Infusible waterborne pigmented resin compositions and methods of preparing and using the same
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Solution Overview
Problem
Existing polyester nonwoven acoustical felt products are expensive, require large minimum order quantities, and colorization can negatively affect flame spread control and smoke performance.
Innovation Solution
A composition comprising an antimigrant polymer, pigment, ammonium polyphosphate, and an anionic surfactant is used to infuse color into polyester products, maintaining flame retardancy and smoke performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If polyester nonwoven products are colored in the fiber forming process or direct dyed, then color is achieved, but minimum order quantities of 4 to 10 tons are required and custom colored products cannot be provided on demand
Solution Approach 1:
The patent separates the coloring process from the fiber manufacturing process. Instead of coloring fibers during production (which requires large batches), the invention applies color infusible compositions to finished nonwoven products, enabling small-quantity custom colorization without retooling fiber lines.
Solution Approach 2:
The patent uses pre-formulated infusible color compositions that are applied to the nonwoven product surface before final assembly. This preliminary coloring action allows custom colors to be applied on-demand to finished goods rather than requiring large-scale fiber production runs.
2Ease of manufacture
If polyester nonwoven products are colored, then color is achieved, but flame spread control and smoke performance are negatively affected
Solution Approach 1:
The patent introduces a binder resin as an intermediary carrier that delivers pigment particles to the nonwoven product. This binder system allows color application without requiring flame-retardant additives, thereby maintaining the product's inherent fire safety performance while achieving durable coloration.
Solution Approach 2:
The patent uses infusible color compositions that replicate the appearance of dyed fibers without requiring actual fiber dyeing. This copying approach applies color to the surface level, avoiding the need to compromise fiber composition or add fire safety additives.
3Productivity
If large lots of product are ordered for coloring, then minimum order quantities are met, but inventory flexibility and on-demand production are reduced
Solution Approach 1:
The patent combines the coloring function with the final product finishing process rather than requiring separate large-scale fiber production and dyeing operations. This integration allows small batches of colored nonwoven products to be produced efficiently alongside standard products using the same application equipment.
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 composition allows for durable color infusion without compromising the flame spread control and smoke performance, enabling on-demand production in small quantities.
Implementation Method 1
an anionic surfactant comprising phosphate
Implementation Method 2
ammonium polyphosphate
Data Source
AI summary
Described herein are compositions useful for infusing color into nonwoven polyester containing product and methods to do so. Such compositions and methods comprise use of a color infusion composition comprising an antimigrant polymer; pigment; ammonium polyphosphate; and an anionic surfactant comprising phosphate. In certain embodiments, thermoplastic polymer having a glass transition temperature (Tg) of 93.0° C. or less is used to enhance color infusion.