3D Crimp PET Multifilament with Phosphorus Flame Retardant

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Solution Overview

Problem

Conventional methods for flame retardancy in polyethylene terephthalate fibers, such as bromine-based compounds, face issues with durability, environmental pollution, and the generation of carcinogenic substances, while phosphorus-based alternatives require optimization for effective incorporation in synthetic fibers.

Innovation Solution

A 3-D crimp polyethylene terephthalate multifilament is developed using a phosphorus-based flame retardant within a specific concentration range, integrated through a steam or air jet texturing process, achieving high flame retardancy and toughness with a tailored stress-strain curve, and optimized production parameters to enhance elongation and tensile strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bromine-based flame retardant is used to achieve flame retardancy, then flame retardant effect is obtained, but the polymer is discolored and has deteriorated lightfastness

Engineering Contradiction:

Improveflame retardancyVSAvoiddiscoloration and lightfastness deterioration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the chemical composition parameter by replacing bromine-based flame retardant with phosphorus-based flame retardant (specifically phosphoric acid and/or phosphorous acid) in the polyethylene terephthalate polymer. This parameter change maintains flame retardancy while eliminating the harmful effects of discoloration and lightfastness deterioration associated with bromine-based compounds.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses readily available phosphoric acid and phosphorous acid as flame retardants, which are simpler and more stable compounds compared to complex bromine-based flame retardants. These phosphorus-based compounds provide lasting flame protection without the side effects, effectively replacing the problematic bromine-based alternatives.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If bromine-based flame retardant is used to achieve flame retardancy, then flame retardant effect is obtained, but carcinogenic substances such as dioxin and benzofuran may be generated

Engineering Contradiction:

Improveflame retardancyVSAvoidgeneration of carcinogenic substances

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention fundamentally changes the chemical parameter by substituting phosphorus-based flame retardants for bromine-based flame retardants in the polyethylene terephthalate polymer structure. This substitution eliminates the generation of carcinogenic dioxin and benzofuran during combustion, as phosphorus-based compounds decompose into non-carcinogenic products while maintaining effective flame retardancy.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the potential harm of using flame retardants (which could generate carcinogenic substances) into a benefit by selecting phosphorus-based compounds that inherently decompose into safe, non-carcinogenic products. The flame retardant provides protection while its decomposition products are environmentally benign, effectively turning a potentially harmful process into a beneficial one.

Inventive Principle:

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

3Object-affected harmful factors

If phosphorus-based flame retardant is used to achieve flame retardancy, then environmental friendliness is improved, but the concentration and incorporation method require optimization for effective flame retardancy

Engineering Contradiction:

Improveenvironmental impactVSAvoidconcentration control and incorporation optimization

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The invention optimizes the concentration parameter of phosphorus-based flame retardants within a specific range (0.05 to 5 wt% based on phosphorus atom) to achieve effective flame retardancy. This parameter optimization ensures that the flame retardant is incorporated at the right concentration to provide adequate protection while maintaining environmental friendliness and avoiding excessive addition that could affect polymer properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention incorporates the phosphorus-based flame retardant (phosphoric acid and/or phosphorous acid) directly into the polyethylene terephthalate polymer during the polymerization process, rather than as a post-treatment. This preliminary incorporation ensures uniform distribution and effective concentration control throughout the polymer structure, achieving optimal flame retardancy from the outset.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If post-process flame retardation treatment is applied to achieve flame retardancy, then flame retardant effect is obtained, but durability is poor and environmental pollution occurs due to wastewater

Engineering Contradiction:

Improveflame retardancyVSAvoiddurability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The invention applies the flame retardant during the polymerization process itself, incorporating phosphoric acid and/or phosphorous acid directly into the polyethylene terephthalate polymer structure. This preliminary action during manufacturing ensures the flame retardant is permanently integrated into the polymer, providing lasting durability without the need for post-process treatments that generate wastewater and offer poor durability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention makes the polyethylene terephthalate polymer self-flame-retardant by incorporating phosphorus-based flame retardants during polymerization. The polymer itself becomes inherently flame resistant through this built-in protection, eliminating the need for external post-treatment processes that are temporary and environmentally polluting.

Inventive Principle:

Principle #25Self-service

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 resulting multifilament exhibits improved flame retardancy, toughness, and elongation, with a limited oxygen index of 25 or more, and a crimp standard deviation of 5% or less, while reducing environmental impact and maintaining economic efficiency.

Implementation Method 1

using a steam jet- or air jet-type texturing process

Methodology Applied

Scientific EffectSteam jet texturing: Fluid Spray

Implementation Method 2

using a steam jet- or air jet-type texturing process

Methodology Applied

Scientific EffectAir jet texturing: Jet

Implementation Method 3

Since a bromine-based compound is easily thermally decomposed at high temperatures

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentEP1845178B13-dimension crimp polyethylene-terephtalate multifilament for carpet

Publication Date: 2009.03.11 HYOSUNG CORP

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AI summary

Disclosed is a 3-D crimp polyethylene terephthalate multifilament (BCF) having a stress-strain curve such that (a) it elongates less than 5.0 % when subjected to an initial stress of 1.0 g/d, (b) it has an initial modulus of 20 to 60 g/d, (c) it elongates at least 20 % when subjected to a stress region of 1.0 to 2.5 g/d and (d) it elongates from a tensile strength of at least 3.0 g/d to the tensile strength at break. The BCF has improved physical properties such as excellent flame retardancy, high toughness, improved crimp uniformity and improved compressive elasticity modulus.