Textile Composite With Expandable Graphite for Reduced Afterflame
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Solution Overview
Problem
Traditional flame-resistant protective garments are expensive, difficult to dye or print, lack abrasion resistance, absorb excessive water, and provide unsatisfactory tactile comfort, making them unsuitable for workers in hazardous environments requiring lightweight, breathable, and affordable options.
Innovation Solution
A flexible textile composite is developed, comprising a meltable outer textile layer, a thermally stable convective barrier, and a heat reactive material made from a polymer resin-expandable graphite mixture, which reduces afterflame time and char length, while maintaining breathability and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inherently flame resistant fibers (aramids, PBI, PBO) are used for protective garments, then flame resistance is improved, but cost increases significantly
Solution Approach 1:
The patent applies composite materials by combining conventional textile fibers (nylon, polyester) with flame retardant additives and coatings to create a composite fabric that achieves flame resistance without using expensive inherent FR fibers. This allows the garment to meet flame resistance standards while using more cost-effective base materials.
Solution Approach 2:
The patent changes the chemical and physical parameters of conventional fibers through treatment with flame retardant agents, coatings, or chemical modifications. This transforms ordinary flammable or low-FR materials into flame-resistant materials, achieving the desired protection level without the cost of inherent FR fibers.
2Reliability
If traditional inherently flame resistant fibers are used, then flame resistance is improved, but tactile comfort deteriorates due to excessive water absorption
Solution Approach 1:
The patent modifies the hygroscopic properties of flame-resistant materials through chemical treatment, coating applications, or fiber selection that reduces water absorption capacity. This allows the material to maintain flame resistance while improving tactile comfort by feeling less clammy and absorbing less perspiration.
3Reliability
If traditional inherently flame resistant fibers are used, then flame resistance is improved, but dyeing and printing difficulty increases
Solution Approach 1:
The patent alters the surface chemistry and physical structure of flame-resistant materials to improve dye affinity and print receptivity. This may involve modifying fiber surfaces, using different polymer bases, or applying treatments that enable conventional dyeing and printing processes to work effectively on flame-resistant fabrics.
4Reliability
If traditional inherently flame resistant fibers are used, then flame resistance is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent creates composite structures where flame-resistant fibers or coatings are combined with abrasion-resistant materials. This may involve layering different fabrics, using blended fibers, or applying protective coatings that enhance both flame resistance and abrasion resistance simultaneously.
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 textile composite achieves a significant reduction in afterflame time and char length, enhanced breathability, and improved comfort, making it suitable for hazardous environments without the drawbacks of traditional materials.
Implementation Method 1
a heat reactive material made from a polymer resin-expandable graphite mixture, which reduces afterflame time and char length
Implementation Method 2
the expandable graphite has an expansion of at least 900 μm upon heating to 280°C
Implementation Method 3
a thermally stable convective barrier
Data Source
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AI summary
A method is described for reducing the afterflame of a flammable, meltable material. A textile composite is described comprising an outer textile comprising a flammable, meltable material, and a heat reactive material comprising a polymer resin-expandable graphite mixture.