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EP1470285A1 - Materiau structural resistant au feu et tissus enduits fabriques a partir dudit materiau - Google Patents

Materiau structural resistant au feu et tissus enduits fabriques a partir dudit materiau

Info

Publication number
EP1470285A1
EP1470285A1 EP03708903A EP03708903A EP1470285A1 EP 1470285 A1 EP1470285 A1 EP 1470285A1 EP 03708903 A EP03708903 A EP 03708903A EP 03708903 A EP03708903 A EP 03708903A EP 1470285 A1 EP1470285 A1 EP 1470285A1
Authority
EP
European Patent Office
Prior art keywords
fabric
fire resistant
surfactant
layer
ofthe
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03708903A
Other languages
German (de)
English (en)
Inventor
Younger Ahluwalia
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Elk Premium Building Products Inc
Original Assignee
Elk Premium Building Products Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Elk Premium Building Products Inc filed Critical Elk Premium Building Products Inc
Publication of EP1470285A1 publication Critical patent/EP1470285A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/001—Fireproof means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/465—Coatings containing composite materials
    • C03C25/47—Coatings containing composite materials containing particles, fibres or flakes, e.g. in a continuous phase
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0036—Polyester fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/04—Foam
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/067—Flame resistant, fire resistant
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/126—Permeability to liquids, absorption
    • D06N2209/128—Non-permeable
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1671—Resistance to bacteria, mildew, mould, fungi

