Expanded Graphite Foam Coating for Flame-Retardant Textiles
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Solution Overview
Problem
Current flame retardant textiles for fire protection are either insufficiently effective, uncomfortable to wear, or toxicologically questionable due to limitations in particle size and distribution of expanded graphite, which affects their flame retardancy and wearing comfort.
Innovation Solution
A method involving post-washing of expanded graphite to reduce salt content, allowing for larger platelet sizes and increased expansion volume, combined with a binder and foam stabilizer, to create a continuous flame retardant foam coating that enhances flame protection without compromising flexibility, breathability, or water vapor permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If small expanded graphite particles are used in flame retardant coatings, then the coating can be applied with lower material proportion, but the flame retardancy effectiveness is significantly reduced due to lower expansion volume and pressure
Solution Approach 1:
The patent changes the particle size parameter of expanded graphite from small particles to large platelet-shaped particles with diameter of at least 0.2 mm. This parameter change enables the graphite to achieve sufficient expansion volume and pressure for effective flame retardancy while maintaining a reasonable proportion in the coating composition.
Solution Approach 2:
The patent creates a composite coating system combining large platelet-shaped expanded graphite with specific binders and foam stabilizers. This composite approach optimizes the interaction between components, allowing the expanded graphite to achieve maximum expansion effectiveness while maintaining coating integrity and appropriate material proportion.
2Reliability
If high proportion of expanded graphite or thick coating layer is used to achieve high flame retardancy, then the flame protection is improved, but the textiles become stiff and wearing comfort is reduced
Solution Approach 1:
The patent changes the morphology parameter of expanded graphite to large platelet shape with specific size requirements (diameter ≥ 0.2 mm, mesh size >50). This morphological parameter change enables effective flame retardancy with lower material proportion, thereby maintaining textile flexibility and wearing comfort.
Solution Approach 2:
The patent optimizes the local distribution and orientation of large platelet-shaped expanded graphite particles in the coating. The platelet structure provides effective flame protection at the particle level while the optimized distribution ensures these protective particles are efficiently arranged without requiring excessive material that would stiffen the textile.
3Reliability
If area-wide coatings are applied to achieve sufficient flame protection, then the protective effect is improved, but the stiffness and reduced freedom of movement increase
Solution Approach 1:
The patent changes the particle size parameter to large platelet-shaped expanded graphite, which provides high flame protection efficiency per unit mass. This enables effective area-wide coatings with reduced material proportion, maintaining textile flexibility and freedom of movement while ensuring comprehensive protective coverage.
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 method results in a flame retardant textile coating with significantly improved expansion volume and pressure, providing enhanced protection against flames while maintaining comfort and usability, as evidenced by a doubled reaction time to skin burns compared to conventional articles.
Implementation Method 1
In the event of a fire or when exposed to high temperatures, the expanded graphite particles expand and increase their volume many times over.
Implementation Method 2
The intumescent layer formed by the expanded expanded graphite, for example on a textile base, protects this textile base very efficiently, as it prevents the access of oxygen or the formation and spread of flames
Implementation Method 3
It has a very good thermal insulation effect due to the lower density of the expanded expanded graphite. It is difficult for the heat to spread through the intumescent layer
Data Source
AI summary
The invention relates to flame protection foam coatings for textile planar products, wherein the coatings comprise reduced-salt-content expanded graphite in the form of platelets, having a particle distribution having a fraction of > 80 weight percent having a diameter of at least 0.2 mm and/or a minimum fraction of 70% having a mesh width of > 50 mesh (0.3 mm), at least one binder, and at least one foam stabilizer. The invention further relates to methods for the production thereof, to the use thereof to produce textile planar products, and to textile planar products having such flame protection foam coatings.