Inherently Fire Resistant Woven Denim Fabric
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fire-resistant denim fabrics rely on topical treatments that can be washed out or diminished by environmental exposures, compromising their flame resistance, moisture management, and abrasion resistance, while also affecting comfort and dyeability.
Innovation Solution
Development of woven fabrics comprising a blend of hydrophobic and hydrophilic fibers, with warp yarns made from cellulose derivatives, providing inherent fire resistance, improved moisture management, and abrasion resistance without the need for additional treatments, and allowing for optional dyeing to maintain a traditional denim appearance and feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If topical fire resistant treatments are applied to cotton denim fabric, then fire resistance is achieved, but the treatments can be washed out or diminished by environmental exposures, compromising flame resistance
Solution Approach 1:
The patent removes the topical treatment layer entirely and instead uses inherently fire-resistant fibers (modacrylic, aramid, PBI) that provide flame resistance without requiring surface coatings. This extraction of the treatment layer eliminates the problem of wash-out while maintaining fire protection.
Solution Approach 2:
The patent creates composite fiber blends combining inherently fire-resistant synthetic fibers (modacrylic, aramid, PBI) with natural cotton fibers. This composite approach provides permanent flame resistance while maintaining the comfort and aesthetic properties of traditional cotton denim.
2Reliability
If chemically treated fabrics are used for fire resistance, then flame protection is provided, but moisture management properties are adversely impacted, leading to slower drying times
Solution Approach 1:
The patent removes chemical treatments entirely and replaces them with inherently fire-resistant fibers. This eliminates the chemical barrier that interferes with moisture management, allowing the fabric to naturally wick and evaporate moisture while maintaining flame resistance through fiber selection.
Solution Approach 2:
The patent changes the fundamental parameter of fire resistance from a surface chemical property to an inherent fiber property. By selecting fibers with naturally high flame resistance (modacrylic, aramid, PBI), the fabric achieves flame protection without chemical coatings that would impede moisture transport.
3Reliability
If fiber selection is optimized for fire resistance and abrasion resistance, then protection is improved, but the ability to dye the fabric is negatively impacted, especially traditional denim look and feel
Solution Approach 1:
The patent applies different fiber types in specific locations within the fabric structure. Cotton fibers provide dyeability and traditional denim appearance, while strategically incorporated fire-resistant fibers (modacrylic, aramid, PBI) provide protection. This local differentiation allows both aesthetic and protective functions to coexist.
Solution Approach 2:
The patent uses composite fiber blends where cotton fibers maintain traditional denim dyeability and appearance, while blended fire-resistant fibers provide protection. The composite structure allows the fabric to be dyed traditionally while incorporating protective elements that do not interfere with the dyeing process or final appearance.
4Quantity of substance
If denim fabric absorbs large percentages of water or sweat, then moisture capacity is increased, but comfort is reduced due to saturated heavy fabric against the skin
Solution Approach 1:
The patent changes the moisture management mechanism from absorption to wicking and evaporation. By using hydrophilic cotton fibers combined with hydrophobic fire-resistant fibers, the fabric creates capillary channels that wick moisture away from the skin and facilitate evaporation, preventing the saturated heavy feeling while maintaining high moisture capacity.
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 woven fabrics exhibit permanent flame resistance, enhanced moisture management, and improved abrasion resistance, maintaining performance through multiple wash cycles and environmental exposures while ensuring comfort and traditional denim aesthetics.
Implementation Method 1
a plurality of weft yarns comprising a blend of fibers with inherently fire resistant fibers with superior moisture management properties
Implementation Method 2
a plurality of weft yarns comprising a blend of fibers with inherently fire resistant fibers with superior moisture management properties
Implementation Method 3
improved moisture management (water release rate, wicking, and drying time)
Data Source
AI summary
Optionally dyed woven fabrics and garments are disclosed that exhibit fire resistance, arc resistance, moisture management (water release rate and wicking), and abrasion resistance without the undesirable addition of topical treatments. Certain embodiments of the woven fabric are disclosed that comprise a plurality of weft yarns comprising a blend of fibers with inherently fire resistant fibers with superior moisture management properties and a plurality of warp yarns, optionally dyed, comprising cellulose derivatives. The woven fabrics are particularly useful in denim work clothes because they are comfortable to wear and exhibit fire resistance and abrasion resistance.