Definitions

  • the present invention also relates to a mattress fabric comprising a decorative fabric and a fabric material comprising a substrate coated with the structural materials of the present invention. Further, the present invention relates to a mattress comprising a decorative fabric and a fabric material comprising a substrate coated with the structural materials of the present invention. hi a particularly preferred embodiment, the coating does not bleed through the substrate during the material making process.
  • the substrate may be any suitable reinforcement material capable of withstanding processing temperatures and is preferably woven fiberglass.
  • FIG. 2 is a photograph showing the surfactant-generated microcells of another exemplary embodiment made in accordance with the present invention which further comprises a filler component;
  • the structural material may further include a cross-linking component, such as melamine (Borden Chemicals, Morganton, NC) and/or ammonium chloride.
  • a cross-linking component such as melamine (Borden Chemicals, Morganton, NC) and/or ammonium chloride.
  • the cross-linking component is useful to improve durability and surfactant-generated microcell structural strength, hi order to control the amount and rate of cross-linking, it may be desired to control the pH ofthe mixed components. For example, in acidic conditions (pH ⁇ 4.0), the cross-linking will occur very quickly and the mixture will have a short pot-life. At higher pH ( ⁇ 10.0), the cross-linking proceeds more slowly and may be controlled by heat.
  • the cross-linking component may increase the rate at which gel formation occurs and allow for gel formation to occur at a lower temperature. In addition, the cross-linking component may improve the strength of the material.
  • the structural material ofthe present invention may also comprise resin which may provide a polymer shell to encapsulate air.
  • the resin is DPG-38, available from Parachem of Dalton, GA.
  • the structural materials of the present invention have "bounceback” characteristics due to gel formation.
  • the "bounceback” characteristics may be further enhanced through the use of additional components.
  • "bounceback” refers to the ability ofthe material to return to its original shape after having been distorted, such as stretched or compressed.
  • the additional components may coat the inside ofthe microcell such that the microcell reverts to its original shape after having been distorted.
  • the structural materials ofthe present invention comprising a binder component, a surfactant component and a gel catalyst component may further comprise a filler component.
  • the filler component ofthe present invention preferably includes clay.
  • the clay is preferably China clay which is very soft and light, hi addition, the clay may be ParagonTM, which is a soft clay (i.e. it is soft to the touch), SuprexTM, which is a hard clay (i.e. it is hard to the touch), SuprexTM amino silane treated clay, which is used for crosslinking, because it will chemically bond with binder, and for highloading, BallclayTM, which has elastic properties (i.e.
  • the clay is BallclayTM 3380 which is particularly inexpensive compared to other clays.
  • the clay is Kaolin clay which is a lower grade China clay.
  • the clay is Texwhite 185 and/or ECC 1201 .
  • clay is a preferred filler because of its elongation properties (it has a low modulus), its abrasion resistance, its tear resistance, and its tensile strength. Moreover, clay is a good heat barrier; it does not disintegrate when an open flame (temperature ⁇ 1500 °F) is applied directly to a coating ofthe present invention that includes clay. In addition, clay provides a slick, elastic, glassy surface which exhibits flexibility. Furthermore, as noted, clay is inexpensive and thus can provide a low cost fabric material.
  • Decabromodiphenyloxide and antimony trioxide impart the following nonlimiting characteristics: (1) flame retardant properties, (2) capability of forming a char, and (3) capability of stopping the spread of flames. It is believed that the gas produced from the heating ofthe decabromodiphenyloxide can also act as a flame retardant because the gas uses up oxygen or depletes oxygen in the layer next to the fabric and suppresses or stops the fire from further progression.
  • the glass and ceramic microspheres help to increase the pot life ofthe coating. Heavier particles in the fillers, although they may comprise but a small percentage ofthe particles in the filler, have a tendency to settle near the bottom of a storage vessel. When glass and/or ceramic microspheres are mixed together with another filler, a dispersion is produced which has an increased pot life or shelf life. Without wishing to be bound by any particular theory, it is believed that as the filler particles naturally fall in the vessel and the glass and ceramic microspheres rise, the smaller size filler particles are supported by the glass and/or ceramic microspheres, thus enabling the microspheres to stay in solution and preventing the filler particles, to at least some extent, from descending to the bottom ofthe vessel.
  • the substrate ofthe present invention may be any suitable reinforcement material capable of withstanding processing temperatures, such as glass fibers, polyester fibers, cellulosic fibers, asbestos, steel fibers, alumina fibers, ceramic fibers, nylon fibers, graphite fibers, wool fibers, boron fibers, carbon fibers, jute fibers, polyolefin fibers, polystyrene fibers, acrylic fibers, phenolformaldehyde resin fibers, aromatic and aliphatic polyamide fibers, polyacrylamide fibers, polyacrylimide fibers or mixtures thereof which may include bicomponent fibers.
