CA2652282A1 - Fiber-containing article and method of manufacture - Google Patents
Fiber-containing article and method of manufacture Download PDFInfo
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- CA2652282A1 CA2652282A1 CA002652282A CA2652282A CA2652282A1 CA 2652282 A1 CA2652282 A1 CA 2652282A1 CA 002652282 A CA002652282 A CA 002652282A CA 2652282 A CA2652282 A CA 2652282A CA 2652282 A1 CA2652282 A1 CA 2652282A1
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- Prior art keywords
- fire
- article
- fire retardant
- fibrous mass
- component
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- Abandoned
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- 239000000835 fiber Substances 0.000 title claims abstract description 96
- 238000000034 method Methods 0.000 title claims abstract description 44
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 30
- 239000003063 flame retardant Substances 0.000 claims abstract description 87
- 230000009970 fire resistant effect Effects 0.000 claims abstract description 41
- 239000011248 coating agent Substances 0.000 claims abstract description 36
- 238000000576 coating method Methods 0.000 claims abstract description 36
- 239000012815 thermoplastic material Substances 0.000 claims abstract description 34
- 239000000203 mixture Substances 0.000 claims description 27
- 239000007788 liquid Substances 0.000 claims description 15
- 240000000797 Hibiscus cannabinus Species 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 13
- -1 polypropylene Polymers 0.000 claims description 13
- 239000004115 Sodium Silicate Substances 0.000 claims description 11
- 239000000843 powder Substances 0.000 claims description 11
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 11
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 11
- 244000025254 Cannabis sativa Species 0.000 claims description 9
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 claims description 9
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 claims description 9
- 239000004743 Polypropylene Substances 0.000 claims description 9
- 235000009120 camo Nutrition 0.000 claims description 9
- 235000005607 chanvre indien Nutrition 0.000 claims description 9
- 239000011487 hemp Substances 0.000 claims description 9
- 229920001155 polypropylene Polymers 0.000 claims description 9
- 230000005540 biological transmission Effects 0.000 claims description 7
- 230000009467 reduction Effects 0.000 claims description 7
- 244000198134 Agave sisalana Species 0.000 claims description 4
- 240000000491 Corchorus aestuans Species 0.000 claims description 4
- 235000011777 Corchorus aestuans Nutrition 0.000 claims description 4
- 235000010862 Corchorus capsularis Nutrition 0.000 claims description 4
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 4
- 235000004431 Linum usitatissimum Nutrition 0.000 claims description 4
- 230000015556 catabolic process Effects 0.000 claims description 4
- 238000006731 degradation reaction Methods 0.000 claims description 4
- 229910052708 sodium Inorganic materials 0.000 claims description 4
- 239000011734 sodium Substances 0.000 claims description 4
- 239000004677 Nylon Substances 0.000 claims description 3
- 239000004698 Polyethylene Substances 0.000 claims description 3
- 238000003490 calendering Methods 0.000 claims description 3
- 229920001577 copolymer Polymers 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- 239000008188 pellet Substances 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- 229920000573 polyethylene Polymers 0.000 claims description 3
- 229910019142 PO4 Inorganic materials 0.000 claims description 2
- 229910021538 borax Inorganic materials 0.000 claims description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 2
- 239000004327 boric acid Substances 0.000 claims description 2
- 235000010338 boric acid Nutrition 0.000 claims description 2
- 150000001642 boronic acid derivatives Chemical class 0.000 claims description 2
- 235000021317 phosphate Nutrition 0.000 claims description 2
- 150000003013 phosphoric acid derivatives Chemical class 0.000 claims description 2
- 239000004328 sodium tetraborate Substances 0.000 claims description 2
- 235000010339 sodium tetraborate Nutrition 0.000 claims description 2
- 240000006240 Linum usitatissimum Species 0.000 claims 1
- 229920001169 thermoplastic Polymers 0.000 abstract description 20
- 239000004416 thermosoftening plastic Substances 0.000 abstract description 20
- 239000011230 binding agent Substances 0.000 abstract description 11
- 239000000463 material Substances 0.000 description 18
- 239000007921 spray Substances 0.000 description 16
- 239000000243 solution Substances 0.000 description 12
- 239000011152 fibreglass Substances 0.000 description 10
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 9
- 238000005192 partition Methods 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
- 239000000779 smoke Substances 0.000 description 7
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 6
- 241000196324 Embryophyta Species 0.000 description 6
- 239000007864 aqueous solution Substances 0.000 description 4
- 241000208202 Linaceae Species 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 238000007664 blowing Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000012855 volatile organic compound Substances 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 238000007766 curtain coating Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229930014626 natural product Natural products 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K21/00—Fireproofing materials
- C09K21/14—Macromolecular materials
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/4334—Polyamides
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
- D04H1/43828—Composite fibres sheath-core
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/38—Boron-containing compounds
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Textile Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Manufacturing & Machinery (AREA)
- Building Environments (AREA)
- Fireproofing Substances (AREA)
Abstract
A fire resistant or acoustical article comprising a bast fiber component, a thermoplastic material that acts as a binder, and a first fire retardant component, the article having a coating of a second fire retardant component, such that the article may be used in the manufacture of structures having a Class A fire rating. According to one method of manufacture, a fibrous mass including a bast fiber component and a thermoplastic binder is heated and compressed to a desired thickness and density, followed by the dispersal of the first fire retardant there through, and coated with the second fire retardant component.
Description
FIBER-CONTAINING ARTICLE AND METHOD OF MANUFACTURE
TECHNICAL FIELD
This invention relates to a fire-resistant and/or acoustical absorbing article comprising a portion of natural fibers. More particularly, this invention relates to a fire-resistant and/or acoustical absorbing article having a portion of natural fibers and being suitable for use in the manufacture of fire-retardant and/or acoustical absorbing structures, and to a method of manufacturing such an article.
BACKGROUND
Fiberglass is well known for use as a component of office furniture, office partitions, and other structures used in office, school, commercial, and industrial settings.
Fiberglass has many advantages for such applications. It is relatively inexpensive, it can be worked into a variety of shapes and densities, and it has good fire-resistance properties.
1s Recently, however, concerns have been raised about such ubiquitous uses of fiberglass. Some have expressed concerns about health or safety risks that might occur during the use or manufacture of fiberglass articles. Concerns also have been raised about the use of certain volatile organic compounds and adhesive systems, such as aidehyde compounds and formaldehyde in particular, that are typically involved in fiberglass-containing structures. Thus there has been increased customer interest in office furniture and other office products that do not include fiberglass as a component.
Agricultural fibers are gaining interest as a natural, renewable resource with potential for use in a variety of manufactured products. In particular, bast fibers such as industrial hemp, kenaf, jute, sisal and flax can be made into non-woven sheet-like products in roll form that can then be used in subsequent manufacturing processes. In some situations, bast fiber products are preferred as natural products that do not harm the environment and that do require the use of volatile organic compounds. It is known to manufacture articles using bast fibers and a thermoplastic binder, as disclosed for example, in U.S. 5,709,925, which discloses the use of such a composition for an interior trim panel for a motor vehicle.
For furniture and other structures intended for use in an office environment it is desirable to have a Class A fire resistance rating. This means that such products have a flame spread index of 25 or less, and a smoke generation index of 450 or less, as measured by the test procedures set forth in ASTM E 84 and UL
723. Agricultural fibers however are inherently flammable. Thus, when such agricultural fiber products are used in an office environment, the products typically include some treatment to provide for adequate flame resistance or to meet Class A requirements.
