Fire Retardant Fluff Pulp Web with Surfactant Distribution
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Solution Overview
Problem
Current fire-resistant fibrous materials for applications like upholstery and insulation do not consistently meet fire resistance tests such as the UL 94 TMVB and Horizontal Burn Through tests, particularly due to uneven distribution and reactivity of fire retardants.
Innovation Solution
A fire-resistant fluff pulp web is developed, comprising unrefined softwood fibers with a fire retardant component and organic amine dispersants, distributed using surfactants to achieve consistent fire resistance, with a basis weight above 40 gsm, caliper of at least 30 mils, and moisture content below 16%, allowing it to pass the UL 94 TMVB and Horizontal Burn Through tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fire retardant chemicals are deposited on fibrous materials using conventional methods, then fire retardant coverage is achieved, but uneven distribution and inconsistent reactivity result in failure to meet fire resistance tests
Solution Approach 1:
The patent introduces a surfactant as an intermediary substance that mediates between the fire retardant chemical and the fibrous material. The surfactant contains both hydrophilic and hydrophobic regions, allowing it to emulsify the fire retardant and facilitate its uniform penetration and distribution throughout the fibrous matrix, thereby achieving consistent fire resistance without uneven spotting or aggregation
Solution Approach 2:
The patent modifies the chemical parameters of the fire retardant application system by adjusting pH levels, surfactant concentrations, and treatment temperatures to optimize the interaction between fire retardant, surfactant, and fibers. These parameter changes ensure proper emulsification, penetration, and bonding, resulting in uniform distribution and consistent fire resistance performance
2Reliability
If higher amounts of fire retardant are applied to ensure fire resistance, then fire protection is improved, but material cost and processing complexity increase
Solution Approach 1:
The surfactant acts as a delivery vehicle that efficiently transports fire retardant chemicals into the fibrous material at optimized concentrations. This intermediary system ensures maximum utilization of the fire retardant, achieving effective fire protection with reduced dosage compared to conventional application methods that suffer from uneven distribution and waste
Solution Approach 2:
The patent applies preliminary treatment steps including surfactant conditioning and controlled pH adjustment before fire retardant application. These preliminary actions prepare the fibrous material to optimally receive and retain the fire retardant, ensuring uniform penetration and reducing the total quantity needed to achieve the required fire resistance level
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 fire-resistant fluff pulp web effectively passes critical fire resistance tests, providing reliable protection against flames and burns, with reduced fire retardant dosage requirements due to efficient surfactant distribution, enhancing both performance and cost-effectiveness.
Implementation Method 1
one or more fire retardant distributing surfactants which distribute the fire retardant component in and/or on the fluff pulp web
Implementation Method 2
the fire retardant component comprising from about 50 to about 98.5% by weight of one or more fire retardants and from about 1.5 to about 50% by weight of one or more organic amine fire retardant dispersants
Data Source
AI summary
A fire resistant fluff pulp web made from a fluff pulp web, a fire retardant component present in and/or on the fluff pulp, and a fire retardant distributing surfactant which distributes the fire retardant component in and/or on the fluff pulp web in a manner so that the fluff pulp web passes one or more fire resistance tests. Also, a process for preparing these fire resistant fluff pulp webs, as well as for treating outer fibrous layers comprising an air-laid mixture of these fire resistant fluff pulp fibers and bicomponent fibers with up to about 5% additional fire retardant and which are used in fire resistant air-laid fibrous structures useful in upholstery, cushions, mattress ticking, panel fabric, padding, bedding, insulation, materials for parts in devices and appliances, etc.