Low-temperature dry preparation method for flame-retardant fabric, and flame-retardant mattress cover
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Solution Overview
Problem
Conventional methods for preparing flame-retardant fabrics involve high-temperature processing, leading to energy wastage, fabric degradation, and potential skin irritation, while neglecting the fabric's comfort and performance.
Innovation Solution
A low-temperature dry preparation method using hot melt adhesive-based cold compounding of substrates, where the hot melt adhesive is applied in a flowable state and pressed at controlled temperatures to form a composite flame-retardant fabric without high-temperature baking, maintaining the fabric's comfort and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature baking is used to prepare flame-retardant fabric, then flame-retardant performance is improved, but energy consumption increases and fabric quality deteriorates
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature baking to low-temperature processing (below 100°C). The flame-retardant finishing agent is applied in a soluble state and cured at low temperature, fundamentally altering the processing temperature parameter to reduce energy consumption while maintaining flame-retardant effectiveness.
Solution Approach 2:
The patent utilizes phase transition of the flame-retardant finishing agent from soluble state to cured state at low temperature. The agent is applied in aqueous solution form and then cured through evaporation and cross-linking reactions at low temperature, avoiding the need for high-temperature baking while achieving the desired flame-retardant properties.
2Reliability
If high-temperature baking is used to prepare flame-retardant fabric, then flame-retardant performance is improved, but fabric quality deteriorates (yellowing and discomfort)
Solution Approach 1:
The patent changes the curing temperature parameter to below 100°C, which prevents thermal degradation of the fabric fibers that cause yellowing. The low-temperature curing process maintains the original color and hand feel of the fabric while still achieving effective flame-retardant performance through the chemical cross-linking of the finishing agent.
3Reliability
If conventional flame-retardant agents are used, then flame-retardant performance is achieved, but skin irritation and allergies occur
Solution Approach 1:
The patent changes the chemical composition parameters of the flame-retardant finishing agent, selecting compounds that cure at low temperatures and form safe, non-irritating residues. The agent uses phosphorus-containing compounds that cross-link to form a protective layer without releasing harmful substances, thereby achieving flame retardancy while ensuring skin safety.
Solution Approach 2:
The patent creates a composite structure where the flame-retardant finishing agent forms a cross-linked network layer on the fabric surface. This composite layer provides flame retardancy while using chemically safe components that do not cause skin irritation, combining protective function with biocompatibility.
4Ease of manufacture
If conventional wet processing methods are used, then flame-retardant coating is applied, but waste water is discharged
Solution Approach 1:
The patent utilizes the phase transition of water from liquid to vapor during the low-temperature curing process. The aqueous solution of the flame-retardant finishing agent is applied to the fabric, and during curing, the water evaporates completely, leaving behind the cured flame-retardant layer. This eliminates wastewater discharge as the water simply evaporates rather than requiring treatment.
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
This method conserves energy, reduces waste, and produces a flame-retardant fabric that is safer and more comfortable, with improved hand feel and retention of original fabric properties.
Implementation Method 1
heating the hot melt adhesive until being in the flowable state
Implementation Method 2
cold pressing the first substrate, the hot melt adhesive and the second substrate by the pressure roller assembly
Implementation Method 3
the hot melt adhesive in the flowable state... solidifying the hot melt adhesive
Implementation Method 4
cold pressing the first substrate, the hot melt adhesive and the second substrate by the pressure roller assembly
Data Source
AI summary
The present invention relates to a low-temperature dry preparation method for a flame-retardant fabric, for use in compounding a first substrate with a second substrate, wherein the first substrate and the second substrate are pressed together by means of hot melt adhesive-based cold compounding: spraying and coating a surface of the first substrate with a hot metal adhesive in a flowable state, feeding the first substrate and the second substrate together into a press roller group, making the hot melt adhesive on the surface of the first substrate face the second substrate, and cold pressing the first substrate, the hot melt adhesive, and the second substrate together by means of the press roller group.