Spacer fabric treated with c6 based perfluoroalkyl polymer and method of preparing thereof
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The automotive industry requires spacer fabrics with good flame retardancy, oil repellency, high spray rating, and low volatile emissions, but existing solutions using C8 fluorocarbon polymers are environmentally problematic due to PFOA and PFOS concerns, and alternative C6 fluoropolymers are less efficient and more expensive.
Innovation Solution
A method involving a C6-perfluoralkyl based fluoropolymer treatment for spacer fabrics, which includes immersing the fabric in a liquid treating composition, removing excess, drying, and fixing, to achieve the desired properties without PFOA and PFOS, using a thermoplastic polymer-based spacer fabric with interconnected layers and monofil fibers, and a solvent-based emulsion with emulsifiers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If C8 fluorocarbon polymers are used to treat spacer fabrics, then oil repellency and spray rating are improved, but environmental harm increases due to PFOA and PFOS concerns
Solution Approach 1:
The patent changes the carbon chain length parameter from C8 to C6 in the fluorocarbon polymer structure. This parameter modification maintains the oil repellency and spray rating performance while eliminating the generation of PFOA and PFOS harmful substances, thereby resolving the contradiction between performance and environmental harm
Solution Approach 2:
The patent adopts C6 fluorocarbon polymers as a temporary replacement for C8 polymers until complete elimination of perfluoroalkyl substances is achieved. The C6 polymers provide the necessary performance characteristics now while being less harmful, serving as a transitional solution
2Object-generated harmful factors
If C6 fluoropolymer is used instead of C8 fluoropolymer, then environmental harm is reduced, but treatment efficiency and performance decrease
Solution Approach 1:
The patent optimizes the concentration parameter of C6 fluoropolymer in the treating composition and adjusts the application parameters (immersion time, drying temperature, fixing conditions) to compensate for the lower efficiency of C6 polymers compared to C8 polymers, thereby maintaining treatment effectiveness while using environmentally friendlier materials
Solution Approach 2:
The patent includes a pre-treatment step where the spacer fabric is prepared before applying the C6 fluoropolymer treatment. This preliminary action ensures better substrate readiness and enhances the effectiveness of the subsequent C6 polymer application, compensating for its inherently lower efficiency
3Object-affected harmful factors
If additional flame retardants are added to achieve flame retardancy, then flame behavior is improved, but volatile emissions increase
Solution Approach 1:
The patent makes the C6 fluoropolymer treatment composition multi-functional by incorporating flame retardant properties within the same treatment that provides oil repellency and spray rating. This eliminates the need for separate flame retardant additions, thereby achieving flame retardancy without the penalty of increased volatile emissions from multiple chemical systems
Solution Approach 2:
The patent merges the flame retardant function with the oil repellent fluoropolymer treatment into a single integrated composition. This combination approach ensures that flame retardancy is achieved through the synergistic action of the C6 fluoropolymer system itself, avoiding the addition of separate flame retardant chemicals that would increase volatile emissions
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 spacer fabric exhibits acceptable flame retardancy, low volatile emissions, high spray rating, and good oil repellency, meeting automotive industry standards without the use of additional flame retardants and with reduced environmental impact.
Implementation Method 1
treating the spacer fabric by immerging the spacer fabric into a bath of the liquid treating composition
Implementation Method 2
a solvent-based emulsion with emulsifiers
Implementation Method 3
drying
Data Source
Figure 1
AI summary
The present invention relates in general to treated spacer fabrics and a method of preparing such spacer fabrics and more particularly to a spacer fabric being treated for imparting the spacer fabric with at least one or all of the properties selected from good flame retardancy, good oil repellency, high spray rating and low volatile emissions. Furthermore, the invention relates to the use of a specific liquid treating composition for preparing a treated spacer fabric having at least one or all of the properties selected from good flame retardancy, good oil repellency, high spray rating and low volatile emissions.