CN1028084C - 隔火性织物 - Google Patents
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Abstract
一种适用于作隔火层的阻燃织物,该织物是包含一种由包芯纱制成的耐火的纺织物基材,该包芯纱是由阻燃的丝芯和短纤维外包层组成的,和一种涂敷在纺织物基材一个表面上的发泡涂层。在一般使用时,织物是柔软的和可成型的并具有良好的透气性。但是遇高温和/或火焰时,发泡涂层发生反应和膨胀至使形成可以封闭织物的空间和孔隙的焦炭,从而可阻止火焰或热气体透过。
Description
本发明涉及一种适合于隔热和隔火性的防护织物的结构和制造。更具体地说,是将织物作为热源和任何可燃材料之间的阻隔层,以此来防止可燃材料的燃烧。
迄今已经研制出各种类型的防护织物,它们可应用在那些遇热和/或火焰不会燃烧的织物覆盖制品(如家具装饰制品或办公室用的壁板)中。例如,在外包装饰布的飞机座位中,一般在外层的装饰织物与可燃的泡沫软垫内层之间放一隔热的防护织物以在火灾事件中延缓或阻止垫子燃烧。值得注意的例子是Parker等人的美国专利NO.4463465公开了一种由芳族酰胺类织物为基材和铝箔层为外层所构成的隔火性织物。但是使用铝箔层就产生了一些缺点,如织物仅有有限的透气性以及减少了外包装饰品所具有的软垫的特性。
Cheetham等人的美国专利No.4509559中公开了一种典型的用于输送易燃液体软管的防护覆盖层用的阻燃织物。这种织物的最里层是一种热发泡材料,中间层为一种浸有三水合氧化铝的织物以及最外层是抛光的金属外层。这种织物是阻燃的,但它具有有限的柔顺性和可成型性。这就使它在许多情况中不适于应用,如作为家具覆盖饰物。
Barrall等人的美国专利No.4569878中公开了一种作办公用隔板的阻燃层压材料,该层压材料包括一系列机织的和非织造的合成材料和玻璃纤维层并用由金属氧化物、硅酸钙和磷酸组成的发泡组合物将各层粘合在一起。这种织物也具有有限的柔顺性和透气性。
用作火焰阻隔层的阻燃织物的另一种生产技术是用阻燃化合物对织物进行涂层。典型的例子是水合无机物为基础的一类化合物,如水合氧化铝、水合氧化镁、氯氧化镁、水合硼酸锌和水合硼酸钙。但是这种类型的涂层,在织物的纤维间留下了空隙。这些空间或空隙会允许热气和/或火焰穿透并引燃里层的可燃材料。
本发明提供一种阻燃的隔火性织物,该织物耐高温火焰、质轻、可透气、并且具有好的可整贴性和柔顺性。本发明的织物包括由包芯纱构成的耐火纺织物基材和涂敷在纺织物基材的表面上的发泡涂层。该包芯纱由玻璃纤维这样的耐火丝为芯和短纤
维为外包层所组成。受到热的作用时,发泡涂层会膨胀并形成一层绝缘的碳,这些碳可填满纱线之间的空隙,起熄火作用,因而使织物基材能耐熔或耐燃。该涂层在正常使用时不会对织物的柔顺性和透气性产生不良的影响,且织物基材也很容易地贴合在里层的可燃材料上。
对本发明的一些特征和优点已作过叙述,其余的特征和优点将在对附图作说明时叙述,附图中
图1是根据本发明所述的具有发泡涂层的部分阻燃织物的细节的等轴投影放大示意图,图中附有纺织物的断层以更清晰地显示出织物的结构。
图2是和图1相类似的表示出细节的等轴投影放大示意图,但图2中阻燃织物的一个表面上有发泡涂层而另一表面上有反光漆涂料。
图3是图1中所示的、夹于家具装饰织物外层和可燃的泡沫垫里层之间的阻燃织物的表示出细节的等轴投影放大示意图。
图4是图2中所示的,夹于家具装饰织物外层和可燃的泡沫垫里层之间的阻燃织物的表示出细节的等轴投影放大示意图。
本发明将参照附图在下文中作更充分的说明,其中也列举了本发明择优的具体实施方案。但是,本发明可体现在许多不同的方式中,因而本发明不应被理解为局限于这里所列之具体实施方案。反之,申请者提供这些具体实施方案以使本说明书更详尽和完整,并能将本发明的范围充分的展示给熟练的专业人员。
如图1所示,本发明的隔火性阻燃织物10是由一个由纱线15制成的纺织物基材11和在织物基材11的一个表面上的发泡涂层20所组成。如图3所示,可将阻燃织物10放置在可燃的里层35与装饰织物外层40之间作为隔火层使用。该阻燃织物上的发泡涂料层20最好与外层40相连接并且面向火源。
