Flame-Resistant Fabric Finishing for Wash Durability and Softness
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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 and wrinkle resistance, while also generating malodors and restricting the application of other finishing agents.
Innovation Solution
A process involving the application and curing of flame retardant chemicals, optionally with softening agents, on textile fabrics, which allows for higher synthetic fiber content without compromising flame resistance, and includes mechanical surface treatment for enhanced softness and tear strength, eliminating the need for additional manufacturing steps and high-temperature processing.
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 process complexity increases
Solution Approach 1:
The patent extracts and eliminates the ammonia treatment step from the conventional flame retardant process. Instead of using the multi-step ammoniation process involving ammonia gas treatment, peroxide baths, and caustic dips, the invention applies flame retardant chemicals directly to the fabric in a simplified single-step process, thereby reducing process complexity while maintaining flame resistance
Solution Approach 2:
The patent combines multiple functions into a single treatment process. The simplified process simultaneously imparts flame resistance and allows for subsequent application of other finishing agents without generating malodors, whereas the conventional ammoniation process required separate, complex steps for each function
2Reliability
If conventional ammoniation process is used, then flame resistance is achieved, but synthetic fiber content is limited
Solution Approach 1:
The patent changes the chemical parameters of the flame retardant treatment process by eliminating ammonia and using alternative chemistry that is compatible with synthetic fibers. This parameter change allows the fabric to contain up to 65% synthetic content while maintaining effective flame resistance, compared to the conventional process which limited synthetic content to below 30%
3Reliability
If conventional ammoniation process is used, then flame resistance is achieved, but wash durability and wrinkle resistance deteriorate
Solution Approach 1:
The patent changes the chemical composition and application parameters of the flame retardant treatment to improve durability. The modified chemistry and processing conditions create a more durable finish that withstands repeated launderings and provides better wrinkle resistance compared to the conventional ammoniation process
4Reliability
If conventional ammoniation process is used, then flame resistance is achieved, but malodors are generated and application of other finishing agents is restricted
Solution Approach 1:
The patent removes the ammonia treatment step that causes malodors. By eliminating the ammonia gas treatment and subsequent peroxide and caustic dips, the process no longer generates the unpleasant odors associated with conventional ammoniation, while still achieving effective flame resistance
Solution Approach 2:
The patent converts the limitation of the conventional process (inability to apply other finishes) into a benefit. The simplified chemistry allows other finishing agents to be applied without generating malodors, turning the original harmful effect into a positive outcome where multiple finishes can be combined
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 softness, capable of withstanding repeated launderings and incorporating additional finishing agents without malodor generation, while enabling higher synthetic fiber content and better wrinkle resistance.
Implementation Method 1
the application and curing of one or more flame retardant compounds
Implementation Method 2
the mechanical surface treatment of the fabrics treated with the flame retardant compounds
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.