Flame Retardant Flash Spun Polyolefin Sheets
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Solution Overview
Problem
Existing polyolefin plexifilamentary film-fibril strands lack effective flame retardancy, which is typically provided by external coatings rather than being inherent in the fiber, resulting in poor mechanical properties.
Innovation Solution
Incorporating flame retardants such as phosphate esters, phosphonate esters, nitrogen-containing polyphosphates, polyphosphazines, hindered amines, and their mixtures into the polyolefin plexifilamentary film-fibril strands through a flash-spinning process to create a thermally stable, durable, and cost-effective flame retardant sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If flame retardant coatings are applied to polyolefin plexifilamentary film-fibril strands, then flame retardancy is achieved, but mechanical properties deteriorate and durability is reduced
Solution Approach 1:
The patent combines the flame retardant function with the fiber structure itself by incorporating flame retardant particles into the polyolefin matrix during the flash spinning process. This merging eliminates the need for separate coatings, as the flame retardancy becomes an inherent property of the fiber strand while maintaining mechanical integrity through the integrated composite structure.
Solution Approach 2:
The invention creates a composite material system where flame retardant particles are dispersed within the polyolefin matrix. This composite approach allows the flame retardant to be distributed throughout the fiber structure, providing flame protection without compromising mechanical properties, as the composite structure maintains the integrity of both the polyolefin and flame retardant components.
2Reliability
If flame retardant is incorporated into the fiber during flash spinning, then durability and cost are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by incorporating the flame retardant into the polyolefin matrix before the flash spinning process. The flame retardant particles are mixed with the polyolefin and extruded through the spinneret as part of the fiber formation process itself. This preliminary incorporation ensures the flame retardant is uniformly distributed within the fiber structure from the outset, eliminating the need for subsequent coating or treatment steps and actually simplifying the overall manufacturing process.
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 resulting flame retardant polyolefin plexifilamentary film-fibril strands exhibit improved mechanical properties and enhanced flame retardancy, comparable to commercially available products like Tyvek®, with effective flame retardancy demonstrated by Limiting Oxygen Index (LOI) and Vertical Flame Propagation Testing.
Implementation Method 1
flash spinning from a spin agent of carbon dioxide and water
Implementation Method 2
The resulting flame retardant polyolefin plexifilamentary film-fibril strands exhibit improved mechanical properties
Data Source
AI summary
The present invention relates to a flame retardant plexifilamentary film-fibril strand comprising at least one polyolefin and at least one flame retardant selected from the group consisting of: phosphate esters, phosphonate esters, phosphinate esters, polyphosphazines, nitrogen-containing polyphosphates, hindered amines and mixtures thereof. The present invention also relates to flame retardant sheet made from the flame retardant plexifilamentary film-fibril strands. The sheet can be made into a flame retardant building substrate, garment, banner, light reflector and cover.