One such effort to make a fire-resistant article with natural fibers is described in U.S. Patent Application Publication No. US 2004/0028958 Al, wherein a moldable batt comprises a fire-retardant cellulose, a fiber component, and a binder component, the batt being compressed and heated to form fire-resistant panels or other products that are said to be particularly useful in the office furniture industry.
SUMMARY OF THE INVENTION
It is thus one objective of the invention to provide an article that can be used in the manufacture of office furniture, partitions, and other structures, which article does not include fiberglass.
It is thus another objective of the invention to provide an article that can be used in the manufacture of office furniture, partitions, and other structures, which article includes bast fibers as a component thereof yet which meets the standards for a Class Afire resistance rating and which has desirable acoustical absorbing properties.
In accordance with the invention, a fire-resistant article comprises a fibrous mass having both a natural fiber component and a thermoplastic binder and about 5-40 wt. % (based on the weight of the fibrous mass) of a first fire retardant component mixed therein. The fibrous mass comprises about 1-50 wt.%
thermoplastic binder and about 50-99 wt.% natural fiber. In addition, the fibrous mass has a coating of a second fire retardant component of about 1-30 wt.% on the exterior surfaces thereof. By appropriate selection of the natural fibers, the thermoplastic binder, and the first and second fire retardant components, it is possible to make an article having both flame spread index values and smoke generation index values that fall within the Class A fire rating. Moreover, the article is made free of fiberglass and free of the formaldehyde commonly used with fiberglass.
In one embodiment, the fiber mass comprises about 10-50 wt.%
thermoplastic binder and about 50-90 wt.% natural fiber and in other embodiments comprises about 10-30 wt.% thermoplastic binder and 70-90 wt.% natural fiber.
In another embodiment, the fiber mass comprises about 5-40 wt.% of the first fire retardant component and in other embodiments comprises about 5-15 wt.% of the first fire retardant component.
The natural fiber content of the fiber component may be made up of a variety of bast fibers, including fibers such as kenaf, jute, industrial hemp, sisal, flax, and mixtures thereof. In some embodiments a mixture of kenaf and industrial hemp is used. In other embodiments, kenaf alone is used. Natural fibers are a renewable resource, and one which does not emit potentially hazardous materials into the environment. The thermoplastic material or binder is mixed with the natural fiber in sufficient quantity to bind the fibers together upon the application of heat. Suitable thermoplastic binders or materials include polypropylene, polyethylene, polyesters, nylon, copolymers, and mixtures thereof. The thermoplastic materials may be in the form of fibers, bi-component fibers, powders, or pellets.
One embodiment of the inventive method of making a fire-resistant article comprises the steps of providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, dispersing a first fire retardant component in the fibrous mass, compressing and heating the fibrous mass to form a shaped article, and applying a coating of a second fire retardant component to the shaped article. The first fire retardant component may be in a powder form that is either blown through the fibrous mass or drawn through under reduced pressure. After the first fire retardant is dispersed through the fibrous mass, the mass is heated to a temperature above the softening temperature of the thermoplastic material but below the temperature where undesired thermal degradation of the natural fibers occurs, and is then compressed. Suitable compression apparatus include, for example, platens, nip rollers, or flat bed laminators. The second fire retardant may be applied to the outer surfaces of the compressed mass such as in a solution or liquid medium. In one embodiment of the method, the article may be heated again to drive off any water used in the solution or liquid medium.
Another embodiment of the inventive method of making a fire-resistant article comprises the steps of providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, compressing and heating the fibrous mass to form a shaped article, and then dispersing a first fire retardant component into the shaped article. A second fire retardant component can be applied on the shaped article after the dispersal of the first fire retardant component into the shaped article. The first fire retardant component may be in a powder form that is either blown through the fibrous mass, drawn through under reduced pressure, or scattered on the surface of the fibrous mass. Alternatively, the first fire retardant component may be applied in a solution or other liquid form. The second fire is retardant may be applied to the outer surfaces of the shaped article such as in a powder, solution, foamed or liquid form. In one embodiment of the method, the article may be heated again to drive off any water used in the solution or liquid medium.
In an alternative method, the first flame retardant component may be dispersed through the fibrous mass, the second flame retardant component can be applied to the outer surfaces of the fibrous mass, and the mass can be compressed with heat to soften the thermoplastic materials, to bind the natural fibers, and to drive off any water used in the solution or liquid medium from the application of the second flame retardant component.
Through appropriate choices of materials and processing conditions, the resulting article can be made to have a flame spread index and smoke generation index low enough to meet a Class A fire rating, as well as having desirable acoustical properties. An article can be designated as having a Class A fire rating if the flame spread index (FSI) is less than 25 and the smoke generation index is 450 or less. Additionally, the article is considered to have desirable acoustical properties if a suitable structure made of the article, such as office partition panels for example, has a sound transmission class (STC) above 15 and/or a noise reduction coefficient above 0.5 The article can be used in the manufacture of office dividers or partition panels, ceiling tiles, bulletin boards, and other structures requiring a Class A fire rating that are used in office, school, commercial and industrial settings.
DESCRIPTION OF THE DRAWINGS
The present invention can be more readily understood by reference to the following drawings.
FIG. 1 is a schematic drawing of a method of making a fire-resistant article of the present invention.
FIG. 2 is a schematic drawing of an alternative method of making a fire-io resistant article of the present invention.
FIG. 3 is a schematic drawing of another alternative method of making a fire-resistant article of the present invention.
FIG. 4 is a schematic drawing of a further alternative method of making a fire-resistant article of the present invention.
is FIG. 5 is a schematic drawing of yet another alternative method of making a fire-resistant article of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A fire-resistant article of the present invention comprises a fibrous mass having a fiber component and about 5-40 wt.% of a first fire retardant component 20 mixed therein; the fiber component comprising about 1-50 wt.% thermoplastic and about 50-99 wt.% natural fiber, the fibrous mass having a coating of a second fire retardant component of about 1-30 wt.% on the exterior surfaces thereof.
Additionally, the fire-resistant article has a Class A fire rating and desirable acoustical properties.
25 The fibrous mass used in the manufacture of the fire-resistant article can be provided in the form of long sheets shipped as rolls. Such rolls may be commercially fabricated to include natural fibers and thermoplastic materials to a purchaser's specifications.
The natural fiber component of the fibrous mass is derived from the family 30 of bast fiber plants in which a plant stalk has bast fibers and a core. The preferred bast fiber plants will be those in which the bast fibers are readily separated from the core of the stalk. Particularly suitable bast fiber plants for this purpose include kenaf, jute, industrial hemp, sisal, and flax. Any of these plant materials may be used alone or in combination with each other, and in various proportions. The selection of the plant materials to be used will be based on ease of manufacture into the fibrous mass for use in the invention, cost, availability, and fire resistance in the finished article based on empirical tests. In one embodiment, a mixture of kenaf and industrial hemp is used. In another embodiment, only kenaf is used.
Further, while various proportions of the different fibers can be used, a fibrous mass in which the natural fiber component comprises kenaf and industrial hemp fibers in about equal proportions by weight is used.
The thermoplastic material or component should have a softening temperature below a temperature that would cause undesired thermal degradation of the natural fibers. Suitable thermoplastic components can be selected from the group consisting of polypropylene, polyethylene, polyesters, nylon, copolymers, and mixtures thereof. Of these, polypropylene is suitable because of its ready availability and its low cost. The thermoplastic component in the form of fibers may be readily incorporated in the fibrous mass in the initial manufacture thereof.
In one embodiment, the fibers may include bi-component fibers, in which fibers of a first thermoplastic material are coated or encased within a second thermoplastic material having a lower softening temperature. Alternatively, the thermoplastic component may be in other forms such as powders or pellets that can be readily incorporated in the fibrous mass.
