Rayon Flame-Retardant Fabric With Surface-Weighted Phosphorus
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Solution Overview
Problem
Existing flame retardant fabrics made from Nomex fibers are uncomfortable in hot environments and limited in color options, while fabrics from continuous filament rayon lack effective flame retardant properties when treated with conventional phosphorus-based compounds.
Innovation Solution
A textile fabric formed from yarns of continuous filament rayon with a unique distribution of a phosphorus-based flame retardant compound, where outer filaments have a phosphorus content at least 25% greater than inner filaments, achieved through a modified dip-squeeze treatment process, ensuring durable and effective flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Nomex fiber is used for flame retardant fabrics, then flame retardant properties are achieved, but comfort and moisture wicking properties deteriorate
Solution Approach 1:
The patent changes the chemical and physical parameters of the flame retardant treatment by using a phosphorus-based compound that can be applied to rayon continuous filaments at controlled concentrations. This allows the fabric to achieve flame retardancy while maintaining the inherent comfort and moisture wicking properties of rayon, unlike Nomex which has inherent flame retardancy but poor comfort properties.
2Ease of operation
If continuous filament rayon yarns are used, then comfort and processability are improved, but flame retardant treatment effectiveness deteriorates
Solution Approach 1:
The patent creates a non-uniform distribution of the flame retardant compound within the yarn structure, with higher concentration in outer filaments and lower concentration in inner filaments. This local quality approach allows the continuous filament rayon to maintain its comfort and processability advantages while achieving adequate flame retardant protection where it is most needed - at the fabric surface.
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 fabric exhibits enhanced flame retardant properties, comfort, and moisture wicking capabilities, suitable for close-fitting garments and various applications, while maintaining softness and suppleness.
Implementation Method 1
the outer filaments of the yarns have a phosphorus content at least 25% greater than the inner filaments
Implementation Method 2
curing the compound on the fabric
Data Source
AI summary
A high performance flame retardant textile fabric is provided which is suitable for use in producing close-fitting garments, such as undergarments, that come into direct contact with the skin of the wearer and provide a protective function, as well as in non-apparel applications. The fabric is formed of yarns of rayon continuous filaments, the yarns having outer filaments along the periphery of the yarn and inner filaments in the interior of the yarn. A cured phosphorus-based flame retardant compound is durably affixed to the filaments and imparts flame retardant properties to the fabric. The outer filaments of the yarns have a phosphorus content at least 25% greater than the inner filaments of the yarn.