Flame-Resistant Woven Fabric Using Non-Melting and Thermoplastic Fibers
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Solution Overview
Problem
Conventional flame-resistant woven fabrics fail to provide long-term flame-blocking capabilities due to limitations in flexibility, texture, and workability, as existing methods either rely on thick materials or non-combustible inorganic composites that compromise these properties.
Innovation Solution
A flame-resistant woven fabric structure comprising non-melting fibers with a high-temperature shrinkage rate of 3% or less and thermoplastic fibers with an LOI value of 25 or more, where the thermoplastic fiber has a melting point lower than the ignition temperature of the non-melting fiber, ensuring a balanced combination of high flame resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer with high flame retardance is used in a composite to improve flame resistance, then the flame retardant effect is enhanced, but the flexibility and workability are significantly impaired
Solution Approach 1:
The patent uses a composite structure consisting of a base fabric (polyester, nylon, or cellulose) combined with a flame-retardant coating layer. This allows the base fabric to maintain flexibility and workability while the coating layer provides the flame resistance. The composite structure enables both requirements to be satisfied simultaneously without compromising either property.
2Reliability
If the material is made sufficiently thick to prevent flame-spreading in long time exposure, then the flame blocking ability is improved, but the flexibility and workability are significantly impaired
Solution Approach 1:
The patent applies a thin flame-retardant coating film on the base fabric rather than using thick materials. The coating forms a protective layer that prevents flame spreading while maintaining the flexibility and thin profile of the underlying fabric. This thin-film approach allows the material to remain flexible and workable while providing effective flame blocking capability.
3Reliability
If a meta-aramid is used in a composite to achieve high LOI value and flexibility, then the flame retardance is improved, but the fabric shrinks and hardens at high temperature, losing its textile form
Solution Approach 1:
The patent modifies the thermal properties of the coating materials by selecting polymers with appropriate glass transition temperatures and thermal stability. The coating is designed to remain flexible at service temperatures while providing flame resistance, avoiding the shrinkage and hardening issues of meta-aramid. The polymer composition and crosslinking density are adjusted to maintain textile form stability across a range of temperatures.
4Object-affected harmful factors
If phosphorus-based agents are used instead of halogen-based agents to comply with environmental regulations, then the environmental compatibility is improved, but the flame retardant effect is reduced
Solution Approach 1:
The patent uses a composite coating system where phosphorus-based flame retardants are combined with other flame-retardant polymers and additives. This synergistic composite approach allows the use of environmentally compatible phosphorus-based agents while achieving effective flame retardance through the combined action of multiple components in the coating layer.
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 fabric achieves excellent flame resistance and prevents flame-spreading for an extended period without compromising flexibility or texture, making it suitable for various applications requiring flame retardance.
Implementation Method 1
a thermoplastic fiber B having an LOI value of 25 or more in accordance with JIS K 7201-2 (2007) and having a melting point lower than the ignition temperature of the non-melting fiber A
Implementation Method 2
a non-melting fiber A having a high-temperature shrinkage rate of 3% or less
Data Source
AI summary
A flame resistant woven fabric has a thickness of 0.08 mm or more in accordance with the method of JIS L 1096-A (2010) and including warps and wefts, the warp and the weft each comprising: a non-melting fiber A having a high-temperature shrinkage rate of 3% or less; and a thermoplastic fiber B having an LOI value of 25 or more in accordance with JIS K 7201-2 (2007) and having a melting point lower than the ignition temperature of the non-melting fiber A; wherein the warp and the weft each have a fracture elongation of 5% or more; and wherein, in the projection area of the weave repeat of the flame resistant woven fabric, the area ratio of the non-melting fiber A is 10% or more and the area ratio of the thermoplastic fiber B is 5% or more.