and pliability deteriorate
Solution Approach 1:
The adhesive bonding is segmented into discrete, non-continuous regions rather than a continuous layer. These discrete adhesive regions provide sufficient bonding strength to hold the layers together while leaving gaps that allow the fabric to flex and drape naturally, thus resolving the contradiction between bonding strength and flexibility.
Solution Approach 2:
The adhesive is applied with local quality variation - concentrated in discrete regions where bonding is needed while absent in regions where flexibility is required. This localized adhesive application maintains bonding strength at critical points while preserving overall fabric pliability and drape.
3Reliability
If permanent flame retardant treatments are applied, then flammability resistance is improved, but texture and surface contact quality deteriorate
Solution Approach 1:
The flame retardant functionality is segmented and isolated in the film layer, separate from the textile fabric substrate that provides surface contact quality. This segmentation allows the flame retardant film to perform its safety function while the textile substrate maintains natural texture and pleasant hand, resolving the contradiction between flammability resistance and surface contact quality.
Solution Approach 2:
The film layer acts as an intermediary between the flame retardant requirement and the textile fabric. It provides the flame retardant protection while the textile substrate directly contacts the user, ensuring pleasant surface contact quality without compromising flammability resistance.
4Ease of operation
If multilayer composite structure with discrete adhesive regions is used, then pliability and drape are improved, but manufacturing complexity increases
Solution Approach 1:
The film layer and fibrous material layer are pre-laminated together with discrete adhesive regions before being applied to the textile fabric substrate. This preliminary lamination simplifies the overall manufacturing process by creating a pre-assembled unit that can be efficiently attached to the fabric, reducing the complexity of producing the complete multilayer structure.
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 provides fabrics with enhanced flame retardancy, natural surface contact, improved drape, and pliability, meeting stringent flammability standards while maintaining a soft and pleasant hand, and reducing production complexities and costs.
Implementation Method 1
The discontinuous adhesive region layer adheres the second surface of the film layer to the first surface of the fibrous material layer
Implementation Method 2
a backcoat layer including a non-acrylic binder
Data Source
AI summary
A finished composite material having a film layer, a fibrous material layer and a discontinuous adhesive region layer situated between the film layer and the fibrous material layer. The discontinuous adhesive region layer adheres the film layer to the fibrous material layer. The discontinuous adhesive layer forms a number of discrete and non-continuous regions including an interface between the film layer and the fibrous material layer such that the film layer touches the fibrous material layer at the interface. The number of discrete and non-continuous regions forms a number of non-adhesive regions therebetween configured to not resist flexing of the film layer and the fibrous material layer. The finished composite material further includes an upholstery or mattress textile fabric substrate having a thickness of 0.5 to 2.0 millimeters. The front surface of the upholstery or mattress textile fabric substrate is configured to contact a user of the fabric substrate.