Because of the inherent flammability of both the natural fibers and the thermoplastic materials used in the fibrous mass, a first fire retardant is dispersed throughout the fibrous mass. The first fire retardant component may be selected from materials such as borates, polyborates, boric acid, borax, phosphates, or mixtures of these materials. Of these, sodium polyborate is suitable.
The first fire retardant may be dispersed through the fibrous mass either before or after being compressed by any one of several methods. Where the first fire retardant is provided in the form of a powder having a bulk particle size of about 10-30 microns (450-800 mesh), such methods can include blowing the fire retardant powder into sheets of the fibrous mass onto one or both sides of the fibrous mass, or drawing the fire retardant powder through sheets of the fibrous mass with a reduction in pressure on one side thereof, or using a combination of blowing on one side of the sheet of fibrous mass and creating a region of reduced pressure on the other side.
Alternatively, the first fire retardant can be incorporated into the fibrous mass during the production thereof such as by pre-mixing with the natural fiber component, pre-mixing with the thermoplastic component, or by mixing together with the natural fiber and thermoplastic component, prior to or during the formation of the fibrous mass. After the first fire retardant is dispersed in the fibrous mass, the fibrous mass is then heated to a temperature above the softening temperature of the thermoplastic component to allow the thermoplastic material to soften and bind the natural fibers of the mass. The heated mass is compressed to a desired thickness and then optionally cooled for a period of time while in the compressed state so that the mass retains the desired thickness and achieves the desired rigidity.
A second fire retardant is applied as a coating to the exterior surfaces of the fibrous mass. Sodium silicate has been found to be well suited to this purpose. In one embodiment, the second fire retardant is present in a solution of liquid medium as either a solution, a suspension or a mixture. This composition may be applied onto the surfaces of the compressed fibrous mass by techniques such as spraying, brushing, roll coating, curtain coating, froth coating and dipping.
In one embodiment, the coating is applied by spraying an aqueous solution including at least 40 wt.% sodium silicate. The coating is then allowed to dry, optionally with heating to drive off the water from the aqueous solution so that the coating sets.
The fire-resistant article of the present invention has a Class A fire rating.
Specifically, the fire-resistant article when incorporated into a completed structural panel that includes conventional covering materials, additional adhesives and, optionally, spacer materials in a laminated construction, has a flame spread index (FSI) below 25 or from 0 to 25 and a smoke generation index below 450 or from to 450. More particularly, the fire-resistant article of the present invention in some embodiments has a FSI of 0 to 15 and a smoke generation index of 0 to 100.
Additionally, the fire-resistant article has desirable acoustical properties.
The noise reduction coefficient (NRC) as well as the sound transmission class (STC) are useful indicators of the acoustical properties of a given material.
The Noise Reduction Coefficient (NRC) is a scalar representation of the amount of sound energy absorbed upon striking a particular surface. In particular, it is the average of four sound absorption coefficients of the particular surface at frequencies of 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz. The Sound Transmission Class (STC) is a widely used integer-number rating of how well a building partition attenuates airborne sound. It is used to rate interior walls, ceilings/floors, doors, windows and exterior wall configurations. The number is derived from sound attenuation values tested at sixteen standard frequencies from 125 Hz to 4000 Hz.
io These transmission-loss values are then plotted on a sound pressure level graph and the resulting curve is compared to a standard reference contour. These values are fit to the appropriate TL Curve (or Transmission Loss) to determine the STC rating. The fire-resistant article when incorporated into a completed structural panel that includes conventional covering materials, additional adhesives and, optionally, spacer materials in a laminated construction, has a noise reduction coefficient (NRC) ranging from 0.35 to 0.65 and a sound transmission class ranging from 15 to 28.
In one embodiment, for example, a fibrous mass made of a 1300 gsm mat of kenaf and polypropylene was heated and compressed according to the method of the present invention to a thickness of 0.25 inches. Powdered polyborate was added to the compressed mat (15-20 wt.%) followed by the addition of sodium silicate (about 1.2 oz. sodium silicate solids per square foot per side). When incorporated into a structural panel, this compressed and treated mat provided a panel having an STC of 25-26 and a NRC of 0.3-0.4. In another embodiment, a fibrous mat made of 1300 gsm mat of kenaf and polypropylene was heated and compressed according to the method of the present invention to a thickness of 0.275 inches. Powdered polyborate was added to the compressed mat (25-30 wt.%) followed by the addition of sodium silicate (about 1.5-2.5 oz. sodium silicate solids per square foot per side). When incorporated into a structural panel, this compressed and treated mat provided a panel having a STC of 15 and above and a NRC of 0.05 and above.
The present invention further encompasses alternative methods of making the fire-resistant article. One inventive method comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) dispersing a first fire retardant component in the fibrous mass, (c) heating the fibrous mass to a temperature above the softening temperature of the thermoplastic material but below the thermal degradation temperature of the natural fibers, (d) compressing the fibrous mass to form a shaped article, (e) applying a coating of a second fire retardant component to the shaped article;
and (f) drying the coating.
Another inventive method comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) heating the fibrous mass to a temperature above the softening temperature of the thermoplastic material, (c) compressing the fibrous mass to form a shaped article, (d) dispersing a first fire retardant component in the fibrous mass forming the shaped article, (e) applying a coating of a second fire retardant component to the shaped article; and (f) drying the coating.
A further inventive method of the present invention comprises the steps of (a) dispersing a first flame retardant component through a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) applying a second flame retardant component to the outer surfaces of the fibrous mass, (c) compressing the mass with heat to both soften the thermoplastic materials to bind the natural fibers and to drive off any water used in the solution or liquid medium from the application of the second flame retardant component.
One method of making the fire-resistant article of the present invention is schematically illustrated in FIG. 1. The fibrous mass 10 is passed through an oven 19 where it is heated to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic material to soften and bind the natural fibers. The heated mass is then passed to a calendaring unit for decreasing the thickness and increasing the density of the fibrous mass 10. As shown in FIG. 1, the calendaring unit includes a set of three nip rollers 25a, 25b and 25c, for decreasing the thickness and increasing the density of the fibrous mass 10. Alternatively, as shown in FIGS. 3 and 4, the fibrous mass 10 can be passed through a press where it is pressed between two press platens 22, 24. In alternative embodiments, any process that provides suitable heat and compression is suitable. The mass is held at the thickness while it is allowed to cool. The fibrous sheet 10 is then conveyed beneath a dispenser 12 that dispenses the first fire retardant 14 to be dispersed within the fibrous mass 10. The dispersal of the first fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass. The choice of whether to use a blower system 16, a vacuum assist 18, or both, may depend on the types of fibers in the fibrous mass, the type of fire retardant used, and the density of the fibrous mass.
The fibrous mass 10 is then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will io be appreciated that an apparatus with one spray head could be used if the mass is sprayed first on one side and then on the other. The spray heads 32, 34 spray both surfaces of the fibrous mass 10 with a composition 36 containing a second fire retardant material that forms a coating 40 on the exterior surfaces of the fibrous mass 10. The article 50 is the compressed fibrous mass 10 with the first fire retardant dispersed therein and having a coating 40 of the second fire retardant. The coating 40 on the article 50 is allowed to set; this last step can be facilitated by heating the article 50 with a heat source 42 to drive off any liquid medium from the mixture 36, with or without a vacuum assist or forced air.
