Flame retardant nanocoated substrate
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Solution Overview
Problem
Conventional flame retardant coatings for foam and fabric substrates face issues such as environmental toxicity, durability concerns, increased processing viscosity, inadequate flame suppression, and stiffness enhancement, which worsen the hand (feel) of the fabric due to bridging between fibers during layer-by-layer assembly.
Innovation Solution
A multilayer thin film coating method involving alternating deposition of cationic and anionic layers on substrates, using polymers, colloidal particles, nitrogen-rich molecules, geopolymers, and carbon-based fillers, with agitation to break fiber bridges and improve consistency and combustion behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated flame retardant materials are used, then flame resistance is improved, but environmental toxicity increases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing halogenated compounds with non-halogenated alternatives such as phosphinated compounds and nitrogen-rich molecules. This parameter change maintains flame resistance while eliminating environmental toxicity associated with halogen release during combustion.
Solution Approach 2:
The patent employs composite material systems combining multiple flame retardant mechanisms - incorporating phosphinated compounds, nitrogen-rich molecules, and metal hydroxides in specific ratios. This composite approach achieves effective flame suppression without the toxic effects of halogenated materials.
2Reliability
If brominated compounds are used for flame retardancy, then flame suppression is improved, but durability decreases
Solution Approach 1:
The patent modifies the chemical structure parameters by using phosphinated compounds with stable P-O and P-N bonds that resist degradation. The nitrogen-rich molecules provide thermal stability through strong bonding, ensuring long-term durability while maintaining flame suppression effectiveness.
3Reliability
If layer by layer assembly is used to apply coating, then flame retardant properties are improved, but fabric stiffness increases
Solution Approach 1:
The patent applies ultra-thin film coatings at the nanometer scale that conform flexibly to fabric surfaces. These thin films provide flame retardant protection without creating rigid bridges between fibers, thereby maintaining fabric flexibility and hand feel.
Solution Approach 2:
The coating is applied locally at the fiber surface level rather than as a thick uniform layer. This localized application provides flame retardancy exactly where needed (at the combustion interface) while minimizing impact on overall fabric mechanical properties and flexibility.
4Quantity of substance
If nanoparticles are used in coating, then processing viscosity increases, but flame suppression may be inadequate
Solution Approach 1:
The patent creates composite material systems where phosphinated compounds and nitrogen-rich molecules work synergistically. The phosphinated compounds provide intumescent flame retardancy while nitrogen-rich molecules contribute to char formation and thermal stability, achieving adequate flame suppression without excessive viscosity.
Solution Approach 2:
The patent optimizes concentration parameters of flame retardant additives to achieve effective flame suppression at levels that do not excessively increase processing viscosity. Specific ratios of phosphinated compounds and nitrogen-rich molecules are used to balance performance and processability.
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 provides a self-extinguishing, flame-retardant coating with improved hand and combustion behavior, maintaining the softness and flexibility of substrates while enhancing flame resistance and antimicrobial properties.
Implementation Method 1
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, a geopolymer, a carbon-based filler, or any combinations thereof. The method also includes agitating the substrate. 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.