Flame retardant fabric and manufacturing method thereof

Abstract

Provided are a flame retardant fabric and a manufacturing method thereof. The flame retardant fabric has a structure in which warp yarns and weft yarns are interwoven with each other, wherein at least one of the warp yarns and the weft yarns includes carbon nanotube fibers, and the content of carbon nanotubes in the flame retardant fabric is at least 0.02 wt. % based on the total weight of the flame retardant fabric.

1 . A flame retardant fabric, having a structure in which warp yarns and weft yarns are interwoven with each other, wherein at least one of the warp yarns and the weft yarns comprises carbon nanotube fibers, and the content of carbon nanotubes in the flame retardant fabric is at least 0.02 wt. % based on the total weight of the flame retardant fabric. 
     
     
         2 . The flame retardant fabric of  claim 1 , wherein a metal layer is disposed on the surfaces of the carbon nanotube fibers. 
     
     
         3 . The flame retardant fabric of  claim 1 , wherein the carbon nanotube fibers contain nitrogen dopants or boron dopants. 
     
     
         4 . The flame retardant fabric of  claim 1 , wherein the carbon nanotube fibers contain natural fiber material. 
     
     
         5 . The flame retardant fabric of  claim 4 , wherein the natural fiber material comprises cotton, linen, wool, rabbit hair, silk, tencel or coffee. 
     
     
         6 . The flame retardant fabric of  claim 1 , wherein the diameter of the carbon nanotube fibers is between 10 nm and 100 nm. 
     
     
         7 . The flame retardant fabric of  claim 1 , wherein the density of the carbon nanotube fibers is between 0.5 g/cm3 and 1.8 g/cm3. 
     
     
         8 . The flame retardant fabric of  claim 1 , wherein the material of the weft yarns is the same as the material of the warp yarns. 
     
     
         9 . The flame retardant fabric of  claim 1 , wherein the material of the weft yarns is different from the material of the warp yarns. 
     
     
         10 . The flame retardant fabric of  claim 9 , wherein one of the warp yarns and the weft yarns comprises carbon nanotube fibers, and the other of the warp yarns and the weft yarns comprises cotton fiber yarn, linen fiber yarn, wool fiber yarn, rabbit hair fiber yarn, silk fiber yarn, tencel fiber yarn, coffee fiber yarn, nylon fiber yarn, polyester fiber yarn, rayon fiber yarn, acrylic fiber yarn or polyurethane fiber yarn. 
     
     
         11 . The flame retardant fabric of  claim 10 , wherein the diameter of the fiber constituting the other of the warp yarns and the weft yarns is between 10 nm and 106 nm. 
     
     
         12 . A manufacturing method of a flame retardant fabric, comprising:
 growing carbon nanotubes on a substrate;   performing a drawing process to draw the carbon nanotubes to form carbon nanotube fibers;   performing a spinning process to spin the carbon nanotube fibers to form carbon nanotube fiber yarns; and   performing a weaving process to weave the carbon nanotube fiber yarns,   wherein the content of carbon nanotubes in the flame retardant fabric is at least 0.02 wt. % based on the total weight of the flame retardant fabric.   
     
     
         13 . The manufacturing method of  claim 12 , further comprising:
 performing a nitrogen doping or a boron doping during the growth of the carbon nanotubes.   
     
     
         14 . The manufacturing method of  claim 12 , further comprising:
 forming a metal layer on the surfaces of the carbon nanotubes after forming the carbon nanotubes but before the drawing process.   
     
     
         15 . The manufacturing method of  claim 14 , wherein a method of forming the metal layer comprises an electroplating process. 
     
     
         16 . The manufacturing method of  claim 12 , further comprising:
 mixing the carbon nanotubes with natural fiber material after forming the carbon nanotubes but before the drawing process.   
     
     
         17 . The manufacturing method of  claim 16 , wherein the natural fiber material comprises cotton, linen, wool, rabbit hair, silk, tencel or coffee. 
     
     
         18 . The manufacturing method of  claim 12 , wherein the carbon nanotube fiber yarns are used as one of the warp yarns and the weft yarns, and the material of the weft yarns is different from the material of the warp yarns during the weaving process. 
     
     
         19 . The manufacturing method of  claim 18 , wherein one of the warp yarns and the weft yarns comprises carbon nanotube fibers, and the other of the warp yarns and the weft yarns comprises cotton fiber yarn, linen fiber yarn, wool fiber yarn, rabbit hair fiber yarn, silk fiber yarn, tencel fiber yarn, coffee fiber yarn, nylon fiber yarn, polyester fiber yarn, rayon fiber yarn, acrylic fiber yarn or polyurethane fiber yarn. 
     
     
         20 . The manufacturing method of  claim 12 , wherein the material of the weft yarns is the same as the material of the warp yarns.