Elastic Flame-Resistant Yarn via Composite Fiber Structure
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Solution Overview
Problem
Existing flame-resistant fabrics often lack durability, abrasion resistance, and comfort, particularly in repeated industrial launderings, and struggle to meet dual-hazard performance specifications such as ASTM F1506 and NFPA 2112-2012, while also providing stretch and dyeability.
Innovation Solution
An elastic flame-resistant yarn and fabric made from an intimate blend of non-flame-resistant cellulosic, modacrylic, and aramid fibers wrapped around elastic continuous fibers, with specific weight ratios and processing methods to achieve both flame resistance and elasticity, ensuring compliance with stringent performance standards and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame-resistant fabrics are made from traditional flame-resistant fibers, then flame resistance is achieved, but durability and abrasion resistance deteriorate
Solution Approach 1:
The patent uses a composite fiber structure combining modacrylic fibers (flame-resistant) with elastic continuous fibers (providing durability and stretch). This composite approach allows the fabric to maintain flame resistance while gaining improved mechanical properties and durability from the elastic fiber component.
Solution Approach 2:
The patent modifies the fiber composition parameters by incorporating specific ratios of modacrylic to elastic continuous fibers, and by controlling the fiber diameter and crimp characteristics. These parameter changes optimize both flame resistance and mechanical durability simultaneously.
2Strength
If flame-resistant fabrics are made to be durable and abrasion-resistant, then durability improves, but comfort and stretchability deteriorate
Solution Approach 1:
The elastic continuous fibers in the composite structure provide stretchability and comfort while the modacrylic fibers ensure flame resistance and durability. The synergistic combination allows the fabric to be durable without sacrificing comfort.
Solution Approach 2:
The patent applies different fiber types to different functional requirements within the same fabric structure. The elastic fibers provide stretch in areas requiring movement, while the modacrylic fibers provide flame resistance throughout the fabric, optimizing both durability and comfort locally.
3Ease of operation
If flame-resistant fabrics are made to have stretch for comfort, then comfort improves, but flame resistance deteriorates
Solution Approach 1:
The composite structure allows the fabric to have stretch from the elastic fibers while maintaining flame resistance from the modacrylic fibers. The flame-resistant properties are not compromised by the addition of elastic fibers because the modacrylic component remains intact and functional.
4Ease of manufacture
If flame-resistant fabrics are made to be readily dyeable to dark shades, then dyeability improves, but flame resistance and durability deteriorate
Solution Approach 1:
The patent selects specific fiber diameter ranges and crimp characteristics for the modacrylic fibers that optimize dyeability to dark shades while maintaining flame resistance. The fiber morphology parameters are controlled to ensure both excellent dye uptake and flame-resistant properties.
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 that meet or exceed ASTM F1506 and NFPA 2112-2012 standards, offering durability, abrasion resistance, comfort, and stretch while maintaining flame resistance and allowing for dark, solid dye shades, thus addressing the limitations of existing fabrics.
Implementation Method 1
The elastic continuous fibers make up at least about 0.01% by weight to at most about 5% by weight of the elastic flame-resistant yarn
Data Source
AI summary
An elastic flame-resistant yarn containing an intimate fiber blend of staple fibers wrapped around a plurality of elastic continuous fibers. The intimate fiber blend of staple fibers contains non-flame-resistant (FR) cellulosic fibers, modacrylic fibers, and aramid fibers. The non-FR cellulosic fibers constitute at least about 31% by weight to at most about 54% by weight of the intimate fiber blend of staple fibers, the modacrylic fibers constitute at least about 30% by weight to at most about 49% by weight of the intimate fiber blend of staple fibers, and the aramid fibers make up at least about 3% by weight to at most about 20% by weight of the intimate fiber blend of staple fibers. The elastic continuous fibers make up at least about 0.01% by weight to at most about 5% by weight of the elastic flame-resistant yarn.