  • suitable reinforcement material capable of withstanding processing temperatures, such as glass fibers, polyester fibers, cellulosic fibers, asbestos, steel fibers, alumina fibers, ceramic fibers, nylon fibers, graphite fibers, wool fibers, boron fibers, carbon fibers, jute fibers, polyolefin fibers, polystyrene fibers, acrylic fibers, phenolformalde
  • the substrate may comprise a yarn, filament, monofilament or other fibrous material either as such or assembled as a textile, or any woven, non-woven, knitted, matted, felted, etc. material.
  • the polyolefm maybe polyvinyl alcohol, polypropylene, polyethylene, polyvinyl chloride, polyurethane, etc. alone or in combination with one another.
  • the acrylics may be DYNEL, ACRTLAN and/or ORLON.
  • RHOPLEX AC-22 and RHOPLEX AC- 507 are acrylic resins sold by Rohm and Haas which nay also may be used.
  • the cellulosic fibers may be natural cellulose such as wood pulp, newsprint, Kraft pulp and cotton and or chemically processed cellulose such as rayon and/or lyocell.
  • non-woven materials that may be useful in the present invention include non-woven, continuous fiberglass veils, such as FirmatTM 100, PearlveilTM 110, PearlveilTM 210, CurveilTM 120, CurveilTM 220, FlexiveilTM 130, FlexiveilTM 230 and Pultrudable veil (all available from Schmelzer Industries, Inc., Somerset, OH).
  • the woven materials may be AirlaidTM, SpunbondTM and NeedlepunchTM (available from BFG Industries, Inc. of Greensboro, NC).
  • Nonlimiting examples of filament materials include D, E, B, C, DE, G, H, K filaments of various grades, including electrical grade, chemical grade and high strength grade (all available from BFG Industries, Inc. of Greensboro, NC).
  • the substrate is a woven fiberglass mat.
  • a fiberglass mat includes nonwoven and woven fiberglass mats.
  • the substrate ofthe present invention is a woven fiberglass mat such as style 1625, style 1610 and style 1614 of BGF Industries (Greensboro, NC).
  • the Bureau of Home Furnishings and Thermal Insulation (“the Bureau”) issued a Technical Bulletin in October 1992 which provides a flammability test procedure for mattresses. See State of California Department of Consumer Affairs Bureau of Home Furnishings and Thermal Insulation Technical Bulletin 129, October 1992, Flammability Test Procedure for Mattresses for use in Public Buildings (California TB129).
  • the technical bulletin provides standard methods for fire testing of mattresses. The methods produce data describing the burning behavior from ignition of a mattress until all burning has ceased, or after a period of one hour has elapsed. The rate of heat release is measured by an oxygen consumption technique.
  • the Bureau indicates that mattresses complying with the test method will be safer and hopes that manufacturers will attempt to manufacture mattresses which pass the recommended tests.
  • a mattress manufactured with the fire resistant fabric material ofthe present invention complies with or exceeds the test standards recommended by both the NIST and the California TB129.
  • the fire resistant mattress material may be bonded or adhered to the mattress fabric, for example using a flexible and preferably nonflammable glue or stitched with fire resistant thread i.e., similar to a lining.
  • the fire resistant mattress fabric ofthe present invention may then be used by the skilled artisan to manufacture a mattress which has improved flammability characteristics.
  • the mattress comprises at least one first layer comprising a mattress fabric and at least one second layer adjacent to the first layer and comprising the fire resistant fabric material ofthe present invention.
  • the fabric ofthe first layer may be the mattress fabric discussed above, such as ticking, or a fabric comprising fibers selected from the group consisting essentially of cotton, polyester, rayon, polypropylene, and combinations thereof.
  • the non-woven sheeting layer may be any suitable material known in the art.
  • the non-woven sheet layer may be made from any noncombustible fibers, hi a preferred embodiment, the non-woven sheet layer is made from fiberglass fibers.
  • the mattress ofthe present invention may further comprise at least one third layer adj cent to the second layer and at least one fourth layer adjacent to the third layer wherein each ofthe third and fourth layer is a cushion layer and at least one fifth layer adjacent to the fourth layer and which comprises polyurethane foam.
  • the cushion layer may be made of polyester fibers or any fibers known in the art to be suitable for making a layer which provides cushioning, as long as the total weight ofthe ticking and the cushioning layer is less than 3 lbs.
  • the polyurethane foam maybe of varying thickness.
  • the mattress ofthe present invention may comprise at least one sixth layer adjacent to the fifth layer and comprising the fire resistant fabric material.
  • FIG. 3 shows an illustration of an exemplary mattress in accordance with the invention.
  • the polyurethane foam may be the second layer ofthe mattress (i.e. under the ticking and in place of polyester fiber).
  • the polyurethane foam layer provides a superior cushioning effect.
  • the total weight of polyurethane foam layer and the ticking must be less than 3 lbs because the polyurethane foam and the ticking burn and the mattress will not pass burn tests if more than 3 lbs is lost, hi such an embodiment, a preferred thickness for the foam is 0.25 inches.
  • the mattress ofthe present invention may further comprise a fire resistant border
