Layered Phenolic-Cellulose Textile for Flame and Heat Insulation
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Solution Overview
Problem
Existing materials for thermal insulation and self-extinguishing textiles lose efficiency over time, fail to protect against convective flames and irradiation, and release toxic gases during combustion, posing safety risks in confined spaces.
Innovation Solution
A layered product comprising a first layer of cellulose fiber and phenolic fiber fabric, an intermediate layer of compressed phenolic fiber cotton wool, and a second layer of artificial cellulose fiber fabric, joined by non-toxic cotton quilting yarn, which provides high thermal insulation, self-extinguishing capacity, and aesthetic appeal without toxic emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fireproofing treatments are applied to textiles during enhancement, then flame propagation is limited or inhibited, but the efficiency levels reduce over time due to maintenance and use
Solution Approach 1:
The patent uses a composite structure combining phenolic fibers (providing flame retardancy) with cellulose fibers (providing comfort and absorbency). The phenolic fibers are inherently flame-retardant without requiring surface treatments, while the cellulose fibers maintain comfort properties. This composite approach eliminates the degradation issue of applied fireproofing treatments by integrating flame retardancy into the fiber structure itself.
2Reliability
If conventional flame-retardant treatments are used, then flame propagation is inhibited, but protection against convective flame and irradiation heat transfer is insufficient
Solution Approach 1:
The patent creates different functional zones within the textile structure. The phenolic fiber component provides flame retardancy and heat resistance, while the cellulose fiber component provides comfort and breathability. The layered construction with different fiber types and densities creates local variations in thermal properties, with the phenolic-rich layers providing heat barrier function while cellulose layers maintain comfort.
3Reliability
If textile elements undergo combustion, then flame propagation may be limited, but noxious gases and toxic fumes are released
Solution Approach 1:
The patent changes the chemical composition parameters of the textile by using phenolic fibers which have inherent flame-retardant properties and do not release toxic fumes when burned. Phenolic materials char rather than burn, producing carbon dioxide and water vapor instead of toxic gases. This parameter change in material composition fundamentally alters the combustion behavior and emission profile of the textile.
4Temperature
If phenolic fiber content is increased to improve thermal insulation, then heat resistance improves, but cost increases considerably
Solution Approach 1:
The patent optimizes the phenolic-to-cellulose fiber ratio to achieve the desired balance between performance and cost. By carefully controlling the composition parameters (e.g., 30-70% phenolic fibers), the textile achieves adequate flame retardancy and thermal insulation without requiring 100% phenolic content, thus reducing material costs while maintaining functional requirements.
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 layered product effectively insulates against heat and flames, maintains safety by preventing toxic gas release during combustion, and offers a cost-effective, aesthetically pleasing solution with enhanced reliability and comfort.
Implementation Method 1
a first layer (2) which is provided by means of a fabric obtained with a yam constituted by the intimate mixing of cellulose fiber and phenolic fiber
Implementation Method 2
an intermediate layer (3), advantageously provided by a cotton wool made of phenolic fiber
Implementation Method 3
the cellulose component provides the level of pleasantness to the touch, with a smooth and comfortable appearance, while the phenolic fiber provides the heat resistance function and the better tenacity during combustion
Data Source
Figure 1~3
Figure 2
AI summary
A layered product (1) with high thermal insulation and self-extinguishing capacity, particularly for blankets and bed accessories, upholstery, coverings, items of clothing and the like, comprising a first layer (2) constituted by a fabric obtained with a yarn provided by an intimate mix of cellulose fiber and phenolic fiber, the first layer being superimposed on an intermediate layer (3) made of a phenolic fiber cotton wool, a second layer (4) being further provided which is constituted by a fabric obtained with a cellulose fiber yarn associated with the intermediate layer (3) on the opposite side with respect to the first layer (2), means (10) for joining the layers being further provided.