Multilayer Substrate Flame Retardant Textile Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current flame retardant treatments for fabrics often result in undesirable characteristics such as poor hand, drape, and pliability, with temporary solutions lacking durability and permanent solutions compromising on texture and feel, failing to meet stringent flammability standards like those in the EU and IMO.
Innovation Solution
A multilayer substrate material is applied to the back surface of upholstery or mattress textiles, comprising a protector layer, adhesive layer with discrete non-continuous regions, a film layer, and a backcoat layer with a non-acrylic binder and flame retardant material, allowing for improved flame retardancy while maintaining natural hand and pliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame retardant treatments are applied to fabrics, then flame retardancy is improved, but hand, drape, and pliability deteriorate
Solution Approach 1:
The adhesive layer is divided into discrete non-continuous regions rather than being continuous, allowing flame retardant protection in adhesive areas while maintaining fabric flexibility in non-adhesive areas. This segmentation resolves the contradiction by localizing the stiffening effect to only where structural support is needed.
Solution Approach 2:
Different regions of the fabric treatment have different properties: adhesive regions provide flame retardancy and structural support, while non-adhesive regions maintain natural fabric hand and pliability. This local differentiation allows the fabric to have both flame resistance and comfort characteristics simultaneously.
2Duration of action of stationary object
If permanent flame retardant treatments are applied, then durability is improved, but texture and feel are compromised
Solution Approach 1:
The treatment is segmented into discrete adhesive regions that provide permanent flame retardant protection through durable bonding, while non-adhesive regions remain untreated to preserve natural fabric texture and feel. This segmentation allows permanent protection without universal texture compromise.
Solution Approach 2:
Permanent flame retardant properties are applied locally only to discrete adhesive regions where durability is critical, while the remainder of the fabric surface maintains its original texture and tactile properties. This local application resolves the contradiction between permanent protection and fabric quality.
3Strength
If continuous adhesive layers are used, then bonding strength is improved, but flexibility and drape are reduced
Solution Approach 1:
The adhesive layer is segmented into discrete non-continuous regions, providing sufficient bonding strength at adhesive locations while allowing fabric flexing and drape in non-adhesive regions. This segmentation resolves the contradiction by distributing bonding function only where structurally necessary.
Solution Approach 2:
The adhesive layer configuration allows the fabric to dynamically flex and drape in non-adhesive regions while maintaining structural integrity at adhesive regions. This dynamic behavior resolves the contradiction between static bonding strength and dynamic flexibility.
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 multilayer substrate imparts effective flame retardancy to fabrics while ensuring a natural surface contact and improved pliability, meeting stringent flammability standards and enhancing production efficiency and cost-effectiveness.
Implementation Method 1
The adhesive layer is formed of a number of discrete and non-continuous regions... The first surface of the adhesive layer is applied to the back surface of the protector layer... The first surface of the film layer is applied to the second surface of the adhesive layer
Data Source
AI summary
A multilayer substrate material configured to be applied to a back surface of an upholstery or mattress textile fabric and a front surface configured to contact a user of the upholstery or mattress textile fabric. The multilayer substrate material includes protector, adhesive, film and backcoat layers. The adhesive layer is applied to the protector layer and formed of a number of discrete and non-continuous regions. The film layer is applied to the adhesive layer. The number of discrete and non-continuous regions include an interface between the protector layer and the film layer such that the protector layer touches the film layer at the interface. The backcoat layer is applied to the film layer and includes a non-acrylic binder and a flame retardant material. The number of discrete and non-continuous regions form a number of non-adhesive regions therebetween configured to not resist flexing of the protector, film and backcoat layers.