Patterned Flame-Retardant Substrates That Preserve Breathability

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Solution Overview

Problem

Existing flexible substrates used in construction, such as roof liners, face challenges in achieving both effective flame retardancy and breathability while meeting safety standards, as halogenated flame retardants produce toxic fumes and organic solvents can reduce water repellence and breathability.

Innovation Solution

A flexible substrate with a flame retardant composition applied in a regular or irregular pattern, covering 15% to 95% of the surface, using phosphorus-based or other non-halogenated compositions to maintain breathability and prevent toxic fume production, with a production process involving coating or printing methods to ensure even distribution and curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated flame retardant composition is applied to coat the surface of the fabric, then flame retardancy is improved, but toxic and corrosive fumes are produced when on fire

Engineering Contradiction:

Improveflame retardancyVSAvoidtoxic fumes

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by using phosphorus-based flame retardants instead of halogenated compounds. This substitution maintains flame retardant effectiveness while eliminating the production of toxic and corrosive fumes during combustion, directly resolving the contradiction between reliability and harmful emissions.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If organic solvent is used to facilitate spreading of flame retardant composition, then coating uniformity is improved, but breathability of the fabric is reduced

Engineering Contradiction:

Improvecoating uniformityVSAvoidbreathability

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent employs a porous or patterned coating application where the flame retardant composition is applied in a way that maintains the porous structure of the fabric. This allows the coating to be uniformly distributed while preserving the void spaces necessary for breathability, thus resolving the contradiction between coating precision and fabric permeability.

Inventive Principle:

Principle #31Porous materials

3Ease of manufacture

If water-soluble flame retardant additives are present in the coating, then ease of application is improved, but water repellence is negatively impacted

Engineering Contradiction:

Improveease of applicationVSAvoidwater repellence

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent applies the flame retardant coating in a patterned or localized manner rather than as a complete surface coating. This localized application provides sufficient flame protection in critical areas while leaving other areas to maintain their natural water-repellent properties, thus resolving the contradiction between ease of application and water repellence.

Inventive Principle:

Principle #3Local quality

4Object-generated harmful factors

If non-halogenated flame retardant compositions are used, then toxic fume production is reduced, but cost increases

Engineering Contradiction:

Improvetoxic fume productionVSAvoidcost

Core Design Contradiction:

Object-generated harmful factorsVSQuantity of substance

Solution Approach 1:

The patent applies the flame retardant composition in a patterned manner covering specific percentages of the fabric surface (e.g., 10-50% coverage). This partial application provides adequate flame protection while using less material compared to full coating, thus reducing the cost impact of using more expensive non-halogenated compositions while still achieving the desired safety performance.

Inventive Principle:

Principle #16Partial or excessive action

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 provides improved flame retardancy while maintaining or minimizing the reduction of breathability and water repellence, meeting fire safety standards with reduced toxic fume production and cost-effective application of flame retardants.

Implementation Method 1

a flame retardant flexible substrate comprising at least one flexible substrate and at least one flame retardant composition, wherein the flame retardant composition partially covers at least one face of the flexible substrate

Methodology Applied

Scientific EffectFlame retardancy:

Implementation Method 2

the flame retardant composition is present in the form of a regular or irregular pattern, wherein the regular or irregular pattern comprises a plurality of individual elements in which the distance between adjacent elements is of from 8 mm to 25 mm

Methodology Applied

Scientific EffectPattern distribution:

Implementation Method 3

using phosphorus-based or other non-halogenated compositions to maintain breathability and prevent toxic fume production

Methodology Applied

Scientific EffectToxic fume prevention:

Implementation Method 4

A production process for a flame retardant flexible substrate, comprising the steps of: providing at least one flexible substrate, applying at least one flame retardant composition in the form of a regular or irregular pattern onto at least one face of the at least one flexible substrate

Methodology Applied

Scientific EffectCoating: Coatings

Implementation Method 5

using coating or printing methods to ensure even distribution and curing

Methodology Applied

Scientific EffectPrinting:

Implementation Method 6

with a production process involving coating or printing methods to ensure even distribution and curing

Methodology Applied

Scientific EffectCuring:

Data Source

PatentEP2726667B1Patterned flame retardant flexible substrates and process of manufacture thereof

Publication Date: 2018.04.04 EI DU PONT DE NEMOURS & CO

AI summary

A flame retardant flexible substrate comprising at least one flexible substrate and at least one flame retardant composition, wherein the flame retardant composition partially covers at least one face of the flexible substrate and wherein the flame retardant composition is present in the form of a regular or irregular pattern.