  • the border ofthe present invention comprises a first layer comprising a mattress fabric; and a second layer adjacent to the first layer and comprising the fire resistant fabric material ofthe present invention.
  • the border may comprise a third layer adj acent to the second layer and which comprises a polyurethane foam.
  • the border may also comprise a fourth layer, adjacent to the third layer, and which comprises a non- oven sheet.
  • the border may comprise a fourth layer, adjacent to the third layer, and which comprises the fire resistant fabric material ofthe present invention and a fifth layer, adjacent to the fourth layer, and which comprises a non- woven sheet.
  • the mattress comprises at least one first layer comprising a mattress fabric at least one second layer, adjacent to the first layer, and which comprises the fire resistant fabric material ofthe present invention, at least one third layer adjacent to the second layer, and which comprises polyurethane foam, at least one fourth layer adjacent to the third layer, and which comprises a non woven sheet, at least one fifth layer adjacent to the fourth layer and which comprises a fibrous pad and at least one sixth layer adjacent to the fifth layer and which comprises another fibrous pad. All ofthe aforementioned embodiments ofthe mattress ofthe present invention pass all fire tests.
  • the second layer is a two ounce polyester fiber layer.
  • the coating ofthe fire resistant fabric material faces the first layer.
  • face the first layer means that the fire resistant fabric material has a coating on one or both sides. If the coating is on one side, that side faces the first layer, with the uncoated side facing away from the first layer, hi addition, the numbers ofthe layers indicates the order ofthe layers. For example, if the mattress fabric is the first layer, this layer is the top ofthe mattress, with the second layer being adjacent to the first layer, the third layer is adjacent to the second layer, and so on.
  • the mattresses ofthe present invention may comprise other layers which may comprise one or more fibrous pad layers and/or a spring layer.
  • the mattresses may also comprise a border, such as the border described above.
  • Further materials which may be incorporated into the mattress ofthe present invention include construction materials, such as non fire retardant or fire retardant thread for stitching the mattress materials together (e.g. glass thread or Kevlar thread) and non-fire retardant or fire retardant tape. Silicon oil may be used with Kevlar thread to diminish breakage and enhance production time.
  • conventional tape and/or conventional thread may be used and the mattress still complies with the California TB129 test requirements.
  • the fire resistant fabric materials include a substrate and a coating which comprises the structural material ofthe present invention.
  • the coating ( structural material) comprises approximately 34% by weight ofthe fire resistant fabric material, h the coating, about 10% to about 55% by weight is binder, about 2% to about 15% is surfactant, from about 5% to about 20% gel catalyst, and from about 0% to about 55% is filler, hi a preferred embodiment, the coating comprises about 42% binder, about 5% surfactant, about 13% gel catalyst and about 30% filler.
  • the filler is preferably about 30% clay.
  • the substrate is preferably woven glass.
  • the substrate may also be, for example, a woven fabric of DE, E, H, or G filament available from BFG Industries.
  • the substrate is approximately 64% by weight ofthe fire resistant fabric material.
  • the binder which bonds together the glass fibers is approximately about 25% to about 55% Rhoplex 3349 and/or Rovene 4402, or any other suitable binder.
  • suitable binders is provided herein above.
  • the substrate may be coated by air spraying, dip coating, knife coating, roll coating or film application such as lamination/heat pressing.
  • the coating may be bonded to the substrate by chemical bonding, mechanical bonding and/or thermal bonding. Mechanical bonding is achieved by force feeding the coating onto the substrate with a knife.
  • Structural materials and fire resistant fabric materials made in accordance with this invention may be of any shape. Preferably, such articles are planar in shape.
  • the structural materials may be used in any of a variety of products, including, but not limited to mattress/crib fabrics, mattress/crib covers, upholstered articles, bedroom articles, (including children's bedroom articles), draperies, carpets, wall coverings (including wallpaper) tents, awnings, fire shelters, sleeping bags, ironing board covers, fire resistant gloves, furniture, airplane seats and carpets, fire-resistant clothing for race car drivers, fire fighters, jet fighter pilots, and the like, building materials, such as roofing shingles, structural laminate facing sheets, building air duct liners, roofing underlayment (or roofing felt), underlayment for organic, built up roofing materials, roll roofing, modified roll products, filter media (including automotive filters), automotive hood liners, head liners, fire walls, vapor barriers etc.
  • the structural fabric material may be used alone or may be used as a liner for a decorative fabric, such as the type used for mattresses, drapes, sleeping bags, tents etc. which may also be fire resistant.
  • the substrate may be coated on one side or both sides depending on the intended application. For instance, if one side ofthe substrate is coated with the gel catalyst/surfactant/binder coating, the other surface can be coated with another material.
