Flameproof Rayon Fiber Composition for Washable Biodegradable Textiles
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Solution Overview
Problem
Conventional cellulose fibers face issues with environmental impact due to the use of halide-based and phosphorous flame retardants, poor launderability, and potential neurotoxicity from aluminum compounds, as well as non-biodegradability and disposal challenges with aramid fibers.
Innovation Solution
A rayon fiber is developed using a compound containing silicon and magnesium, formed through a process involving a silicic compound-added viscose solution spun into a sulfuric acid bath and treated with a magnesium-containing solution, resulting in an amorphous magnesium silicate structure that is biodegradable and environmentally safer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halide-based or phosphorous flame retardants are used in cellulose fibers, then flame resistance is improved, but environmental harm and toxicity increase
Solution Approach 1:
The invention changes the chemical composition parameters by using silicon and magnesium compounds instead of conventional halide or phosphorous flame retardants. This substitution maintains flame resistance while eliminating the toxic and environmentally harmful effects of traditional flame retardant chemicals.
Solution Approach 2:
The invention creates a composite structure within the cellulose fiber by forming a hydrated compound layer containing aluminum silicate and other inorganic compounds. This composite approach provides flame resistance through the physical and chemical properties of the composite material rather than relying on toxic chemical additives.
2Reliability
If silicon dioxide is used in cellulose fibers, then flame resistance is improved, but launderability deteriorates due to alkali elution
Solution Approach 1:
The invention forms a composite inorganic layer containing aluminum silicate and other compounds that protects the silicon dioxide from alkali elution. This composite structure maintains flame resistance while preventing the loss of silicon dioxide during washing, thereby preserving launderability.
Solution Approach 2:
The aluminum silicate and other inorganic compounds act as an intermediary protective layer between the silicon dioxide and the alkaline detergent environment. This intermediary prevents direct contact and reaction between silicon dioxide and alkalis, eliminating the elution problem while maintaining flame resistance.
3Reliability
If water-soluble aluminum compounds are used to treat cellulose fibers, then flame resistance is improved, but environmental harm increases due to aluminum ion toxicity
Solution Approach 1:
The invention extracts and removes water-soluble aluminum compounds from the fiber treatment process. Instead, it uses water-insoluble or low-solubility aluminum silicate and other inorganic compounds that provide flame resistance without releasing toxic aluminum ions into the environment during washing or disposal.
Solution Approach 2:
The invention changes the solubility parameter of the aluminum-containing compounds by using aluminum silicate and other low-solubility materials instead of water-soluble aluminum compounds. This parameter change eliminates aluminum ion release while maintaining flame resistance.
4Reliability
If aramid fibers are used for flameproof applications, then flame resistance is improved, but biodegradability deteriorates
Solution Approach 1:
The invention creates a composite structure where flame-resistant inorganic compounds are integrated within the biodegradable cellulose fiber matrix. This allows the fiber to maintain flame resistance during use while retaining the ability to biodegrade after disposal, as the cellulose base material remains biodegradable despite the presence of inorganic flame-retardant components.
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 rayon fiber achieves excellent flame resistance, launderability, and biodegradability, reducing environmental impact while maintaining strength and hand, and is suitable for various applications including fire protection and interior materials.
Implementation Method 1
impregnation of cellulose fibers with an organic solvent that swells the cellulose fibers and an inorganic compound that is dissolved in that organic solvent, followed by drying
Implementation Method 2
forming a hydrated compound layer having aluminum as an essential component on the surface of the cellulose fibers
Implementation Method 3
a rayon fiber having flameproofness... contains components of silicon and magnesium, characterized in that a compound containing the components of silicon and magnesium is amorphous
Data Source
AI summary
A rayon fiber that does not use a halide-based flame retardant, a phosphorous flame retardant or an organic solvent, has excellent flameproofness and launderability and is biodegradable when buried in the soil at the time of disposal, and a method for manufacturing the same are provided. The flameproof rayon fiber according to the present invention contains components of silicon and magnesium, and a compound containing the components of silicon and magnesium is amorphous. This rayon fiber can be manufactured by preparing a viscose solution, adding a solution containing a silicate compound containing an alkali metal to the viscose solution so as to make a silicic compound-added viscose spinning solution containing the alkali metal, performing spinning by extruding the silicate compound-added viscose spinning solution containing the alkali metal through a spinneret into a spinbath containing a sulfuric acid, thus producing a fiber to be treated containing the silicate compound, and treating the fiber to be treated using a magnesium-containing solution in a scouring process or an aftertreatment process.