Flameproof Union Upholstery Fabric With Chenille for Burn-Through Resistance
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Solution Overview
Problem
Current flame retardant textiles for chair upholstery, such as those using chenille yarn or flame retardant polyester fibers, face issues with flammability, designability, comfort, and cost, as well as insufficient flame retardant performance over time due to factors like moisture absorption and washing.
Innovation Solution
A union fabric combining chenille yarn with halogen and metal compound flame retardants and cellulose fibers, where the chenille yarn contains 10-70% halogen and 1-35% metal compound flame retardant, and the fabric includes 6-60% polyester, 35-85% halogen-containing fibers, and 5-55% cellulose fibers, enhancing both designability and flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chenille yarn is used to produce napped cloth for designability, then the cloth has good designability and texture, but the cloth becomes highly flammable because the napped part contacts large amount of air
Solution Approach 1:
The patent uses composite fibers combining acrylic fiber with flame retardant additives (such as aluminum hydroxide, magnesium hydroxide, or boron compounds) to create chenille yarn that maintains both designability and flame retardant properties. The composite structure allows the napped surface to provide aesthetic value while the flame retardant components prevent excessive combustion.
2Object-affected harmful factors
If resin containing flame retardant is applied to the rear surface of flammable cloth, then flame retardant properties are provided, but the cloth becomes whitened, sticky, discolored, stiffened, or reduced in volume, and the flame retardant effect is lost over time due to exposure to daylight, moisture absorption, or washing
Solution Approach 1:
The patent changes the fundamental approach from surface coating to bulk integration. Instead of applying flame retardant resin to the surface, the flame retardant additives are incorporated into the fiber structure itself during manufacturing. This ensures the flame retardant properties are intrinsic to the material and cannot be lost through washing, exposure to moisture, or UV radiation.
Solution Approach 2:
The patent creates a permanent copy of the flame retardant function within the fiber structure itself, rather than using a temporary surface coating. The flame retardant additives are integrated into the acrylic fiber during spinning, creating a self-contained flame retardant system that persists throughout the product lifecycle.
3Object-affected harmful factors
If flame retardant polyester fiber is used, then flame retardant properties are provided, but the cloth makes big holes at the time of combustion due to melting of polyester fiber, allowing urethane foam to be ignited
Solution Approach 1:
The patent applies flame retardant additives locally within the acrylic fiber structure at concentrations optimized for flame suppression. The additives are distributed throughout the fiber cross-section, creating zones of flame inhibition that prevent the formation of large holes during combustion, thereby maintaining structural integrity.
4Object-affected harmful factors
If flame retardant acrylic fiber is used, then flame retardant properties are provided, but polyester fiber warp opens holes due to melting and shrinkage or thermal decomposition of flame retardant acrylic fiber at the time of combustion
Solution Approach 1:
The patent uses composite acrylic fibers containing flame retardant additives that work synergistically with the acrylic matrix. The composite structure allows the acrylic fiber to maintain its dimensional stability and resist thermal decomposition, preventing hole formation in both the warp and weft directions during combustion.
5Object-affected harmful factors
If crosslinked highly flame-retardant acrylic fiber is used, then flame retardant properties are improved in slackened state, but tension applied to the fiber during combustion causes shrinkage and hole formation, allowing urethane foam to be ignited
Solution Approach 1:
The patent optimizes the crosslinking degree and type of crosslinking agents to achieve a balance between flame retardancy and dimensional stability. The crosslinked structure provides flame retardant properties while maintaining sufficient flexibility and resistance to shrinkage under tension during combustion, preventing hole formation.
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 fabric exhibits excellent designability, comfort, abrasion resistance, and high flame retardant properties, preventing the internal padding from igniting even when exposed to fire, with self-extinguishing properties and carbonized film formation.
Implementation Method 1
the fancy yarn is a flame retardant fancy yarn... the halogen-containing fiber has a decomposition starting temperature of 200 to 260°C... the fabric exhibits self-extinguishing properties
Implementation Method 2
containing 10 to 70% by weight of halogen and 1 to 35% by weight of metal compound flame retardant... forms a carbonized film... effectively preventing the ignition of internal padding materials
Implementation Method 3
the weft contains a flame retardant chenille yarn and another weaving yarn... the cellulose fiber... maintains flame retardant performance even when exposed to fire
Data Source
AI summary
A union fabric comprising 6 to 60% by weight of a polyester fiber (A), 35 to 85% by weight of a halogen-containing fiber (B), and 5 to 55% by weight of a cellulose fiber (C) in which fabric the warp comprises weaving yarn containing the polyester fiber and the weft comprises flameproof chenille yarn and other weaving yarn, with the chenille yarn containing 10 to 70% by weight of halogen and 1 to 35% by weight of a flame retardant consisting of a metal compound, and in which fabric the content of the warp-constituting weaving yarn containing the polyester fiber is 20 to 40% by weight and those of the weft-constituting flameproof chenille yarn and the weft-constituting other weaving yarn are 35 to 70% by weight and 10 to 45% by weight respectively. This union fabric is excellent in design, texture, comfortableness in use.