Multilayer coating for flame retardant substrates
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Solution Overview
Problem
Current flame retardant materials, such as halogenated compounds and nanoparticles, face issues like environmental toxicity, lack of durability, increased processing viscosity, and inadequate flame suppression, necessitating a more effective and sustainable solution for fire-resistant coatings on substrates like foam and fabric.
Innovation Solution
A multilayer thin film coating method involving the alternating deposition of cationic and anionic layers on substrates, using polymers, colloidal particles, and nitrogen-rich molecules to create a fire-resistant barrier that is optically transparent and maintains the substrate's flexibility and structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated materials are used as flame retardants, then flame suppression is improved, but environmental toxicity and harm to humans increase
Solution Approach 1:
The patent converts the harmful effects of traditional flame retardants by using nitrogen-rich molecules that form protective char layers instead of releasing toxic gases. The char formation mechanism transforms potential harm into a beneficial protective barrier that suppresses flame while being environmentally benign.
Solution Approach 2:
The patent changes the chemical composition parameters by using nitrogen-rich molecules (with nitrogen content greater than 10% by weight) instead of halogenated compounds. This parameter change maintains flame suppression effectiveness while eliminating environmental toxicity associated with halogenated materials.
2Reliability
If brominated compounds are used as flame retardants, then flame retardancy is improved, but durability decreases
Solution Approach 1:
The patent employs composite material structures by combining nitrogen-rich molecules with polymers, colloidal particles, or nanoparticles in multilayer coatings. This composite approach enhances both flame retardancy and durability through synergistic effects of different materials working together.
Solution Approach 2:
The patent applies local quality by creating concentrated nitrogen-rich zones within the coating structure that specifically target flame suppression at critical locations, while the overall coating structure provides enhanced durability through its composite nature and adhesion to the substrate.
3Reliability
If nanoparticles are used to improve flame suppression, then flame retardancy is improved, but processing viscosity increases
Solution Approach 1:
The patent uses thin film multilayer coatings that provide effective flame retardancy without requiring high concentrations of nanoparticle materials. The layered structure achieves protective functionality with minimal material quantity, maintaining low processing viscosity while ensuring adequate flame suppression.
Solution Approach 2:
The patent optimizes the concentration and size parameters of nanoparticle inclusions within the nitrogen-rich molecule framework. By carefully controlling these parameters, the patent achieves effective flame retardancy while minimizing the impact on processing viscosity and material flow characteristics.
4Reliability
If nanoparticles are used as flame retardants, then flame suppression is improved, but melt-dripping resistance becomes inadequate
Solution Approach 1:
The patent creates composite material systems where nitrogen-rich molecules work synergistically with polymers and colloidal particles to provide both flame suppression and melt-dripping resistance. The composite structure forms a cohesive char layer that prevents melt dripping while suppressing flame propagation.
Solution Approach 2:
The patent employs a nested multilayer coating structure where different functional layers are deposited sequentially. The nitrogen-rich molecule layer provides flame suppression, while outer layers provide mechanical strength and melt-dripping resistance, creating a nested protective system where each layer contributes specific functionality.
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 method significantly enhances flame retardancy by reducing after-flame times, preserving substrate structure, and allowing for the retention of physical properties like flexibility and strength, while being environmentally benign and cost-effective.
Implementation Method 1
a method for coating a substrate to provide a flame resistant substrate includes exposing the substrate to a cationic solution to produce a cationic layer deposited on the substrate... exposing the cationic layer to an anionic solution to produce an anionic layer deposited on the cationic layer
Data Source
AI summary
A method includes coating a substrate to provide a flame resistant substrate. In an embodiment, the method includes exposing the substrate to a cationic solution to produce a cationic layer deposited on the substrate. The cationic solution comprises cationic materials. The cationic materials comprise a polymer, a colloidal particle, a nanoparticle, a nitrogen-rich molecule, or any combinations thereof. The method further includes exposing the cationic layer to an anionic solution to produce an anionic layer deposited on the cationic layer to produce a layer comprising the anionic layer and the cationic layer. The anionic solution comprises a layerable material.