In a variation of the above-described embodiment of the invention, the shaped article is passed through at least one additional set of rollers 28a-c as shown in FIG. 2. During the application of the second fire retardant component in the form of a solution or spray, the liquid from the second fire retardant component can cause the natural fibers on the exterior surface of the shaped article to expand. The expanded natural fibers on the exterior surface of the shaped article may extend away from the surface creating a fuzz-like appearance or texture.
The shaped article may be passed through at least one additional set of rollers 28a-c in order to remove any excess liquid from the shaped article and to compress and smooth any extended fibers formed on the exterior surface of the shaped article resulting from the application of the second fire retardant component.
An alternative method of making the fire-resistant article of the present invention is schematically illustrated in FIG. 3. A sheet 10 of a fibrous mass comprising natural fibers and a thermoplastic material is conveyed beneath a dispenser 12 that dispenses the first fire retardant to be dispersed within the fibrous mass. The dispersal of the first fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass. The choice of whether to use a blower system 16, a vacuum assist 18, or both, may depend on the types of fibers in the fibrous mass, the type of fire retardant used, and the density of the fibrous mass. After the first fire retardant is applied, the fibrous mass 10 is passed through an oven 19 where it is heated to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic io material to soften and bind the natural fibers. The heated mass is then passed to a press 20 where it is pressed between two press platens 22, 24, which decreases the thickness and increases the density of the fibrous mass 10. The mass is held at the thickness while it is allowed to cool. The fibrous mass 10 is then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will be appreciated that an apparatus with one spray head could be used if the mass 10 is sprayed first on one side and then on the other. The spray heads 32, 34 spray both surfaces of fibrous mass 10 with a composition 36 containing a second fire retardant material that forms a coating 40 on the exterior surfaces of the fibrous mass 10. The article 50 is the compressed fibrous mass 10 with the first fire retardant dispersed therein and having a coating 40 of the second fire retardant.
The coating 40 on the article 50 is allowed to set; this last step can be facilitated by heating the article 50 with a heat source 42 to drive off any liquid medium from the mixture 36, with or without a vacuum assist or forced air.
Another method of making a fire-resistant article of the present invention comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) dispersing a first fire retardant component in the fibrous mass, (c) applying a coating of a second fire retardant component to the fibrous mass, (d) heating the fibrous mass, and (e) compressing the fibrous mass to form a shaped article, and allowing the compressed mass to cool. In this method, the heating and compression steps can be conducted separately or simultaneously. The materials that can be used in this second method are the same as those that can be used in the first method. This method is illustrated in FIG. 4, wherein the same elements shown in FIG. 3 are indicated by the same reference numerals. Referring to FIG. 4, a sheet 10 of a fibrous mass comprising natural fibers and a thermoplastic material is conveyed beneath a dispenser 12 that dispenses the first fire retardant 14 to be dispersed within the fibrous mass 10. The dispersal of the fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass. The choice of whether to use a blower system 16, a vacuum assist 18, or both, may depend on the types of fibers in the fibrous mass, the type of fire retardant used, and the density of the io fibrous mass. After the first fire retardant is applied, the fibrous mass 10 is then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will be appreciated that an apparatus with one spray head could be used if the mass 10 is sprayed first on one side and then on the other. The spray heads 32, 34 spray both surfaces of the fibrous mass 10 with a mixture 36 containing a second fire retardant material present in a liquid medium that forms a coating 40 around fibrous mass 10. The fibrous mass 10 is then passed to a heating press 20 where it is pressed between two press platens 22, 24 with heat to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic material to bind the natural fibers, while decreasing the thickness and increasing the density of the fibrous mass 10. This step also can drive off the liquid medium from the coating 40. The resulting article can be used to produce a satisfactory Class A rated fire resistant structure.
Another method of making the fire-resistant article of the present invention is schematically illustrated in FIG. 5. In this variation of the method illustrated in FIG. 1, a sheet 10 of a fibrous mass comprising natural fibers and a thermoplastic material is conveyed beneath a dispenser 12 that dispenses the first fire retardant to be dispersed within the fibrous mass. The dispersal of the first fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass as described above. After the first fire retardant is applied, the fibrous mass 10 is passed through an oven 19 where it is heated to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic material to soften and bind the natural fibers. The heated mass is then passed to a set of three nip rollers 25a, 25b and 25c, which decreases the thickness and increases the density of the fibrous mass 10. After passing through the nip rollers 25a, 25b and 25c, the fibrous mass 10 is cooled and then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will be appreciated that an apparatus with other methods of applying the coating onto the exterior surfaces of the fibrous mass would be suitable. The spray heads 32, 34 spray both surfaces of fibrous mass 10 with a composition 36 containing a second fire retardant material that lo forms a coating 40 on the exterior surfaces of the fibrous mass 10. The coating 40 on the article 50 is allowed to set; this last step can be facilitated by heating the article 50 with a heat source 42 to drive off any water from the composition 36.
The fire-resistant and/or acoustical absorbing article disclosed herein avoids the use of fiberglass and added formaldehyde-containing materials. The is article so made can be used in the manufacture of furniture, office partition panels, ceiling tiles, bulletin boards, and other articles and structures useful in office, school, and industrial environments that require Class A fire-resistant structure and/or noise control. Articles made according to the present method also have satisfactory structural properties. For example, articles having a density in a 20 range of 17-24 pcf were found to have a modulus of elasticity (MOE) of more than 300,000 psi across the width and more than 270,000 psi across the length for multiple samples tested in a three point bend test modeled after ASTM D 1037-96a (the testing deviated from the ASTM methods because the samples were not conditioned, the moisture content was not measured and the sample size span 25 was greater than the ASTM standard). In addition, the various samples were found to have a modulus of rupture (MOR) of more than 1900 psi across the width and more than 1800 across the length of the samples.
A fibrous mass is provided comprising about 20% by weight of 30 polypropylene fibers and about 80% by weight of a natural fiber component, the component containing 50% by weight of kenaf fiber and 50% by weight of industrial hemp fiber. The mass is heated to a temperature of about 375 -380 F
TECHNICAL FIELD
This invention relates to a fire-resistant and/or acoustical absorbing article comprising a portion of natural fibers. More particularly, this invention relates to a fire-resistant and/or acoustical absorbing article having a portion of natural fibers and being suitable for use in the manufacture of fire-retardant and/or acoustical absorbing structures, and to a method of manufacturing such an article.
BACKGROUND
Fiberglass is well known for use as a component of office furniture, office partitions, and other structures used in office, school, commercial, and industrial settings.
Fiberglass has many advantages for such applications. It is relatively inexpensive, it can be worked into a variety of shapes and densities, and it has good fire-resistance properties.
1s Recently, however, concerns have been raised about such ubiquitous uses of fiberglass. Some have expressed concerns about health or safety risks that might occur during the use or manufacture of fiberglass articles. Concerns also have been raised about the use of certain volatile organic compounds and adhesive systems, such as aidehyde compounds and formaldehyde in particular, that are typically involved in fiberglass-containing structures. Thus there has been increased customer interest in office furniture and other office products that do not include fiberglass as a component.
Agricultural fibers are gaining interest as a natural, renewable resource with potential for use in a variety of manufactured products. In particular, bast fibers such as industrial hemp, kenaf, jute, sisal and flax can be made into non-woven sheet-like products in roll form that can then be used in subsequent manufacturing processes. In some situations, bast fiber products are preferred as natural products that do not harm the environment and that do require the use of volatile organic compounds. It is known to manufacture articles using bast fibers and a thermoplastic binder, as disclosed for example, in U.S. 5,709,925, which discloses the use of such a composition for an interior trim panel for a motor vehicle.
