Flame-Resistant Fabric Curing for Synthetic Blend Durability
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Solution Overview
Problem
Conventional ammoniation processes for imparting flame resistance to textiles are costly, limit the use of synthetic fibers due to flammability issues, and result in fabrics with poor wash durability, wrinkle resistance, and odor generation, especially when incorporating high synthetic content.
Innovation Solution
A process involving the application and curing of flame retardant chemicals, optionally with softening agents, and mechanical surface treatment, which allows for higher synthetic fiber content without compromising flame resistance, and includes additional finishing agents like stain release and soil repellents, eliminating the need for high-temperature processing that generates malodors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ammoniation process is used to impart flame resistance, then flame resistant properties are achieved, but manufacturing cost increases and fabric wash durability decreases
Solution Approach 1:
The patent changes the chemical parameters by using phosphorous-based flame retardant chemicals (such as ammonium phosphomolybdate, ammonium phosphotungstate, or ammonium polyphosphate) instead of conventional ammoniation chemicals. This parameter change maintains flame resistance while eliminating the need for expensive ammonia chambers and complex environmental controls, thereby reducing manufacturing cost.
Solution Approach 2:
The patent extracts and eliminates the ammonia chamber step from the conventional ammoniation process. By using alternative phosphorous-based chemicals that can be applied through standard dip-and-dry processes, the expensive and complex ammonia treatment infrastructure is removed while maintaining flame resistant properties.
2Reliability
If conventional ammoniation process is used, then flame resistance is achieved, but synthetic fiber content must be limited due to flammability issues
Solution Approach 1:
The patent changes the chemical composition parameter by using phosphorous-based flame retardant chemicals that are compatible with synthetic fibers. These chemicals (ammonium phosphomolybdate, ammonium phosphotungstate, or ammonium polyphosphate) can be effectively applied to fabrics containing up to 65% synthetic content, unlike conventional ammoniation processes that limit synthetic fiber usage.
3Reliability
If conventional ammoniation process is used, then flame resistant finish is achieved, but fabric produces malodors especially with high synthetic content
Solution Approach 1:
The patent changes the chemical parameter by replacing conventional ammoniation chemicals with phosphorous-based flame retardant chemicals. This substitution eliminates the generation of malodorous compounds during the drying and curing processes, particularly benefiting fabrics with high synthetic fiber content that are prone to odor generation in conventional processes.
4Reliability
If conventional ammoniation process is used, then flame resistance is achieved, but wrinkle resistance and appearance retention are poor
Solution Approach 1:
The patent changes the chemical treatment parameters by using phosphorous-based flame retardant chemicals that do not interfere with the fabric's inherent wrinkle resistance and appearance properties. The alternative chemistry system maintains better fabric stability and aesthetic qualities compared to conventional ammoniation processes.
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 process produces durable, flame-resistant fabrics with improved tear strength and appearance retention, capable of withstanding multiple launderings and incorporating higher synthetic fiber content without loss of flame resistance, while avoiding the drawbacks of conventional ammoniation methods.
Implementation Method 1
the application and curing of one or more flame retardant compounds
Implementation Method 2
the peroxide oxidizes the phosphorous compound. This step is illustrated below.
Data Source
AI summary
A process for imparting flame resistance and the flame resistant fabrics produced by such process are provided. The process for imparting flame resistant properties involves treating a target fabric with one or more flame retardant chemicals (and, preferably, a softening agent) and then curing the treated fabric to durably affix the flame retardant to the fabric. In many cases, it may be desirable to subject the treated fabric to mechanical face finishing to increase softness. Optionally, stain release agents, soil repellent agents, permanent press resins, and the like may be added to the bath of flame retardant chemicals, eliminating the need for one or more additional manufacturing processes. Alternately, soil repellent agents may be applied to only one side of the treated fabric after the application of the flame retardant chemicals. The present fabrics exhibit improved performance and tear strength, even after repeated launderings, as compared to conventionally treated fabrics.