Flame-retardant material
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Solution Overview
Problem
Existing methods of rendering textiles fire-resistant, such as back coating, often compromise the fabric's handle and appearance due to excessive use of flame retardants, which can bleed through, and are costly and environmentally harmful.
Innovation Solution
A modular approach involving a flame-retardant composite with a backing layer printed in a pattern of shapes separated by channels, where the flame-retardant substance is positioned between a face and backing layer, reducing the amount needed and minimizing seep-through.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If back coating method is used to apply flame retardant on the back of fabric, then fire resistance standard is met, but fabric handle and appearance are compromised due to excessive flame retardant application and bleeding through
Solution Approach 1:
The fabric surface is divided into printed shapes and channels, with flame-retardant substance applied selectively to the shapes. This segmentation allows flame protection only where needed, reducing overall chemical usage and preventing excessive accumulation that degrades fabric handle.
Solution Approach 2:
Flame-retardant substance is applied locally to printed shapes rather than uniformly across the entire fabric back. This localized application provides fire resistance at critical areas while minimizing chemical penetration into the fabric structure, preserving the fabric's natural handle and drape.
2Reliability
If back coating method is used to apply flame retardant on the back of fabric, then fire resistance standard is met, but appearance is compromised due to bleeding through to the front
Solution Approach 1:
The fabric surface is divided into printed shapes and channels, with flame-retardant substance applied selectively to the shapes. This segmentation allows flame protection only where needed, reducing overall chemical usage and preventing excessive accumulation that degrades fabric handle.
Solution Approach 2:
Flame-retardant substance is applied locally to printed shapes rather than uniformly across the entire fabric back. This localized application provides fire resistance at critical areas while minimizing chemical penetration into the fabric structure, preserving the fabric's natural handle and drape.
3Reliability
If excessive flame retardant is applied to meet fire resistance standards, then fire resistance is ensured, but environmental harm and cost increase
Solution Approach 1:
The fabric surface is divided into printed shapes and channels, with flame-retardant substance applied selectively to the shapes. This segmentation allows flame protection only where needed, reducing overall chemical usage and preventing excessive accumulation that degrades fabric handle.
Solution Approach 2:
Instead of applying flame-retardant substance excessively across the entire fabric surface, the invention applies it partially only to printed shapes. This partial action is sufficient to meet fire resistance standards while significantly reducing the total amount of chemical used, lowering environmental impact and cost.
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
The invention provides a flame-retardant composite material comprising a backing layer with a flame-retardant substance printed thereon and a face layer, the face layer and backing layer joined together such that the flame-retardant substance is positioned in between the face layer and the backing layer. The flame-retardant substance is printed onto the backing layer in a pattern comprising shapes separated by channels and provides an obstacle to flame progression in at least one direction. Compared to known methods of providing fabrics with flame-retardant properties, an enhanced flame retardancy performance may be observed whilst reducing the amount of flame-retardant substance that is required for the same area of fabric.