Flame retardants for textile applications
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Solution Overview
Problem
Existing flame retardant technologies for textiles do not provide sufficient and consistent flame retardancy performance in both NFPA-701 and FMVSS-302 tests.
Innovation Solution
Development of aqueous flame retardant dispersions containing brominated aromatic polymeric flame retardants, which are applied to textile substrates using a coating composition that includes dispersants, wetting agents, thickeners, and flame retardant synergists.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flame retardant treatments are applied to textiles, then some level of flame resistance is achieved, but the performance is insufficient and inconsistent in both NFPA-701 and FMVSS-302 tests
Solution Approach 1:
The patent uses brominated aromatic polymeric flame retardants that function as composite materials, combining brominated aromatic structures with polymeric chains to achieve both high flame retardancy and consistent performance across different test standards (NFPA-701 and FMVSS-302). The polymeric nature allows for controlled application and uniform distribution on textile substrates.
Solution Approach 2:
The invention achieves improved flame retardant performance by changing key parameters: using aromatically-bound bromine (rather than aliphatic), achieving high bromine content (40-70 wt%), and controlling particle size (0.1-20 μm). These parameter changes result in consistent pass rates in both NFPA-701 and FMVSS-302 tests.
2Reliability
If flame retardant coatings are applied to textiles, then fire resistance is improved, but the coating composition and application process become more complex
Solution Approach 1:
The coating composition is segmented into distinct functional components: brominated aromatic polymeric flame retardant (active ingredient), dispersant (for uniform distribution), wetting agent (for substrate penetration), thickener (for viscosity control), and flame retardant synergist (for enhanced performance). This segmentation allows each component to be optimized independently while maintaining overall system effectiveness.
Solution Approach 2:
The patent introduces intermediary substances to facilitate the application process: dispersants mediate between the hydrophobic flame retardant and aqueous medium, wetting agents mediate between the coating and textile substrate, and thickeners mediate the rheology for proper application. These intermediaries simplify the overall process despite the multi-component nature of the coating.
3Reliability
If high concentration of brominated flame retardant is used in the dispersion, then flame retardant performance is enhanced, but the dispersion stability and handling become more difficult
Solution Approach 1:
The patent uses dispersants as intermediaries to stabilize high concentrations of brominated aromatic polymeric flame retardant in aqueous dispersions. The dispersant molecules adsorb at the interface between the hydrophobic polymer particles and water, preventing aggregation and maintaining stable dispersions even at 40-70 wt% flame retardant content.
Solution Approach 2:
The invention changes the particle size parameter to 0.1-20 μm, which optimizes both the surface area for flame retardant activity and the stability of the dispersion. The controlled particle size, combined with high bromine content (40-70 wt%), achieves superior flame retardancy while maintaining manageable dispersion properties through proper formulation.
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 proposed solution achieves excellent flame retardant performance in both NFPA-701 and FMVSS-302 tests, ensuring effective fire resistance for textile substrates.
Implementation Method 1
aqueous flame retardant dispersions comprising water, a brominated flame retardant, at least one dispersant
Implementation Method 2
aqueous flame retardant dispersions comprising water, a brominated flame retardant, at least one dispersant, at least one wetting agent
Data Source
AI summary
This invention provides aqueous flame retardant dispersions comprising water, a brominated flame retardant containing aromatically-bound bromine, at least one dispersant, at least one wetting agent, and at least one thickener. The brominated flame retardant has an average particle size of about 20 μm or less. The flame retardant dispersion contains about 50 wt% or more of brominated polymeric flame retardant, based on the total weight of the dispersion. Also provided are coating compositions, processes for forming flame retardant dispersions, processes for forming coating compositions, and processes for applying the coating compositions to textile substrates.