纺织物基材11是耐火的,而且在遇火时至少有些部分是不会受损伤的,这样织物基材11成为发泡涂层20的底面或支承物。织物基材11可以是各种织物结构中的任何一种,如针织物、机织织物、非织造物、编织织物、经编织物以及稀松的增强纤维网结构。其中以针织结构较为理想,这是因为此种结构舒适和价廉并且这种结构具有优良的柔顺性和整贴性,而且这种结构由于其固有的多孔性使其可透气。
这些织物的纱线15是包芯纱结构,作为这种产品的例子已在1989年3月3日递交的、共同未决且已转让给本申请人的美国专利申请318239中叙述过。一种尤为适合的包芯纱结构是由一个占包芯纱总重量的20至40%的丝芯和一个占包芯纱总重量的80至60%的短纤维的外皮层所组成。作丝芯用的纤维有玻璃纤维、聚苯并咪唑纤维、聚亚酰胺纤维、聚芳烯烃纤维、各种金属纤维、聚对苯二甲酰对苯二胺纤维(kevlar)、聚间苯二甲酰间苯二胺纤维(Nomex)以及碳纤维和可碳化的化合物的纤维。纱芯也可以是这些纤维的混合物或多芯结构。其中以玻璃纤维较为理想,这是因为它的价廉和耐燃性。包覆着丝芯的短切纤维可以是天然的或者合成材料,如棉纤维、聚酯纤维、粘胶纤维、羊毛、锦纶纤维、腈纶纤维、改性腈纶纤维、聚醋酯纤维或者这些纤维的混合物。
参照图1,该图表示出了具有针织结构的纺织物基材11。针织结构特征在于纱线15的线圈是相互串套的。纱线系统可以是由单根纱线组成(即纬编)或者可由纱线组合体组成(即经编)。如图1所示,纱线的线圈15是由一根纬线构成并贯穿织物纬向。这种结构是多孔和可透气的。
本发明的隔火性阻燃织物是将发泡涂层20涂敷在纺织物基材11的表面上而制得的。这种发泡涂层最好是以轻质的并有多孔性泡沫的形式加工或用一般的涂层技术如刮刀涂层器、辊式涂层器、喷涂、上轧、转移涂层或网印等方法进行涂层。各种发泡化合物已为大家所熟悉,一类特别合适的发泡化合物是由一种碳源物(即碳化作用物)、一种催化剂和一种非可燃气体源(即起泡剂或吹泡剂)所组成。作为碳化作用物的典型例子有碳水化合物,蛋白质或多元醇,如淀粉、酪蛋白或季戊四醇。遇火时,催化剂使得碳化作用物膨胀和焦化。作为催化剂的典型例子为无机酸,如硼酸、磷酸或硫酸,或者在分解时可生成无机酸的那些化合物,如磷酸氢铵或磷酸氢二铵、三聚氰氨和尿素。用来使发泡涂层起泡的非可燃气体源可以由催化剂提供,例如三聚氰氨用作催化剂,或者也可以用那些遇火时能产生气体(如氨、二氧化碳、氯化氢)的一类化合物。一些特定应用的涂层中,发泡组合物也可混有粘结剂、增稠剂及类似物起辅助作用。此外也可加
入常用的阻燃填充料如氧化铝的三水合物、硅酸盐、高岭土、石膏和水合粘土。
在日常使用中,本发明的隔火性织物是轻质、柔顺和可透气的,这是由于所用的涂层是一种多孔的泡沫膜而不是非多孔膜,从而造成它们的多孔性的结果。织物的多孔性和透气性是用织物的“透气率”的术语来表示。透气率是根据纺织物透气率的ASTM标准测试方法D737测定的。该方法是调节通过已知面积的织物的流速以保证在测试面积的织物两个表面间有一规定的压力差,根据这个流速即可测得该织物的透气率。据此,假如用一口径为4mm经校正的细管,空气以1760立方厘米/秒的速率通过此管吹出,本发明的涂层织物具有472至1.42×105立方厘米/秒的透气率,一般的是94至3.78×104立方厘米/秒,较好是4720至1.42×104立方厘米/秒。
这种隔火性织物尤其适合用作家具装饰品中的隔火层,这是由于这种织物隔火层很容易地与制品的形状相贴合,并且它的优良的透气性不会有损于外层装饰织物的应有的美感。尤其是隔火性织物的透气率保证了舒适所需要的良好的空气循环。当隔火层用于座位的软垫制品中时,隔火性织物的透气率就特别重要。因为当垫子受到压缩时隔火性织物的透气性可让空气自由地从垫子中跑出。这样织物就可避免硬的不舒适的“气球”效应,后者是大多数按照先有工艺所制得的不透气的隔火性织物的特点。
但是,当本发明的隔火性织物遇高温和/或火焰时,发泡化合物会发生反应和膨胀碳化,这种碳可以堵塞化合物本身的孔隙或堵塞纱线间的孔隙。这种碳基本上是不可燃的并具有蜂窝状的结构特征。从而碳也相当于隔火层并限制了火焰或热气体透过织物去点燃里层可燃材料。包芯纱也对织物的阻燃性质起作用。遇火时阻燃的芯丝仍保持不变,它与外包层纤维碳化的残余物一起为发泡涂层提供了一个网格或支承结构。
