Polyolefin Coated Yarn Composition for Recyclable Flame Retardancy
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Solution Overview
Problem
Conventional PVC coated yarns are difficult to recycle due to their non-removable coating layer and release toxic pollutants when burned, posing environmental and health hazards.
Innovation Solution
A coating composition comprising a polypropylene random copolymer resin and a polypropylene elastomer resin with a flame retardant, such as melamine phosphate or magnesium dihydroxide, applied to a core yarn made of polyolefin resin, allowing for easy recycling and reducing toxic emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PVC resin is used as coating material, then flame retardancy and antibiosis are improved, but recyclability deteriorates due to non-removable coating layer
Solution Approach 1:
The patent changes the chemical composition parameters of the coating material from PVC (polyvinyl chloride) to polypropylene-based resins. This parameter change enables the coating to be removed and recycled while maintaining flame retardancy through the incorporation of flame retardant additives like aluminum trihydroxide and melamine phosphate.
Solution Approach 2:
The patent creates a composite coating material consisting of polypropylene resin combined with flame retardant additives (aluminum trihydroxide, melamine phosphate, etc.). This composite structure provides both the recyclability of polypropylene and the flame retardancy of the additives, resolving the contradiction between these two properties.
2Reliability
If PVC coating layer is used, then flame retardancy is improved, but harmful factors increase due to chlorine release and toxic pollutant generation
Solution Approach 1:
The patent replaces the harmful chlorine-containing PVC material with benign polypropylene resin. The flame retardancy function previously provided by PVC is now achieved through environmentally friendly flame retardant additives that do not release toxic pollutants, converting a harmful system into a beneficial one.
Solution Approach 2:
The patent uses aluminum trihydroxide and other inorganic flame retardants that decompose to form protective char layers and inert gases during combustion, creating an inert atmosphere that suppresses flame propagation without releasing toxic substances, thereby eliminating the harmful effects associated with PVC combustion.
3Stability of the object's composition
If PVC resin with plasticizer is used, then elasticity and anti-wrinkle property are improved, but environmental friendliness deteriorates due to phthalate-based compound toxicity
Solution Approach 1:
The patent changes the base resin from PVC to polypropylene and eliminates the need for phthalate-based plasticizers. Elasticity and flexibility are achieved through the inherent properties of the polypropylene resin and the elastomeric components in the coating composition, removing the toxic plasticizer requirement.
Solution Approach 2:
The patent adopts a coating system where the polypropylene-based coating can be easily removed and disposed of or recycled without causing environmental harm, replacing the persistent toxic plasticizers in PVC with a recyclable system that does not require harmful additives for flexibility.
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 coated yarn is recyclable and exhibits improved flame retardancy, eliminating the need for halogen-based materials and reducing environmental pollution, making it suitable for various industrial applications.
Implementation Method 1
when the coated yarn is subjected to flame, the flame retardant melts and decomposes to increase the limited oxygen index
Implementation Method 2
when the coated yarn is subjected to flame, the flame retardant melts and decomposes to increase the limited oxygen index
Implementation Method 3
A PVC coated yarn is prepared by coating a PVC resin on a high-tenacity polyethylene terephthalate (PET) yarn at a coating rate of 300 to 1100 m/min in an extrusion coating machine
Data Source
Figure 1
AI summary
A coated yam prepared by coating a polyolefin yam with a coating composition comprising a polyolefin resin and a flame retardant is provided, wherein the polyolefin is selected from the group consisting of a polyethylene resin, a polyethylene copolymer resin, a polypropylene resin and a polypropylene copolymer resin. The coated yam can readily be recycled to produce a coreless yam useful as a flooring material or other industrial materials, which improves the flame retardancy of conventional non-PVC coated yarns. A fabric woven from the coated yam is useful in the preparation of a blind, a flooring material, wall paper, household items and other interior elements.