For furniture and other structures intended for use in an office environment it is desirable to have a Class A fire resistance rating. This means that such products have a flame spread index of 25 or less, and a smoke generation index of 450 or less, as measured by the test procedures set forth in ASTM E 84 and UL
723. Agricultural fibers however are inherently flammable. Thus, when such agricultural fiber products are used in an office environment, the products typically include some treatment to provide for adequate flame resistance or to meet Class A requirements.
One such effort to make a fire-resistant article with natural fibers is described in U.S. Patent Application Publication No. US 2004/0028958 Al, wherein a moldable batt comprises a fire-retardant cellulose, a fiber component, and a binder component, the batt being compressed and heated to form fire-resistant panels or other products that are said to be particularly useful in the office furniture industry.
SUMMARY OF THE INVENTION
It is thus one objective of the invention to provide an article that can be used in the manufacture of office furniture, partitions, and other structures, which article does not include fiberglass.
It is thus another objective of the invention to provide an article that can be used in the manufacture of office furniture, partitions, and other structures, which article includes bast fibers as a component thereof yet which meets the standards for a Class Afire resistance rating and which has desirable acoustical absorbing properties.
In accordance with the invention, a fire-resistant article comprises a fibrous mass having both a natural fiber component and a thermoplastic binder and about 5-40 wt. % (based on the weight of the fibrous mass) of a first fire retardant component mixed therein. The fibrous mass comprises about 1-50 wt.%
thermoplastic binder and about 50-99 wt.% natural fiber. In addition, the fibrous mass has a coating of a second fire retardant component of about 1-30 wt.% on the exterior surfaces thereof. By appropriate selection of the natural fibers, the thermoplastic binder, and the first and second fire retardant components, it is possible to make an article having both flame spread index values and smoke generation index values that fall within the Class A fire rating. Moreover, the article is made free of fiberglass and free of the formaldehyde commonly used with fiberglass.
In one embodiment, the fiber mass comprises about 10-50 wt.%
thermoplastic binder and about 50-90 wt.% natural fiber and in other embodiments comprises about 10-30 wt.% thermoplastic binder and 70-90 wt.% natural fiber.
In another embodiment, the fiber mass comprises about 5-40 wt.% of the first fire retardant component and in other embodiments comprises about 5-15 wt.% of the first fire retardant component.
The natural fiber content of the fiber component may be made up of a variety of bast fibers, including fibers such as kenaf, jute, industrial hemp, sisal, flax, and mixtures thereof. In some embodiments a mixture of kenaf and industrial hemp is used. In other embodiments, kenaf alone is used. Natural fibers are a renewable resource, and one which does not emit potentially hazardous materials into the environment. The thermoplastic material or binder is mixed with the natural fiber in sufficient quantity to bind the fibers together upon the application of heat. Suitable thermoplastic binders or materials include polypropylene, polyethylene, polyesters, nylon, copolymers, and mixtures thereof. The thermoplastic materials may be in the form of fibers, bi-component fibers, powders, or pellets.
One embodiment of the inventive method of making a fire-resistant article comprises the steps of providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, dispersing a first fire retardant component in the fibrous mass, compressing and heating the fibrous mass to form a shaped article, and applying a coating of a second fire retardant component to the shaped article. The first fire retardant component may be in a powder form that is either blown through the fibrous mass or drawn through under reduced pressure. After the first fire retardant is dispersed through the fibrous mass, the mass is heated to a temperature above the softening temperature of the thermoplastic material but below the temperature where undesired thermal degradation of the natural fibers occurs, and is then compressed. Suitable compression apparatus include, for example, platens, nip rollers, or flat bed laminators. The second fire retardant may be applied to the outer surfaces of the compressed mass such as in a solution or liquid medium. In one embodiment of the method, the article may be heated again to drive off any water used in the solution or liquid medium.
Another embodiment of the inventive method of making a fire-resistant article comprises the steps of providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, compressing and heating the fibrous mass to form a shaped article, and then dispersing a first fire retardant component into the shaped article. A second fire retardant component can be applied on the shaped article after the dispersal of the first fire retardant component into the shaped article. The first fire retardant component may be in a powder form that is either blown through the fibrous mass, drawn through under reduced pressure, or scattered on the surface of the fibrous mass. Alternatively, the first fire retardant component may be applied in a solution or other liquid form. The second fire is retardant may be applied to the outer surfaces of the shaped article such as in a powder, solution, foamed or liquid form. In one embodiment of the method, the article may be heated again to drive off any water used in the solution or liquid medium.
In an alternative method, the first flame retardant component may be dispersed through the fibrous mass, the second flame retardant component can be applied to the outer surfaces of the fibrous mass, and the mass can be compressed with heat to soften the thermoplastic materials, to bind the natural fibers, and to drive off any water used in the solution or liquid medium from the application of the second flame retardant component.
Through appropriate choices of materials and processing conditions, the resulting article can be made to have a flame spread index and smoke generation index low enough to meet a Class A fire rating, as well as having desirable acoustical properties. An article can be designated as having a Class A fire rating if the flame spread index (FSI) is less than 25 and the smoke generation index is 450 or less. Additionally, the article is considered to have desirable acoustical properties if a suitable structure made of the article, such as office partition panels for example, has a sound transmission class (STC) above 15 and/or a noise reduction coefficient above 0.5 The article can be used in the manufacture of office dividers or partition panels, ceiling tiles, bulletin boards, and other structures requiring a Class A fire rating that are used in office, school, commercial and industrial settings.
DESCRIPTION OF THE DRAWINGS
The present invention can be more readily understood by reference to the following drawings.
FIG. 1 is a schematic drawing of a method of making a fire-resistant article of the present invention.
FIG. 2 is a schematic drawing of an alternative method of making a fire-io resistant article of the present invention.
FIG. 3 is a schematic drawing of another alternative method of making a fire-resistant article of the present invention.
FIG. 4 is a schematic drawing of a further alternative method of making a fire-resistant article of the present invention.
is FIG. 5 is a schematic drawing of yet another alternative method of making a fire-resistant article of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A fire-resistant article of the present invention comprises a fibrous mass having a fiber component and about 5-40 wt.% of a first fire retardant component 20 mixed therein; the fiber component comprising about 1-50 wt.% thermoplastic and about 50-99 wt.% natural fiber, the fibrous mass having a coating of a second fire retardant component of about 1-30 wt.% on the exterior surfaces thereof.
Additionally, the fire-resistant article has a Class A fire rating and desirable acoustical properties.
25 The fibrous mass used in the manufacture of the fire-resistant article can be provided in the form of long sheets shipped as rolls. Such rolls may be commercially fabricated to include natural fibers and thermoplastic materials to a purchaser's specifications.
The natural fiber component of the fibrous mass is derived from the family 30 of bast fiber plants in which a plant stalk has bast fibers and a core. The preferred bast fiber plants will be those in which the bast fibers are readily separated from the core of the stalk. Particularly suitable bast fiber plants for this purpose include kenaf, jute, industrial hemp, sisal, and flax. Any of these plant materials may be used alone or in combination with each other, and in various proportions. The selection of the plant materials to be used will be based on ease of manufacture into the fibrous mass for use in the invention, cost, availability, and fire resistance in the finished article based on empirical tests. In one embodiment, a mixture of kenaf and industrial hemp is used. In another embodiment, only kenaf is used.
Further, while various proportions of the different fibers can be used, a fibrous mass in which the natural fiber component comprises kenaf and industrial hemp fibers in about equal proportions by weight is used.
