Flame-Retardant Cotton Thermoset Fabric With Stretch-Applied Treatment
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Solution Overview
Problem
Existing methods for treating woven fabrics with flame retardants, such as cotton blends, are inadequate in providing comprehensive protection against flames and electrostatic discharges, particularly in hazardous environments, as they do not effectively penetrate the fabric and may not meet regulatory standards for flame resistance.
Innovation Solution
A method involving stretching woven or knitted fabrics with cotton and thermoset or thermoplastic blends, followed by immersion in an aqueous bath containing a phosphorous polymer like THP, squeezing, drying, treating with ammonia gas, and oxidizing with hydrogen peroxide, while allowing the fabric to shrink back to its original dimensions, ensuring even deposition and cross-linking of the flame retardant, and incorporating carbon/polyester filaments for anti-static properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flame retardant treatment methods are used on cotton blend fabrics, then the treatment process is simple, but the flame retardant does not effectively penetrate the fabric and fails to meet regulatory standards for flame resistance
Solution Approach 1:
The fabric is pre-stretched to 105-115% of its original dimensions before flame retardant application. This preliminary action opens the fabric structure, allowing the flame retardant solution to penetrate more effectively into the fibers, thereby improving flame resistance without requiring excessively complex treatment equipment
Solution Approach 2:
The patent changes the physical state and dimensions of the fabric during treatment by stretching it to specific dimensions (105-115% of original size). This parameter change enables better penetration of the flame retardant solution while maintaining a manageable treatment process using standard textile equipment
2Manufacturing precision
If the fabric is stretched and treated with flame retardant, then penetration and distribution of the flame retardant are improved, but the treatment process becomes more complex
Solution Approach 1:
Stretching the fabric before treatment creates a more open and uniform fabric structure, which allows the flame retardant solution to distribute more evenly throughout the material. This preliminary dimensional adjustment simplifies the need for multiple complex application steps while achieving uniform penetration
Solution Approach 2:
The patent introduces dimensional change by stretching the fabric in length and/or width directions before treatment. This dimensional adjustment creates better access pathways for the flame retardant solution to penetrate uniformly, achieving improved distribution without adding excessive process complexity
3Object-affected harmful factors
If cotton fibers are used for industrial garments, then the garments are comfortable and cost-effective, but they lack adequate protection against flames and electrostatic discharges in hazardous environments
Solution Approach 1:
The patent applies chemical treatments that modify the surface properties and internal structure of cotton fibers, changing their parameters to achieve flame resistance and electrostatic discharge protection while maintaining the comfort and cost-effectiveness of cotton garments
Solution Approach 2:
The treatment process creates a composite structure where flame retardant chemicals are integrated within and on the cotton fiber structure. This composite approach provides flame and electrostatic protection while retaining the base cotton fabric's desirable properties of comfort and affordability
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 method achieves enhanced flame retardancy and electrostatic discharge protection, meeting regulatory standards and ensuring the flame retardant remains effective after washing, with improved penetration and even distribution of the flame retardant within the fabric.
Implementation Method 1
The fabric is treated with an aqueous solution of an organo phosphorous compound such as tetrakis (hydroxyorgano) phosphonium compound especially with a tetrakis (hydroxymethyl) phosphonium which will be hereinafter called 'THP'
Implementation Method 2
U.S. Pat. No. 4,909,805 to Geoffrey W. Smith, U.S. Pat. No. 4,900,613 to James R. Green, and U.S. Pat. No. 5,468,545 to George R. Fleming, et al.
Data Source
AI summary
A flame retardant fabric wherein a flame retardant composition is applied to the fabric while the fabric is being stretched. Preferably the fabric is a blend of cotton and a thermoset. Carbon fibers may be included to impart anti-static properties.