Flame-Resistant Composite Fabric With TPU Layers for Wearability
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Solution Overview
Problem
Existing flame-resistant fabrics made from polyester or nylon fibers face issues such as melting before ignition, leading to skin burns and loss of desirable properties like wearability and flexibility due to inadequate flame-retardant compositions, and composite fabrics are more susceptible to damage with exposed cores during degradation.
Innovation Solution
A flame-retardant fabric composite comprising a woven nylon fabric sheet, intrinsically flame-retardant polyurethane polymer layers, and thermoplastic polyurethane layers, with optional impregnation by thiourea formaldehyde and fluorinated durable water repellants, to enhance flame resistance and maintain fabric properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame-retardant compositions are applied to polyester or nylon fabrics, then flame resistance is improved, but the fabric loses desirable properties such as wearability, weight, and flexibility
Solution Approach 1:
The patent applies composite materials by combining inherently flame-retardant polyurethane polymer layers with flame-retardant treated fabric layers. This creates a multi-layer composite structure where each layer contributes different properties: the polyurethane layers provide intrinsic flame resistance without compromising fabric hand, while the treated fabric layers add additional flame protection. This composite approach allows the fabric to maintain its original wearability and flexibility while achieving enhanced flame resistance.
Solution Approach 2:
The patent uses an adhesive layer as an intermediary between the flame-retardant treated fabric and the polyurethane polymer layer. This adhesive intermediary ensures proper bonding while allowing the flame-retardant properties to be effectively transferred and maintained. The adhesive layer mediates the interaction between different materials, enabling the composite structure to function as a unified flame-resistant system without compromising the fabric's desirable properties.
2Reliability
If coating fabric with flame-retardant composition is done to improve fire resistance, then flame resistance is improved, but the fabric's wearability and flexibility are reduced
Solution Approach 1:
The patent applies parameter changes by using polyurethane polymers with specific physical and chemical properties (such as glass transition temperature, molecular weight, and flame-retardant additives) that can be adjusted to optimize both flame resistance and fabric hand. By carefully selecting and tuning these parameters, the patent achieves flame resistance without the fabric becoming too rigid or losing its wearability.
3Strength
If composite fabrics are used with intermediate cores, then structural integrity is improved, but the fabric becomes more susceptible to flame damage as the core is exposed during degradation
Solution Approach 1:
The patent applies continuity of useful action by ensuring that flame-retardant protection is continuous throughout the entire composite fabric structure, including the intermediate core. Multiple polyurethane polymer layers are applied to both sides of the fabric, creating continuous flame-resistant barriers that prevent flame penetration to the core. This continuous protection ensures that even if the outer fabric degrades, the core remains protected from flame damage.
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 composite fabric provides enhanced flame resistance while preserving wearability and flexibility, meeting ASTM specifications for arc flash and flash fire protection without significant loss of fabric properties.
Implementation Method 1
the first and second flame-retardant polyurethane polymer layers each independently comprise (1) an intrinsically flame-retardant polymer, and (2) a flame-retardant additive
Implementation Method 2
a thermoplastic polyurethane (TPU) layer
Implementation Method 3
a fluorinated durable water repellant (DWR)
Data Source
AI summary
The present invention is directed to a fabric composite comprising nylon or polyester fibers having flame-retardant properties without sacrificing many of the desirable properties of the fabric composite. The fabric composite may have external fabric layers (e.g., nylon sheets, etc.) each internally coated with a flame-retardant layer and attached to one another through a thermoplastic polyurethane film. The present invention also provides methods of making such fabric composites.