Flame Resistant Textile Warp Weft Phosphorous Reduction
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Solution Overview
Problem
There is a need for flame-resistant textiles that reduce the use of harmful phosphorous-based chemicals while maintaining effective flame resistance and other characteristics, particularly in institutional settings like hospitals and commercial buildings.
Innovation Solution
A flame-resistant textile is developed using a combination of warp and weft yarns where the warp yarns contain inherent phosphorous-based flame-resistant polyester with 1500-3500 ppm of phosphorous and the weft yarns contain less than 100 ppm, with a higher weight percentage of weft yarns, woven in a standard weave pattern to achieve low phosphorous content while passing relevant flame tests like NFPA 701 v2015 and GREENSCREEN certification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorous-based FR chemistry is used in textile to achieve flame resistance, then flame resistance performance is improved, but harmful chemical usage increases
Solution Approach 1:
The patent applies local quality by concentrating phosphorous-based FR chemistry only in the warp yarns (1500-3500 ppm) while keeping weft yarns phosphorous-free (<100 ppm). This localized application achieves effective flame resistance through the warp yarns while minimizing overall chemical usage in the textile, resolving the contradiction between FR performance and harmful chemical reduction.
Solution Approach 2:
The patent segments the textile into two functional components: warp yarns that provide flame resistance through phosphorous-based chemistry, and weft yarns that provide structural support without chemicals. This segmentation allows the textile to meet FR requirements while reducing total phosphorous content to 1500 ppm or less, addressing both performance and chemical reduction goals.
2Object-affected harmful factors
If phosphorous-based FR chemistry is reduced to meet environmental standards, then harmful chemical usage is reduced, but flame resistance performance may deteriorate
Solution Approach 1:
The patent optimizes the phosphorous concentration parameter in warp yarns to a specific range (1500-3500 ppm) that balances FR performance with chemical reduction. This parameter optimization ensures the textile meets both environmental standards (1500 ppm or less overall) and flame resistance requirements, resolving the contradiction between chemical reduction and performance maintenance.
3Reliability
If warp yarns contain high phosphorous content to ensure flame resistance, then flame resistance is improved, but total phosphorous content in textile increases
Solution Approach 1:
The patent localizes phosphorous content to warp yarns only, concentrating the FR chemistry where it is most effective for flame resistance. By limiting phosphorous to 1500-3500 ppm in warp yarns and excluding it from weft yarns, the textile achieves optimal FR performance while minimizing total phosphorous content to 1500 ppm or less, resolving the contradiction between performance and quantity reduction.
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 textile achieves effective flame resistance with reduced phosphorous-based chemical usage, meeting stringent fire tests and environmental standards, and is wash durable and environmentally friendly, suitable for various applications including bedding and upholstered furniture.
Implementation Method 1
The warp yarns contain inherent FR polyester yarns having between about 1500 and 3500 ppm of a phosphorous based FR chemistry
Implementation Method 2
the inherent FR polyester yarns were formed by the process of extruding molten polyester and the phosphorous based FR chemistry together
Data Source
AI summary
A flame resistant textile containing a plurality of warp yarns in a warp direction of the textile interwoven with a plurality of weft yarns in the weft direction approximately perpendicular to the warp direction. The warp yarns contain inherent FR polyester yarns having between about 1500 and 3500 ppm of a phosphorous based FR chemistry and the weft yarns contain polyester yarns. the textile contains more weft yarns by weight than warp yarns and wherein the FR textile contain about 1500 ppm or less of the phosphorous based FR chemistry.