Flameproof Spun Yarn Using Modacrylic and Polyarylate Fibers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flameproof work clothes are expensive and lack designability due to the high cost and limited color options associated with high para-aramid fiber content, and existing blends do not significantly enhance flameproofness.
Innovation Solution
A flameproof spun yarn and fabric combining modacrylic fibers with an antimony compound and polyarylate-based fibers, where the polyarylate-based fiber content is 1-30% by weight, offering improved flameproofness and designability at a lower cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the blend rate of para-aramid fiber is increased to improve flameproofness, then flameproofness is improved, but product price increases
Solution Approach 1:
The patent replaces expensive para-aramid fiber with a combination of modacrylic fiber and polyarylate-based fiber. The modacrylic fiber provides flame resistance through its chemical composition (containing halogen and antimony compound), while the polyarylate-based fiber provides strength and heat resistance. This substitution with more affordable materials achieves comparable flameproofness without the high cost of para-aramid fiber.
Solution Approach 2:
The patent creates a composite fiber blend consisting of modacrylic fiber (5-50 wt%), polyarylate-based fiber (50-95 wt%), and optionally para-aramid fiber (0-5 wt%). This composite structure combines the flame-resistant properties of modacrylic fiber with the mechanical strength and heat resistance of polyarylate-based fiber, achieving effective flameproofness at lower cost than using high proportions of para-aramid fiber alone.
2Reliability
If the blend rate of para-aramid fiber is increased to improve flameproofness, then flameproofness is improved, but designability deteriorates
Solution Approach 1:
The patent replaces inherently yellowish para-aramid fiber with modacrylic fiber and polyarylate-based fiber that can be dyed in various colors. The modacrylic fiber accepts dye well and the polyarylate-based fiber can be processed into different hues, enabling diverse color options and patterns for flameproof work clothes without being limited to the natural yellow color of para-aramid fiber.
Solution Approach 2:
The patent changes the chemical composition parameters of the fiber blend, using modacrylic fiber containing halogen (30-80 wt% of total fiber weight) and antimony compound (1-20 wt% of total fiber weight) to achieve flame resistance without relying on the inherent yellow color of para-aramid. This compositional change enables versatile dyeing options while maintaining flameproofness.
3Ease of manufacture
If modacrylic fiber and polyarylate-based fiber are combined to reduce cost, then product price decreases, but flameproofness may be insufficient
Solution Approach 1:
The patent creates a synergistic composite where modacrylic fiber (providing flame resistance through halogen and antimony compound) is combined with polyarylate-based fiber (providing mechanical strength and heat resistance). The specific ratio range (modacrylic 5-50 wt%, polyarylate 50-95 wt%) ensures both flameproofness and structural integrity, achieving effective flame resistance at lower cost than para-aramid alone.
Solution Approach 2:
The patent optimizes the compositional parameters by specifying that modacrylic fiber contains 17-86 wt% halogen and 6-50 wt% antimony compound, with the fiber blend containing 1-20 wt% antimony compound overall. These parameter specifications ensure sufficient flame resistance through the chemical flame-retardant mechanism while using cost-effective materials.
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 combination provides flameproof work clothes with reduced char length and enhanced designability, allowing for various color expressions, thus making flameproof clothing more accessible and versatile.
Implementation Method 1
a modacrylic fiber containing an antimony compound and a polyarylate-based fiber... the combination provides flameproof work clothes with reduced char length
Data Source
AI summary
A flameproof spun yarn of the present invention includes a modacrylic fiber containing an antimony compound and a polyarylate-based fiber, and the flameproof spun yarn contains 1 to 30 wit% of the polyarylate-based fiber relative to the total weight of the flameproof spun yarn. A flameproof fabric of the present invention includes a modacrylic fiber containing an antimony compound and a polyarylate-based fiber, and the flameproof fabric contains 1 to 30 wt% of the polyarylate-based fiber relative to the total weight of the flameproof fabric. And clothes and flameproof work clothes of the present invention include the flameproof fabric. The present invention thereby provides at a low cost a flameproof spun yarn and a flameproof fabric having excellent designability and flameproofness, and clothes and a flameproof work clothes using the same.