如图2所示,一种反光漆涂料30也可涂敷在有发泡涂层20的隔火性织物的另一个表面上。这一层是用来反射掉里层可燃材料的辐射热。另外这一层也不对隔火性织物的透气性和柔顺性产生明显的影响。反光漆涂料30最好是金属涂料,它含有片状金属颜料和耐燃的粘合剂。具有良好的金属悬浮性质和良好的反射性质的片状金属颜料是较为理想的。具有高反射性的片状金属颜料的典型例子有铝、黄铜、铜、金、镍和银。其中较理想的是铝,这是因为铝的价格便宜。作为片状铝,典型的例子是由弗吉尼亚州,Bichmond的Reynolod金属公司提供的LSB-547 Leafing Alumiuum Flake,理想的耐燃粘合剂是硅酮醇酸树脂,其中合适的商品是新泽西州,Hightstown的Spencer-Kellogg公司出售的Kelsol 3970改性硅酮醇酸树脂。遇火时这种树脂是这样反应的,即颜料中的片状金属紧密地与基材粘合,并且它们彼此也紧密地粘合在一起。如果希望用水来调节涂料的粘度,可加入氨水溶液来改善粘合剂与水之间的可混合性。
合适的反光金属涂料还有新泽西州的包括South Plain-field在内的三大工业的Tempil分部出售的Pyromark 2500和Pyromark 800铝涂材以及Princeton的Solar Energy公司出售的Lo-Mit-l铝涂料。反光漆涂料30可按常规技术涂敷,并在高温下长时间干燥以改善此涂料对织物层的粘合性。为保证反光漆涂料对织物层的粘合具有最大的耐磨性,一般约在149℃下干燥60秒是最佳的。
本发明的隔火性织物特别适于作为一隔火层用在家具制品和办公用的建筑材料中如护墙材料、壁板、办公用隔板、顶逢板、地板面材料等类似物,卧室制品如褥垫和枕套、褥垫和枕头的罩、装饰用布、蓬帐布、椅布、野外防火屏障和睡袋罩。这种织物质轻、可透气和柔韧并且易于造型,这样当织物包覆在奇特形状的家具制品和建筑材料上时就能很好地成型。
在操作中,发泡涂层20是以泡沫状或起泡而使用的,并用上述的常规涂层技术将它涂敷在纺织物基材上。涂层用量约为每平方米织物约9.3至744克(干的),较理想的是每平方米为74.4至130.2克(干)。然后将已涂层的基材干燥并焙烘涂层。涂有或未涂有反光漆涂料30的已涂层基材和装饰表面织物或家具装饰织物层40可用常用的粘合剂或者用发泡涂层本身的粘结性和粘合剂特性将它们粘合在一起。在后者粘合技术中,发泡涂层仅是部分地焙烘因而涂层是粘性的,然后在压力下将基材和家具装饰织物层40熔融粘合在一起,继之以使发泡涂层在低温下完全焙烘。可以把可燃的
里层35如泡沫材料层、非织造织物棉絮层、填充用纤维层或羽毛层放于不涂有发泡涂层的织物基材的那个面上,可燃层35用常规的粘合剂粘合在一起。
这样如图3中所示,此织物可用作家具装饰制品的隔火层,其中织物10放在可燃的里层如聚氨酯泡沫层和家具装饰织物层40之间,织物上的发泡涂层面向火源而背向可燃层35。如图4中所示,涂有发泡涂层20和与可燃层35相连接的反光漆涂料30的织物也可用作可燃层35与家具装饰织物层40之间的隔火层。
下面的实施例中列举了一些涂层织物的例子,它们被认为是本发明的解释例子。应该清楚本发明并不受这些实施例的具体细节的限制。
实施例
由玻璃纤维丝芯和棉短纤维外包层组成的包芯纱用常规技术制得针织织物。对这些织物进行发泡涂层并且在实施例2中还用反光漆涂料对织物进行涂层。涂层后,将聚氨酯泡沫衬垫以背向发泡涂层方式与泡沫层/基材界面固定在一起。这些织物与由未涂层的由玻璃纤维/棉纤维包芯纱制成的标准针织织物进行比较。测试方法是将涂有发泡涂层的织物紧靠近本生灯的火焰在648.9℃下作用2.5分钟。样品用目测法来估算对聚氨酯泡沫衬垫里层的损害程度。
实施例1
一包芯纱的针织织物用含下列组份的发泡涂层剂作涂层加工:
% 克/平方米
(重量)干固体织物
偏氯乙烯/丙烯酸乳胶 26.69 65.1
十二烷基硫酸钠起泡剂 0.76 1.86
磺基琥珀酰亚胺酸正十八酯钠盐 0.04 0.111
三聚氰胺发泡剂 2.20 5.36
季戊四醇碳化化合物 4.58 11.16
五氧化二磷阻燃剂 13.72 33.48
瓜耳树胶增稠剂 0.92 2.232
水 51.09 -
将此涂层组合物放入混合器中并在高速下混合以使其发泡。随后将此泡沫比为2.5至1的已发泡的涂层组合物涂敷在织物的一个表面上并加热干燥之。织物上经干燥的涂层,每平方码含有3.2盎司的干固体量。