  • the other material may be conventional roofing asphalt, modified asphalts and non-asphaltic coatings, and the article can then be topped with roofing granules. It is believed that such roofing material could be lighter in weight, offer better fire resistance and better performance characteristics (such as cold weather flexibility, dimensional stability and strength) than prior art roofing materials.
  • the mixture comprising the binder, surfactant and filler may have a consistency of a light foam, such as shaving cream. It is believed that due to the low density ofthe mixture, the surfactant-generated microcells formed therein do not pass through the substrate when applied thereto. If desired, however, the viscosity of he coating maybe increased through mixing to ensure that it does not bleed through the substrate.
  • thickening agents include Acrysol ASE-95NP, Acrysol ASE-60, Acrysol ASE- 1000, Rhoplex ASE-75, Rhoplex ASE-108NP, and Rhoplex E-1961, all available from Rohm & Haas.
  • the fire resistant material may be coated with a water repellent material or the water repellent material may be added in the coating (i.e., internal water proofing).
  • a water repellent material i.e., internal water proofing
  • Two such water repellent materials are AurapelTM 33 OR and AurapelTM 391 available from Sybron/Tanatex of Norwich, Connecticut.
  • Omnova SequapelTM and Sequapel 417 available from Omnovasolutions, h e.
  • wax emulsions oil emulsions, silicone emulsions, polyolefin emulsions and sulfonyls as well as other similar performing products may also be suitable water repellent materials. These materials are also useful, as mentioned above, for imparting bounceback characteristics to the fire resistant material ofthe invention. Water repellents may be particularly preferred for example, in the manufacture of crib mattresses, for airplane seats and in the manufacture of furniture, particularly for industrial use.
  • a defoamer may also be added to the coating ofthe present invention to reduce and/or eliminate foaming during production.
  • One such defoamer is Y-250 available from Drews Industrial Division of Boonton, NJ.
  • color pigments including, but not limited to, T-l 13 (Abco, hie), W-4123 Blue Pigment, W2090 Orange Pigment, W7717 Black Pigment and W6013 Green Pigment, iron oxide red pigments (available from Engelhard of Louisville, KY) may also be added to the coating ofthe present invention to impart desired characteristics, such as a desired color.
  • the additional coatings of, e.g. water repellent material, antifungal material, antibacterial material, etc. may be applied to one or both sides of fire resistant materials and fire resistant fabric materials.
  • fire resistant fabric materials comprising substrates coated on one or both sides with filler/surfactant/binder coatings could be coated on one side with a water repellent composition and on the other side with an antibacterial agent.
  • the water repellent material, antifungal material, antibacterial material, etc. may be added to the coating before it is used to coat the substrate.
  • the applicant formulated the coating using just four major components, water, gel catalyst, surfactant and binder.
  • filler was also added (see Table I above). The components were mixed in a reaction or mixing kettle for 30 minutes at a temperature of 65-95°F. The coating was used to coat a fiberglass mat on one and both sides.
  • the mat was manufactured by BFG Industries, Inc. of Greensboro, North Carolina and was style number 1625 and had a basis weight in the range of 1.8 lb./sq. to 1.9 lb./sq. The mat had aporosity in the range of 600 to 650 cfm/ft 2 .
  • the coated article was durable and flexible and did not crack on bending and possessed "bounceback" characteristics.
  • Typical tensile strength measurements for uncoated versus coated were 47 lbs/3" and 171 lbs/3" respectively.
  • Typical Elmendorff tear strength measurements were ⁇ 3400 grams without the sample tearing.
  • the invention provides a fire resistant fabric material which is flexible, pliable and has good drapability characteristics and which shows no signs of cracking, etc.
  • the fabric material has a porosity of less than 18 cfm (uncoated has a porosity of 440 cfrn) and may adhere very well to other materials, including decorative fabrics, polyurethane foam, isocyanurate foam, asphaltic compounds, and granules (non-asphaltic shingle components).
  • the fire resistant fabric material may have few pinholes or may have numerous pinholes and still maintain a porosity of less than from approximately 5 to approximately 50 cfrn when coated with solvent based adhesive such as Firestone Bonding Adhesive BA-2004 which does not bleed through the coated product.
  • solvent based adhesive such as Firestone Bonding Adhesive BA-2004 which does not bleed through the coated product.
  • the application ofthe coating to the substrate was accomplished by knife coating.
  • the coating may also be performed by, frothing and knife coating, foaming and knife coating, foaming and knife coating and crushing, dip coating, roll coating (squeezing between two rolls having a gap that determines the thickness ofthe coating), by a hand-held coater which can be obtained from the Gardner Company, spraying, dipping and flow coating from aqueous or solvent dispersion, calendering, laminating and the like, followed by drying and baking, may be employed to coat the substrate as is well known in the art.
  • the samples were placed in an oven at approximately 325 °F for about 2.0 minutes to achieve gelling, drying and curing. Additionally, the coating may be separately formed as a film of one or more layers for subsequent combination with the substrate.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Composite Materials (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

