Treated textile material and process for producing the same
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Solution Overview
Problem
Existing flame-resistant fabrics, particularly cellulosic or cellulosic-blend fabrics, often fail to meet demanding flammability standards, necessitating the use of costly inherent flame-resistant fibers like meta-aramid, and there is a need for alternative flame retardant compounds to enhance fabric flame resistance.
Innovation Solution
A flame retardant, phosphorus-containing polymer is applied to textile materials through a process involving a phosphonium compound and a nitrogen-containing cross-linking compound, which undergoes condensation and oxidation to form microprotuberances on the fabric surface, enhancing flame resistance without the need for expensive inherent fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cellulosic or cellulosic-blend fabrics are used with existing flame retardant treatments, then fabric availability and wearer comfort are improved, but flammability performance is insufficient to meet demanding industry requirements
Solution Approach 1:
The patent applies parameter changes by modifying the chemical structure of flame retardant compounds, specifically using phosphonium compounds with controlled hydroxyalkyl group content (≤10% of functional groups). This chemical parameter modification enables cellulosic fabrics to achieve superior flame resistance (meeting ASTM D6413 standards for 250 cal/cm² arc rating) while maintaining the comfort and availability advantages of cellulosic materials.
2Reliability
If inherent flame resistant fibers (e.g., meta-aramid) are employed to meet flammability requirements, then flame resistance is improved, but fabric cost increases
Solution Approach 1:
The patent employs inexpensive phosphonium compounds as flame retardant agents that can be applied to standard cellulosic fabrics, replacing the need for costly inherent flame-resistant fibers like meta-aramid. This approach achieves equivalent or superior flame resistance (250 cal/cm² arc rating) at significantly lower material cost, as the phosphonium-based treatment is applied as a coating rather than requiring expensive specialized fibers throughout the fabric structure.
3Reliability
If phosphonium compounds with high hydroxyalkyl group content are used, then flame retardant effectiveness is improved, but residual hydroxyalkyl groups increase which may affect fabric performance
Solution Approach 1:
The patent optimizes the chemical composition parameter by specifying that hydroxyalkyl groups constitute ≤10% of the functional groups in the phosphonium compound. This parameter control achieves effective flame retardancy while minimizing residual hydroxyalkyl groups that could negatively impact fabric performance, representing a balanced optimization of chemical composition for both effectiveness and fabric quality.
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 treated textiles exhibit improved flame resistance, meeting stringent standards with a unique microprotuberance morphology and reduced residual hydroxyalkyl groups, providing effective protection against flames and arc flashes while maintaining comfort and durability.
Implementation Method 1
reacting the phosphonium compound and the nitrogen-containing cross-linking compound in a condensation reaction to produce a first intermediate polymer comprising a plurality of phosphorus atoms
Implementation Method 2
oxidizing the first intermediate polymer to convert at least a portion of the phosphorus atoms to a pentavalent, phosphine oxide state
Implementation Method 3
a flame retardant, phosphorus-containing polymer at least a portion of which is present in the form of a plurality of microprotuberances having a diameter of ≤ 10 μm and protruding from the surface of the textile fibers
Data Source
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AI summary
An article comprises a textile material and a flame retardant, phosphorus-containing polymer. The flame retardant, phosphorus, containing polymer can be present in the form of a plurality of microprotuberances. The flame retardant, phosphorus, containing polymer can contain a relatively low amount of residual hydroxyalkyl groups bonded to the phosphorus atoms in the polymer. A process for producing a treated textile material is also provided.