Fabric and method for obtaining said fabric
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Solution Overview
Problem
Conventional upholstery fabrics treated with chemical flame retardants, such as brominated and phosphorus-based compounds, are toxic and pose health risks, while existing methods for producing flame-resistant fabrics that comply with safety standards like California TB 117: 2013 Section 2 often require harmful treatments and do not prevent filling materials like feathers from escaping.
Innovation Solution
A method involving an intimate blend yarn with 65% polyester and 35% cotton, woven in a 2/1 twill weave, and treated with hot calendering to create a combustion-resistant fabric that meets safety standards without the use of flame retardant chemicals, ensuring the fabric is soft, prevents filling material leakage, and passes air permeability tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical flame retardants (brominated and phosphorus-based compounds) are used to treat upholstery fabrics, then flame resistance is improved, but toxicity and harmful effects on human health worsen
Solution Approach 1:
The invention extracts and removes the harmful chemical flame retardant treatment step from the fabric production process. Instead of applying chemical salts to the fabric, the patent uses the natural properties of the cotton-polyester blend yarn and weave structure to achieve flame resistance without toxic substances.
Solution Approach 2:
The invention changes the fundamental approach from chemical treatment to physical/structural properties. By adjusting the yarn composition (65% cotton, 35% polyester) and weave density, the fabric achieves flame resistance through its inherent material properties rather than chemical additives.
2Reliability
If the fabric weave is made tight to prevent filling material escape, then containment performance is improved, but air permeability and comfort worsen
Solution Approach 1:
The invention optimizes the weave parameters to achieve a balance between containment and breathability. The specific 2/1 twill weave with calculated thread densities creates a structure that is tight enough to prevent feather escape while maintaining sufficient air permeability for comfort and cushion functionality.
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 resulting fabric is safe, compliant with sector regulations, resistant to combustion, and prevents filling material escape without the need for toxic treatments, while maintaining a soft texture and passing stringent flammability tests like California TB 117: 2013 Section 2.
Implementation Method 1
at least one step of pressing said bleached fabric, preferably by hot calendering; in particular, the pressing step involves inserting said bleached fabric inside at least one calender
Implementation Method 2
at least one step of pressing said bleached fabric, preferably by hot calendering
Data Source
AI summary
A method for producing a combustion resistant upholstery fabric with a weight of approximately 180-210 g/m2 includes:at least one preparation step of an intimate blend yarn with 65% by weight of polyester fibers and 35% by weight of cotton fibers,at least one weaving step with a 2/1 twill weave of the yarn thus prepared to obtain a fabric,at least one washing step of said fabric to obtain a bleached fabric,at least one step of pressing said bleached fabric, the pressing step involves inserting said bleached fabric inside at least one calender to obtain an upholstery fabric.