The thermoplastic material or component should have a softening temperature below a temperature that would cause undesired thermal degradation of the natural fibers. Suitable thermoplastic components can be selected from the group consisting of polypropylene, polyethylene, polyesters, nylon, copolymers, and mixtures thereof. Of these, polypropylene is suitable because of its ready availability and its low cost. The thermoplastic component in the form of fibers may be readily incorporated in the fibrous mass in the initial manufacture thereof.
In one embodiment, the fibers may include bi-component fibers, in which fibers of a first thermoplastic material are coated or encased within a second thermoplastic material having a lower softening temperature. Alternatively, the thermoplastic component may be in other forms such as powders or pellets that can be readily incorporated in the fibrous mass.
Because of the inherent flammability of both the natural fibers and the thermoplastic materials used in the fibrous mass, a first fire retardant is dispersed throughout the fibrous mass. The first fire retardant component may be selected from materials such as borates, polyborates, boric acid, borax, phosphates, or mixtures of these materials. Of these, sodium polyborate is suitable.
The first fire retardant may be dispersed through the fibrous mass either before or after being compressed by any one of several methods. Where the first fire retardant is provided in the form of a powder having a bulk particle size of about 10-30 microns (450-800 mesh), such methods can include blowing the fire retardant powder into sheets of the fibrous mass onto one or both sides of the fibrous mass, or drawing the fire retardant powder through sheets of the fibrous mass with a reduction in pressure on one side thereof, or using a combination of blowing on one side of the sheet of fibrous mass and creating a region of reduced pressure on the other side.
Alternatively, the first fire retardant can be incorporated into the fibrous mass during the production thereof such as by pre-mixing with the natural fiber component, pre-mixing with the thermoplastic component, or by mixing together with the natural fiber and thermoplastic component, prior to or during the formation of the fibrous mass. After the first fire retardant is dispersed in the fibrous mass, the fibrous mass is then heated to a temperature above the softening temperature of the thermoplastic component to allow the thermoplastic material to soften and bind the natural fibers of the mass. The heated mass is compressed to a desired thickness and then optionally cooled for a period of time while in the compressed state so that the mass retains the desired thickness and achieves the desired rigidity.
A second fire retardant is applied as a coating to the exterior surfaces of the fibrous mass. Sodium silicate has been found to be well suited to this purpose. In one embodiment, the second fire retardant is present in a solution of liquid medium as either a solution, a suspension or a mixture. This composition may be applied onto the surfaces of the compressed fibrous mass by techniques such as spraying, brushing, roll coating, curtain coating, froth coating and dipping.
In one embodiment, the coating is applied by spraying an aqueous solution including at least 40 wt.% sodium silicate. The coating is then allowed to dry, optionally with heating to drive off the water from the aqueous solution so that the coating sets.
The fire-resistant article of the present invention has a Class A fire rating.
Specifically, the fire-resistant article when incorporated into a completed structural panel that includes conventional covering materials, additional adhesives and, optionally, spacer materials in a laminated construction, has a flame spread index (FSI) below 25 or from 0 to 25 and a smoke generation index below 450 or from to 450. More particularly, the fire-resistant article of the present invention in some embodiments has a FSI of 0 to 15 and a smoke generation index of 0 to 100.
Additionally, the fire-resistant article has desirable acoustical properties.
The noise reduction coefficient (NRC) as well as the sound transmission class (STC) are useful indicators of the acoustical properties of a given material.
The Noise Reduction Coefficient (NRC) is a scalar representation of the amount of sound energy absorbed upon striking a particular surface. In particular, it is the average of four sound absorption coefficients of the particular surface at frequencies of 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz. The Sound Transmission Class (STC) is a widely used integer-number rating of how well a building partition attenuates airborne sound. It is used to rate interior walls, ceilings/floors, doors, windows and exterior wall configurations. The number is derived from sound attenuation values tested at sixteen standard frequencies from 125 Hz to 4000 Hz.
io These transmission-loss values are then plotted on a sound pressure level graph and the resulting curve is compared to a standard reference contour. These values are fit to the appropriate TL Curve (or Transmission Loss) to determine the STC rating. The fire-resistant article when incorporated into a completed structural panel that includes conventional covering materials, additional adhesives and, optionally, spacer materials in a laminated construction, has a noise reduction coefficient (NRC) ranging from 0.35 to 0.65 and a sound transmission class ranging from 15 to 28.
In one embodiment, for example, a fibrous mass made of a 1300 gsm mat of kenaf and polypropylene was heated and compressed according to the method of the present invention to a thickness of 0.25 inches. Powdered polyborate was added to the compressed mat (15-20 wt.%) followed by the addition of sodium silicate (about 1.2 oz. sodium silicate solids per square foot per side). When incorporated into a structural panel, this compressed and treated mat provided a panel having an STC of 25-26 and a NRC of 0.3-0.4. In another embodiment, a fibrous mat made of 1300 gsm mat of kenaf and polypropylene was heated and compressed according to the method of the present invention to a thickness of 0.275 inches. Powdered polyborate was added to the compressed mat (25-30 wt.%) followed by the addition of sodium silicate (about 1.5-2.5 oz. sodium silicate solids per square foot per side). When incorporated into a structural panel, this compressed and treated mat provided a panel having a STC of 15 and above and a NRC of 0.05 and above.
The present invention further encompasses alternative methods of making the fire-resistant article. One inventive method comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) dispersing a first fire retardant component in the fibrous mass, (c) heating the fibrous mass to a temperature above the softening temperature of the thermoplastic material but below the thermal degradation temperature of the natural fibers, (d) compressing the fibrous mass to form a shaped article, (e) applying a coating of a second fire retardant component to the shaped article;
and (f) drying the coating.
Another inventive method comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) heating the fibrous mass to a temperature above the softening temperature of the thermoplastic material, (c) compressing the fibrous mass to form a shaped article, (d) dispersing a first fire retardant component in the fibrous mass forming the shaped article, (e) applying a coating of a second fire retardant component to the shaped article; and (f) drying the coating.
A further inventive method of the present invention comprises the steps of (a) dispersing a first flame retardant component through a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) applying a second flame retardant component to the outer surfaces of the fibrous mass, (c) compressing the mass with heat to both soften the thermoplastic materials to bind the natural fibers and to drive off any water used in the solution or liquid medium from the application of the second flame retardant component.
One method of making the fire-resistant article of the present invention is schematically illustrated in FIG. 1. The fibrous mass 10 is passed through an oven 19 where it is heated to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic material to soften and bind the natural fibers. The heated mass is then passed to a calendaring unit for decreasing the thickness and increasing the density of the fibrous mass 10. As shown in FIG. 1, the calendaring unit includes a set of three nip rollers 25a, 25b and 25c, for decreasing the thickness and increasing the density of the fibrous mass 10. Alternatively, as shown in FIGS. 3 and 4, the fibrous mass 10 can be passed through a press where it is pressed between two press platens 22, 24. In alternative embodiments, any process that provides suitable heat and compression is suitable. The mass is held at the thickness while it is allowed to cool. The fibrous sheet 10 is then conveyed beneath a dispenser 12 that dispenses the first fire retardant 14 to be dispersed within the fibrous mass 10. The dispersal of the first fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass. The choice of whether to use a blower system 16, a vacuum assist 18, or both, may depend on the types of fibers in the fibrous mass, the type of fire retardant used, and the density of the fibrous mass.
The fibrous mass 10 is then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will io be appreciated that an apparatus with one spray head could be used if the mass is sprayed first on one side and then on the other. The spray heads 32, 34 spray both surfaces of the fibrous mass 10 with a composition 36 containing a second fire retardant material that forms a coating 40 on the exterior surfaces of the fibrous mass 10. The article 50 is the compressed fibrous mass 10 with the first fire retardant dispersed therein and having a coating 40 of the second fire retardant. The coating 40 on the article 50 is allowed to set; this last step can be facilitated by heating the article 50 with a heat source 42 to drive off any liquid medium from the mixture 36, with or without a vacuum assist or forced air.
