Flame Retardant Fabric Finish for Nylon Char Formation

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Solution Overview

Problem

Phosphorus-based flame retardants are ineffective on nylon fabrics, causing them to burn faster, and sulfur-based systems result in stiff fabrics with formaldehyde residues and poor hand feel, while high nylon blends melt and stick to skin during fires, posing burn hazards.

Innovation Solution

Combining melamine-based resins with tetrakis(hydroxymethyl)phosphonium-based compounds to enhance flame retardancy, char formation, and durability, minimizing molten nylon polymer formation during combustion, and passing flammability tests after multiple launderings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If phosphorus-based flame retardants are used on nylon fabrics, then flame retardant treatment is applied, but the fabric burns at a greater rate than untreated fabric

Engineering Contradiction:

Improveflame retardant effectivenessVSAvoidburn rate

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent combines phosphorus-based flame retardants with melamine resin to create a composite treatment system. The melamine resin serves as a carrier and synergistic agent that prevents the phosphorus compound from causing nylon to unzip during combustion, thereby resolving the contradiction between applying flame retardant treatment and preventing accelerated burning

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Melamine resin acts as an intermediary substance between the phosphorus flame retardant and the nylon fabric. It modifies the interaction mechanism by forming a protective matrix that prevents direct contact between the phosphorus compound and nylon polymer chains during combustion, eliminating the harmful unzipping effect

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sulfur-containing materials are used to treat nylon fabrics, then flame retardancy is improved, but the fabric hand becomes very stiff and formaldehyde residues increase

Engineering Contradiction:

Improveflame retardancyVSAvoidfabric hand

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent changes the chemical composition parameters by replacing sulfur-containing compounds with phosphorus-based compounds combined with melamine resin. This parameter change maintains flame retardancy while eliminating the stiffening effect and formaldehyde residue problems associated with sulfur-based treatments

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The melamine resin provides localized quality improvement by forming a flexible protective layer on the fabric surface that maintains the soft hand feel while the phosphorus compound provides the flame retardant function, separating the mechanical properties from the chemical protection function

Inventive Principle:

Principle #3Local quality

3Strength

If high nylon content blends are used, then fabric performance is improved, but molten nylon polymer sticks to skin during fires causing serious burns

Engineering Contradiction:

Improvefabric performanceVSAvoidskin burn hazard

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful melting behavior of nylon into a beneficial protective mechanism. The melamine-phosphorus treatment system promotes charring of the nylon polymer during combustion, transforming the molten puddle hazard into a protective char layer that insulates the skin and prevents direct contact with flame and molten material

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If phosphorus and halogen systems are used for nylon flame retardancy, then flame retardant performance is achieved, but environmental concerns increase due to halogen use

Engineering Contradiction:

Improveflame retardant performanceVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes the halogen component from the flame retardant system, retaining only the phosphorus-based compound combined with melamine resin. This extraction eliminates the environmental harm associated with halogen use while maintaining effective flame retardant performance through the synergistic phosphorus-nitrogen system

Inventive Principle:

Principle #2Taking out (Extraction)

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 melamine-THP combination improves flame retardant performance, maintains fabric softness and strength, and meets flammability standards, preventing molten nylon from sticking to skin during fires, with fabrics passing rigorous testing after extensive use.

Implementation Method 1

promote char formation in the combustion zone of fabrics and fabric blends

Methodology Applied

Scientific EffectChar formation:

Implementation Method 2

This improved FR performance may be due to a synergistic effect between phosphorus of the THP and nitrogen of the melamine where the nitrogen may catalyze or promote phosphorylation or char formation in the combustion process

Methodology Applied

Scientific EffectSynergistic effect between phosphorus and nitrogen:

Implementation Method 3

the nitrogen may catalyze or promote phosphorylation or char formation in the combustion process

Methodology Applied

Scientific EffectPhosphorylation:

Implementation Method 4

produce a nylon/cellulosic FR fabric which will produce a minimum of molten nylon polymer in the combustion process

Methodology Applied

Scientific EffectReduction of molten polymer formation:

Data Source

PatentUS9945068B2Flame retardant fabrics and methods for manufacturing the same

Publication Date: 2018.04.17 MATCHMASTER DYEING & FINISHING

AI summary

Embodiments of the present invention use melamine-based resins as a pretreatment on fabrics and fabric blends in combination with phosphorus-based flame retardants to improve flame retardant performance, durability, and further promote char formation in a combustion zone of the fabric.