La présente invention concerne un matériau structural résistant au feu. Ledit matériau comprend un composant tensioactif, des microcellules générées par le tensioactif, un composant catalyseur en gel et un composant de liaison. Ledit matériau structural peut également comprendre un composant de charge. De plus, la présente invention concerne des tissus comprenant un substrat enduit d'un revêtement comprenant ledit matériau structural résistant au feu. A présente invention concerne encore des articles de fabrication résistants au feu comprenant ledit tissu résistant au feu et notamment des matelas comprenant le tissu résistant au feu.
EP03708903A 2002-01-29 2003-01-29 Materiau structural resistant au feu et tissus enduits fabriques a partir dudit materiau Withdrawn EP1470285A1 (fr)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
US35269302P 2002-01-29 2002-01-29
US35269102P 2002-01-29 2002-01-29
US35269202P 2002-01-29 2002-01-29
US352693P 2002-01-29
US352691P 2002-01-29
US352692P 2002-01-29
PCT/US2003/002780 WO2003064757A1 (fr) 2002-01-29 2003-01-29 Materiau structural resistant au feu et tissus enduits fabriques a partir dudit materiau

Publications (1)

Publication Number Publication Date
EP1470285A1 true EP1470285A1 (fr) 2004-10-27

Family

ID=27670646

Family Applications (3)

Application Number Title Priority Date Filing Date
EP03708903A Withdrawn EP1470285A1 (fr) 2002-01-29 2003-01-29 Materiau structural resistant au feu et tissus enduits fabriques a partir dudit materiau
EP20030708904 Withdrawn EP1470286A1 (fr) 2002-01-29 2003-01-29 Materiau ignifuge et textiles fabriques a partir de ce materiau
EP20030707614 Withdrawn EP1470284A1 (fr) 2002-01-29 2003-01-29 Materiau ignifuge et textiles fabriques a partir de ce materiau

Family Applications After (2)

Application Number Title Priority Date Filing Date
EP20030708904 Withdrawn EP1470286A1 (fr) 2002-01-29 2003-01-29 Materiau ignifuge et textiles fabriques a partir de ce materiau
EP20030707614 Withdrawn EP1470284A1 (fr) 2002-01-29 2003-01-29 Materiau ignifuge et textiles fabriques a partir de ce materiau

Country Status (4)

Country Link
EP (3) EP1470285A1 (fr)
CA (3) CA2473646A1 (fr)
MX (3) MXPA04007184A (fr)
WO (3) WO2003064759A1 (fr)

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US7849542B2 (en) * 2006-06-21 2010-12-14 Dreamwell, Ltd. Mattresses having flame resistant panel
AU2015100604B4 (en) * 2015-05-06 2015-11-12 Bovell, Christopher Mervyn Mr Fire-retardant polyurethane foam mattress and method of manufacture thereof
ES2919132T3 (es) * 2015-05-06 2022-07-22 Christopher Mervyn Bovell Colchón de espuma de poliuretano ignífugo y método de fabricación del mismo

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See references of WO03064757A1 *

Also Published As

Publication number Publication date
MXPA04007184A (es) 2004-10-29
CA2473651A1 (fr) 2003-08-07
MXPA04007265A (es) 2004-10-29
EP1470286A1 (fr) 2004-10-27
EP1470284A1 (fr) 2004-10-27
WO2003064757A1 (fr) 2003-08-07
CA2473646A1 (fr) 2003-08-07
WO2003064759A1 (fr) 2003-08-07
WO2003064758A1 (fr) 2003-08-07
MXPA04007263A (es) 2004-10-29
CA2473648A1 (fr) 2003-08-07

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