In a variation of the above-described embodiment of the invention, the shaped article is passed through at least one additional set of rollers 28a-c as shown in FIG. 2. During the application of the second fire retardant component in the form of a solution or spray, the liquid from the second fire retardant component can cause the natural fibers on the exterior surface of the shaped article to expand. The expanded natural fibers on the exterior surface of the shaped article may extend away from the surface creating a fuzz-like appearance or texture.
The shaped article may be passed through at least one additional set of rollers 28a-c in order to remove any excess liquid from the shaped article and to compress and smooth any extended fibers formed on the exterior surface of the shaped article resulting from the application of the second fire retardant component.
An alternative method of making the fire-resistant article of the present invention is schematically illustrated in FIG. 3. A sheet 10 of a fibrous mass comprising natural fibers and a thermoplastic material is conveyed beneath a dispenser 12 that dispenses the first fire retardant to be dispersed within the fibrous mass. The dispersal of the first fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass. The choice of whether to use a blower system 16, a vacuum assist 18, or both, may depend on the types of fibers in the fibrous mass, the type of fire retardant used, and the density of the fibrous mass. After the first fire retardant is applied, the fibrous mass 10 is passed through an oven 19 where it is heated to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic io material to soften and bind the natural fibers. The heated mass is then passed to a press 20 where it is pressed between two press platens 22, 24, which decreases the thickness and increases the density of the fibrous mass 10. The mass is held at the thickness while it is allowed to cool. The fibrous mass 10 is then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will be appreciated that an apparatus with one spray head could be used if the mass 10 is sprayed first on one side and then on the other. The spray heads 32, 34 spray both surfaces of fibrous mass 10 with a composition 36 containing a second fire retardant material that forms a coating 40 on the exterior surfaces of the fibrous mass 10. The article 50 is the compressed fibrous mass 10 with the first fire retardant dispersed therein and having a coating 40 of the second fire retardant.
The coating 40 on the article 50 is allowed to set; this last step can be facilitated by heating the article 50 with a heat source 42 to drive off any liquid medium from the mixture 36, with or without a vacuum assist or forced air.
Another method of making a fire-resistant article of the present invention comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) dispersing a first fire retardant component in the fibrous mass, (c) applying a coating of a second fire retardant component to the fibrous mass, (d) heating the fibrous mass, and (e) compressing the fibrous mass to form a shaped article, and allowing the compressed mass to cool. In this method, the heating and compression steps can be conducted separately or simultaneously. The materials that can be used in this second method are the same as those that can be used in the first method. This method is illustrated in FIG. 4, wherein the same elements shown in FIG. 3 are indicated by the same reference numerals. Referring to FIG. 4, a sheet 10 of a fibrous mass comprising natural fibers and a thermoplastic material is conveyed beneath a dispenser 12 that dispenses the first fire retardant 14 to be dispersed within the fibrous mass 10. The dispersal of the fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass. The choice of whether to use a blower system 16, a vacuum assist 18, or both, may depend on the types of fibers in the fibrous mass, the type of fire retardant used, and the density of the io fibrous mass. After the first fire retardant is applied, the fibrous mass 10 is then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will be appreciated that an apparatus with one spray head could be used if the mass 10 is sprayed first on one side and then on the other. The spray heads 32, 34 spray both surfaces of the fibrous mass 10 with a mixture 36 containing a second fire retardant material present in a liquid medium that forms a coating 40 around fibrous mass 10. The fibrous mass 10 is then passed to a heating press 20 where it is pressed between two press platens 22, 24 with heat to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic material to bind the natural fibers, while decreasing the thickness and increasing the density of the fibrous mass 10. This step also can drive off the liquid medium from the coating 40. The resulting article can be used to produce a satisfactory Class A rated fire resistant structure.
Another method of making the fire-resistant article of the present invention is schematically illustrated in FIG. 5. In this variation of the method illustrated in FIG. 1, a sheet 10 of a fibrous mass comprising natural fibers and a thermoplastic material is conveyed beneath a dispenser 12 that dispenses the first fire retardant to be dispersed within the fibrous mass. The dispersal of the first fire retardant 14 into the body of fibrous mass 10 can be facilitated by a blower system 16, and/or a vacuum assist 18 to pull air and fire retardant through the fibrous mass as described above. After the first fire retardant is applied, the fibrous mass 10 is passed through an oven 19 where it is heated to a temperature greater than the softening temperature of the thermoplastic component. This allows the thermoplastic material to soften and bind the natural fibers. The heated mass is then passed to a set of three nip rollers 25a, 25b and 25c, which decreases the thickness and increases the density of the fibrous mass 10. After passing through the nip rollers 25a, 25b and 25c, the fibrous mass 10 is cooled and then conveyed to a coating application apparatus, which in the illustrated embodiment is in the form of two spray heads 32, 34, although it will be appreciated that an apparatus with other methods of applying the coating onto the exterior surfaces of the fibrous mass would be suitable. The spray heads 32, 34 spray both surfaces of fibrous mass 10 with a composition 36 containing a second fire retardant material that lo forms a coating 40 on the exterior surfaces of the fibrous mass 10. The coating 40 on the article 50 is allowed to set; this last step can be facilitated by heating the article 50 with a heat source 42 to drive off any water from the composition 36.
The fire-resistant and/or acoustical absorbing article disclosed herein avoids the use of fiberglass and added formaldehyde-containing materials. The is article so made can be used in the manufacture of furniture, office partition panels, ceiling tiles, bulletin boards, and other articles and structures useful in office, school, and industrial environments that require Class A fire-resistant structure and/or noise control. Articles made according to the present method also have satisfactory structural properties. For example, articles having a density in a 20 range of 17-24 pcf were found to have a modulus of elasticity (MOE) of more than 300,000 psi across the width and more than 270,000 psi across the length for multiple samples tested in a three point bend test modeled after ASTM D 1037-96a (the testing deviated from the ASTM methods because the samples were not conditioned, the moisture content was not measured and the sample size span 25 was greater than the ASTM standard). In addition, the various samples were found to have a modulus of rupture (MOR) of more than 1900 psi across the width and more than 1800 across the length of the samples.
A fibrous mass is provided comprising about 20% by weight of 30 polypropylene fibers and about 80% by weight of a natural fiber component, the component containing 50% by weight of kenaf fiber and 50% by weight of industrial hemp fiber. The mass is heated to a temperature of about 375 -380 F
for about 10-15 minutes in a conventional oven. The mass is compressed to a desired thickness and allowed to cool. Next, sodium polyborate powder is blown through the mass. Then, the compressed mass is sprayed on all surfaces with a 40% by weight aqueous solution of sodium silicate, at about 1-2 oz. solution per s square foot of surface area. The mass is then heated to a temperature of about 375 for about 1-2 minutes to drive off the water and allow the sodium silicate coating to set. Structures made with the article can be useful in furniture, office partitions, ceiling tiles, and the like.
A fibrous mass is provided comprising about 20% by weight of polypropylene fibers and about 80% by weight of a natural fiber component, the component containing 50% by weight of kenaf fiber and 50% by weight of industrial hemp fiber. Sodium polyborate powder is blown through the mass. The mass is heated to a temperature of about 375 -380 F for about 10-15 minutes in a conventional oven. The mass is compressed to a desired thickness and allowed to cool. The compressed mass is sprayed on all surfaces with a 40% by weight aqueous solution of sodium silicate, at about 1-2 oz. solution per square foot of surface area. The mass is then heated to a temperature of about 375 for about 1-2 minutes to drive off the water and allow the sodium silicate coating to set. The resulting article can be used in the manufacture of a structure having a flame spread index of less than 25 and a smoke generation index of less than 450, which meets the requirement for a Class A rated fire resistant article.
