Modacrylic-Lyocell-Nylon Blended Fabric Smoldering Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flame-retardant fabrics face challenges in controlling smoldering time within 2 seconds under the GB/T 5455 vertical ignition test, often requiring expensive phosphorus-based flame-retardant viscose or post-treatment, which increases costs and affects physical properties.
Innovation Solution
A modacrylic-lyocell-nylon blended fabric with a mass ratio of 55-65% modacrylic, 20-35% lyocell, and 5-15% nylon, woven with double yarns every 5 mm in the warp and weft directions, achieving zero after-flame time and smoldering time within 2 seconds without using expensive phosphorus-based viscose or post-treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorus-based flame-retardant viscose or post flame-retardant processing is added to control smoldering time, then smoldering time is reduced to within 2 seconds, but fabric cost increases significantly
Solution Approach 1:
The patent uses a composite fiber blend consisting of modacrylic (50-70%), lyocell (15-30%), and nylon (5-15%) to achieve flame retardancy without expensive phosphorus-based additives. The synergistic effect of these three fiber types provides both flame resistance and smoldering control, eliminating the need for costly flame-retardant viscose or post-treatment processes while meeting the 2-second smoldering time requirement
Solution Approach 2:
The patent optimizes the ratio parameters of the three fiber components to achieve the desired flame retardant performance. By adjusting the modacrylic content to 50-70%, lyocell to 15-30%, and nylon to 5-15%, the fabric achieves both flame resistance and rapid smoldering termination without additional expensive materials or processing steps
2Reliability
If modacrylic content is increased to improve flame retardancy, then flame resistance improves, but fabric cost increases due to higher modacrylic content
Solution Approach 1:
Instead of using 100% modacrylic or high modacrylic content with expensive flame-retardant additives, the patent creates a cost-effective composite using moderate modacrylic content (50-70%) combined with lyocell and nylon. This composite approach achieves the required flame retardancy at lower cost by leveraging the complementary properties of all three fiber types rather than relying solely on expensive modacrylic content
Solution Approach 2:
The patent assigns different functional roles to different fiber types within the blend: modacrylic provides the primary flame retardant barrier, lyocell contributes to fabric structure and comfort properties, and nylon enhances strength and durability. This functional distribution allows each component to contribute optimally without requiring excessive amounts of any single expensive material
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 solution effectively controls after-flame and smoldering times within specified limits, reducing material costs and maintaining fabric integrity, while ensuring flame retardancy and industrial applicability.
Implementation Method 1
The modacrylic belongs to gas phase flame retardancy to hinder the contact between oxygen and the non-flame retardant fibers and retard the burning of the non-flame retardant fibers
Implementation Method 2
The blended fabric of modacrylic and non-flame retardant cotton fibers in a certain ratio has permanent flame retardancy
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention discloses a modacrylic-lyocell-nylon blended flame-retardant fabric. Yarns of the flame-retardant fabric contain modacrylic, lyocell and nylon, the mass ratio of each to the yarns being: modacrylic: 40-70%; lyocell: 20-52%; and nylon: 5-15%. The after-flame time of the fabric effectively blended from modacrylic, lyocell and nylon can be controlled within 2 seconds under the test condition of GB/T 5455, and the smoldering time can be controlled within 2 or 5 seconds.