Flame-retardant polyester fiber with excellent dyeability and manufacturing method therefor
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Solution Overview
Problem
Existing polyester fibers face issues with dyeability and flame retardancy due to the use of antimony and cobalt compounds, which are harmful to human health and the environment, and titanium-based catalysts result in yellow coloration and acetaldehyde generation, while additive-type flame retardants affect color yield and durability.
Innovation Solution
A flame-retardant polyester fiber with 10 to 20 ppm titanium and an additive-type flame retardant (Chemical Formula 1) is developed, using a titanium-based catalyst (Chemical Formula 2) to enhance dyeability and reduce acetaldehyde generation, with specific manufacturing steps to ensure optimal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimony compounds are used as catalysts in polyester resin manufacturing, then flame retardancy is improved, but safety and hygiene deteriorate due to toxicity
Solution Approach 1:
The patent replaces expensive and toxic antimony compounds with inexpensive titanium-based catalysts that are safe and environmentally friendly. The titanium catalyst achieves the desired flame retardancy without the harmful effects of antimony, effectively using a safer, shorter-lived (in terms of catalytic activity) alternative to achieve the same functional outcome.
Solution Approach 2:
The patent changes the chemical composition parameters by substituting antimony compounds with titanium-based catalysts. This parameter change maintains or improves flame retardancy while eliminating toxicity, directly resolving the contradiction between flame safety and health safety.
2Object-affected harmful factors
If germanium compounds are used as catalysts in polyester resin manufacturing, then safety and hygiene are improved, but cost increases due to expense
Solution Approach 1:
The patent employs inexpensive titanium-based catalysts to replace costly germanium compounds. This substitution maintains the safety and hygiene benefits while dramatically reducing manufacturing costs, making the process economically viable.
Solution Approach 2:
The patent changes the catalyst composition from expensive germanium compounds to affordable titanium-based catalysts. This parameter change preserves the safety advantages while eliminating the economic disadvantage, resolving the contradiction between safety and cost.
3Ease of manufacture
If titanium-based catalysts are used in polyester resin manufacturing, then cost is reduced and safety is improved, but color stability deteriorates due to yellow coloration
Solution Approach 1:
The patent applies local quality control by using titanium-based catalysts in specific controlled conditions and combinations with other additives to minimize yellowing. The catalyst is used in optimized quantities and paired with stabilizing agents to maintain color stability in critical areas while preserving cost and safety benefits.
Solution Approach 2:
The patent creates a composite catalytic system combining titanium-based catalysts with other materials that counteract yellowing effects. This composite approach maintains the economic and safety advantages of titanium while compensating for color stability issues through material combination.
4Reliability
If additive-type flame retardants are used in polyester fiber, then flame retardancy is improved and ease of mixing is achieved, but color yield deteriorates due to high b value
Solution Approach 1:
The patent optimizes the parameters of additive-type flame retardants by selecting specific chemical compositions and concentrations that reduce the b value (yellowing tendency). This parameter optimization maintains excellent flame retardancy while improving color yield to acceptable levels.
Solution Approach 2:
The patent applies local quality enhancement by using flame retardant additives with modified chemical structures that provide flame protection in critical areas while having minimal impact on overall color properties. The additive is strategically selected to balance flame safety and color quality.
5Productivity
If high-temperature dyeing conditions are applied to flame-retardant polyester fiber, then dyeing efficiency is improved, but fiber strength deteriorates due to thermal decomposition
Solution Approach 1:
The patent changes the dyeing process parameters by optimizing temperature, time, and chemical composition to achieve efficient dyeing at moderate temperatures. This parameter optimization maintains dyeing efficiency while preventing thermal decomposition that would weaken the fiber.
Solution Approach 2:
The patent applies preliminary protective measures by incorporating heat stabilizers and optimizing fiber structure before the dyeing process. This preliminary action protects the fiber from thermal decomposition during dyeing, maintaining strength while achieving good dyeing results.
6Illumination intensity
If excess amount of dye is applied during dyeing, then color strength is improved, but flame retardancy deteriorates due to hydrolysis and omission of flame retardant
Solution Approach 1:
The patent optimizes the dyeing parameters by controlling dye concentration, temperature, and time to achieve sufficient color strength without excessive dye application. This parameter control prevents hydrolysis and flame retardant omission, maintaining both color quality and flame safety.
Solution Approach 2:
The patent implements feedback control in the dyeing process by monitoring color development and adjusting dye application accordingly. This feedback mechanism achieves the desired color strength while preventing over-dyeing that would compromise flame retardancy through hydrolysis and additive loss.
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 fiber achieves excellent dyeability, low acetaldehyde generation, and high flame retardancy without antimony or cobalt, maintaining human safety and economic feasibility.
Implementation Method 1
a titanium-based catalyst (Chemical Formula 2) to enhance dyeability and reduce acetaldehyde generation
Implementation Method 2
an additive-type flame retardant represented by Chemical Formula 1 below in an amount of 0.55 to 0.75 wt. % based on the amount of phosphorus (P) element in 100 wt. % of the fiber
Data Source
AI summary
The present invention relates to a flame-retardant polyester fiber manufactured by using a titanium-based catalyst and an additive-type flame retardant, and relates to a flame-retardant polyester fiber with excellent dyeability characterized by generating a small amount of acetaldehyde, with excellent dyeability, and generating remarkably low contamination on a nozzle surface, and to a manufacturing method therefor.