Structures made with the article can be useful in furniture, office partitions, ceiling tiles, and the like.
Modifications and variations of the inventive article and methods are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
A fibrous mass is provided comprising about 20% by weight of polypropylene fibers and about 80% by weight of a natural fiber component, the component containing 50% by weight of kenaf fiber and 50% by weight of industrial hemp fiber. Sodium polyborate powder is blown through the mass. The mass is heated to a temperature of about 375 -380 F for about 10-15 minutes in a conventional oven. The mass is compressed to a desired thickness and allowed to cool. The compressed mass is sprayed on all surfaces with a 40% by weight aqueous solution of sodium silicate, at about 1-2 oz. solution per square foot of surface area. The mass is then heated to a temperature of about 375 for about 1-2 minutes to drive off the water and allow the sodium silicate coating to set. The resulting article can be used in the manufacture of a structure having a flame spread index of less than 25 and a smoke generation index of less than 450, which meets the requirement for a Class A rated fire resistant article.
Structures made with the article can be useful in furniture, office partitions, ceiling tiles, and the like.
Modifications and variations of the inventive article and methods are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
Claims (23)
1. A method of making a fire-resistant article, said method comprising the steps of:
(a) providing a fibrous mass comprising a mixture of thermoplastic material and bast fibers;
(b) heating the fibrous mass to a temperature above the softening temperature of the thermoplastic material but below a thermal degradation temperature of the bast fibers;
(c) compressing the mass to form a shaped article;
(d) dispersing a first fire retardant component in the fibrous mass;
and (e) applying a coating of a second fire retardant component to the shaped article.
(a) providing a fibrous mass comprising a mixture of thermoplastic material and bast fibers;
(b) heating the fibrous mass to a temperature above the softening temperature of the thermoplastic material but below a thermal degradation temperature of the bast fibers;
(c) compressing the mass to form a shaped article;
(d) dispersing a first fire retardant component in the fibrous mass;
and (e) applying a coating of a second fire retardant component to the shaped article.
2. The method according to claim 1, further comprising at least one additional step of compressing the shaped article after applying the coating of the second fire retardant component to the shaped article.
3. The method of claim 1 wherein the fibrous mass comprises about 1-50 wt.% thermoplastic material and about 50-99 wt.% natural fiber.
4. The method of claim 1 wherein the bast fibers are kenaf, jute, industrial hemp, sisal, flax, or mixtures thereof.
5. The method of claim 4 wherein the natural fibers comprise kenaf.
6. The method of claim 1 wherein the thermoplastic material is fibers, bi-component fibers, powder, or pellets.
7. The method of claim 1 wherein the thermoplastic material comprises polypropylene, polyethylene, polyesters, nylon, copolymers, or mixtures thereof.
8. The method of claim 7 wherein the thermoplastic material is polypropylene.
9. The method of claim 1 wherein the first fire retardant comprises borates, polyborates, boric acid, borax, phosphates, or mixtures thereof.
10. The method of claim 9 wherein the first fire retardant component comprises sodium polyborate.
11. The method of claim 1 wherein the second fire retardant component is applied as a liquid composition.
12. The method of claim 1 comprising the further step of heating the article after the application of the second fire retardant component to set the second fire retardant component on the article.
13. The method of claim 1 wherein the second fire retardant component comprises sodium silicate.
14. The method of claim 1, wherein the compressing the mass includes calendaring the mass.
15. The method according to claim 1, wherein the fire resistant article comprises a fibrous mass having a fiber component and about 5-40 wt.% of a first fire retardant component mixed therein, said fiber component comprising about 1-50 wt.% thermoplastic material and about 50-99 wt.% bast fiber, wherein the fibrous mass has a coating of a second fire retardant component on exterior surfaces of the fibrous mass.
16. The method according to claim 1, wherein the fire resistant article has a Class A fire rating.
17. The method according to claim 1, wherein the fire resistant article has a noise reduction coefficient ranging from 0.35 to 0.65.
18. The method according to claim 1, wherein the fire-resistant article has a sound transmission class ranging from 15 to 28.
19. A fire-resistant article comprising: a fibrous mass having a fiber component and about 5-40 wt.% of a first fire retardant component mixed therein, said fiber component comprising about 1-50 wt.% thermoplastic material and about 50-99 wt.% bast fiber, the fibrous mass having a coating of a second fire retardant component on exterior surfaces of the fibrous mass;
wherein the fire-resistant article has acoustical absorbing properties.
wherein the fire-resistant article has acoustical absorbing properties.
20. The fire-resistant article according to claim 19, wherein the article has a sound transmission class ranging from 15 to 28.
21. The fire-resistant article according to claim 19, wherein the article has a noise reduction coefficient ranging from 0.35 to 0.65.
22. A fire-resistant article manufactured according to the method of claim 1.
23. The fire-resistant article of claim 21, wherein the fire-resistant article has acoustical properties.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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US11/421,328 US20060252323A1 (en) | 2005-02-14 | 2006-05-31 | Fiber-containing article and method of manufacture |
US11/421,328 | 2006-05-31 | ||
US11/470,799 | 2006-09-07 | ||
US11/470,799 US20070042658A1 (en) | 2005-02-14 | 2006-09-07 | Fiber-containing article and method of manufacture |
PCT/US2007/067871 WO2007143302A1 (en) | 2006-05-31 | 2007-05-01 | Fiber-containing article and method of manufacture |
Publications (1)
Publication Number | Publication Date |
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CA2652282A1 true CA2652282A1 (en) | 2007-12-13 |
Family
ID=40457872
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA002652282A Abandoned CA2652282A1 (en) | 2006-05-31 | 2007-05-01 | Fiber-containing article and method of manufacture |
Country Status (4)
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CA (1) | CA2652282A1 (en) |
MX (1) | MX2008015122A (en) |
TW (1) | TW200804071A (en) |
WO (1) | WO2007143302A1 (en) |
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WO2013079635A1 (en) * | 2011-12-01 | 2013-06-06 | Global Telecom Organisation S.A. | Substrate binding process |
AU2013314173B2 (en) * | 2012-11-08 | 2016-03-31 | Yoshidafusa Orimono Co., Ltd. | Flame retardant planar element and floor covering hardly generating hazardous gas using the flame retardant planar element, and production method of the floor covering hardly generating hazardous gas |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
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DE4314853A1 (en) * | 1993-05-05 | 1994-11-10 | Gerhard Dr Pohl | Flame-inhibiting thermoplastics |
JP2851244B2 (en) * | 1994-02-09 | 1999-01-27 | 児玉化学工業株式会社 | Multilayer laminate and method of manufacturing multilayer laminate panel |
US20060182940A1 (en) * | 2005-02-14 | 2006-08-17 | Hni Technologies Inc. | Fire-resistant fiber-containing article and method of manufacture |
-
2007
- 2007-05-01 CA CA002652282A patent/CA2652282A1/en not_active Abandoned
- 2007-05-01 MX MX2008015122A patent/MX2008015122A/en unknown
- 2007-05-01 WO PCT/US2007/067871 patent/WO2007143302A1/en active Application Filing
- 2007-05-03 TW TW096115692A patent/TW200804071A/en unknown
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MX2008015122A (en) | 2008-12-10 |
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