Textile Flame-Retardant Coating With Fine FR-720 and Low Binder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flame retardant formulations for textiles suffer from high bromine content, high dry add-on, streak marks on dark fabrics, excessive dripping during combustion, and adverse effects on aesthetic and textural properties, due to the use of aromatic bromine compounds and high binder content, which also contribute to flammability and inefficiency.
Innovation Solution
A novel flame retardant formulation using tetrabromobisphenol A bis(2,3-dibromopropyl ether) (FR-720) particles with a particle size of less than 50 microns, applied with a low binder content, forming a homogeneous and transparent film on textiles, combined with aluminum ammonium super phosphoric acid salt (AIASP) as a smoldering suppressant, to achieve durable flame retardancy and reduced afterglow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aromatic bromine-containing formulations are used for flame retardation, then flame retardant effect is achieved, but high binder content is required which contributes to flammability and dripping
Solution Approach 1:
The invention changes the particle size parameter of the flame retardant agent to sub-50 microns, which fundamentally alters how the binder interacts with the FR agent. This size reduction increases surface area and improves distribution, allowing effective flame retardation with significantly reduced binder content (from 50% down to much lower levels), thereby reducing the flammability contribution from binders
Solution Approach 2:
The invention creates a composite formulation system combining sub-50 micron FR-720 particles with specific binder types and concentrations. This composite approach optimizes the interaction between FR agent and binder, achieving effective flame retardation while minimizing binder content and its associated flammability issues
2Reliability
If high binder content is used to fix flame retardant agents, then adhesion is improved, but aesthetical and textural properties of fabric are adversely affected
Solution Approach 1:
Reducing binder content through particle size optimization directly lessens the adverse effects on fabric aesthetics and texture. The sub-50 micron particles require minimal binder (significantly less than 50% by weight), preventing fabric stiffening, harshness, duller shades, and poor tear strength that result from high binder applications
Solution Approach 2:
The fine particle size enables localized effective distribution of flame retardant properties throughout the fabric structure with minimal binder intervention, preserving the local aesthetic and textural qualities of the fabric while achieving uniform flame protection
3Ease of operation
If thickening agents are added to increase viscosity, then application is facilitated, but flammability increases requiring additional flame retardant
Solution Approach 1:
The sub-50 micron particle size modification changes the rheological properties of the formulation, providing adequate viscosity and application characteristics without requiring excessive thickening agents. This reduces the flammability burden while maintaining ease of application
Solution Approach 2:
The invention minimizes or eliminates the need for flammable thickening agents by using the inherent properties of finely ground FR-720 particles, effectively replacing long-term flammable additives with a permanent, non-flammable particle size characteristic
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 formulation provides effective flame retardancy and smoldering suppression with a low binder content, maintaining properties through multiple washing cycles, reducing afterglow time, and enhancing the homogeneity and transparency of the flame retardant film on textiles.
Implementation Method 1
Flame retardant formulations that form homogeneous flame retardant films on textiles
Implementation Method 2
aluminum ammonium super phosphoric acid salt (AIASP) as a smoldering suppressant, to achieve durable flame retardancy and reduced afterglow
Data Source
Figure 1A~1B
Figure 2A
Figure 2B~2C
AI summary
The present invention discloses a flame retardant formulation comprising tetrabromobisphenol A bis(2,3-dibromopropyl ether) (FR-720) particles in a liquid carrier, wherein the particle size of at least 50 % of said particles (d50) is smaller than about 50 microns. Furthermore, the present invention discloses a flammable textile fabric, coated by a flame retardant film comprising FR-720 particles which are substantially homogeneously dispersed in or on the flammable textile fabric, and further of a process of preparing these flame retardant formulations and of a process of applying these formulations onto a flammable textile fabric.