实施例2
将实施例1的已有发泡组合物涂层的织物在其另一面涂上0.5盎司/平方码(干固体重量)的组成如下的反光漆涂料:
%(重量) 克/平方米
干固体织物
水相容的漆浮片状铝 17 117.6
可缩减水的硅酮醇酸树脂 34 6.324
氨水 7 1.302
水 42 -
标准织物造成里层泡沫垫有较大的损害,而实施例1和2的织物对直接在火焰上方的泡沫衬垫造成轻微的碳化现象。另外实施例1和2的织物仍有好的强度和柔顺性。
在附图和说明书中,列举了本发明的一些择优的具体实施方案,尽管也使用了专门的术语。但这些实例仅是作为一般性的说明,其目的不是限制本发明。
Claims (12)
1、一种适宜用作隔火层的阻燃织物,其特征在于一种包芯纱制成的耐火纺织物基材,所述的纱包含一种阻燃丝的芯丝和一种短纤维的外包层,和一种涂敷在所述的纺织物基材的一个表面上的发泡涂层,该发泡涂层是由一种碳化的化合物、一种催化剂和一种非可燃气体源组成的。
2、一种根据权利要求1中所述的阻燃织物,其中发泡涂层是起泡的并以每平方米9.3至744克的量使用。
3、一种根据权利要求2中所述的阻燃织物,其中发泡涂层具有472至1.42×105立方厘米/秒的透气率。
4、一种根据权利要求3中所述的阻燃织物,其中发泡涂层具有94至3.78×104立方厘米/秒的透气率。
5、一种根据权利要求4中所述的阻燃织物,其中发泡涂层具有4720至1.42×104立方厘米/秒的透气率。
6、一种根据权利要求1中所述的阻燃织物,其中所述的芯丝是玻璃纤维,所述的外包层的短纤维可从棉纤维、聚酯纤维、粘胶纤维、羊毛、锦纶纤维、腈纶纤维、改性腈纶纤维、醋酯纤维和它们的混合物一组纤维中选取。
7、一种根据权利要求1中所述的阻燃织物,其中纺织物基材是针织结构的织物。
8、一种根据权利要求1中所述的阻燃织物,其中纺织物基材是机织结构的织物。
9、一种根据权利要求1中所述的阻燃织物,其中还有反光的耐火漆涂料涂敷在所述织物的另一个表面上。
10、一种根据权利要求9中所述的阻燃织物,其中所述的反光漆涂料是一种反光金属涂料。
11、一种根据权利要求10中所述的阻燃织物,其中所述的反光金属涂料是由片状金属颜料和一种耐火的硅酮醇酸树脂粘合剂组成。
12、权利要求1至11的阻燃织物用于制造家具装饰制品、办公用建筑材料、卧室用制品、装饰用布、帐蓬、帆布蓬、野外防火屏障和睡袋罩。
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-
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- 1989-04-04 US US07/333,174 patent/US5091243A/en not_active Expired - Lifetime
- 1989-09-14 CA CA000611360A patent/CA1331721C/en not_active Expired - Fee Related
- 1989-10-16 AU AU42870/89A patent/AU617010B2/en not_active Ceased
- 1989-10-16 DE DE68920026T patent/DE68920026T2/de not_active Expired - Fee Related
- 1989-10-16 EP EP89310591A patent/EP0391000B1/en not_active Expired - Lifetime
- 1989-10-16 AT AT89310591T patent/ATE115658T1/de not_active IP Right Cessation
- 1989-11-17 JP JP1297747A patent/JP2564011B2/ja not_active Expired - Fee Related
- 1989-12-14 KR KR1019890018534A patent/KR930000627B1/ko not_active IP Right Cessation
-
1990
- 1990-04-04 CN CN90101886A patent/CN1028084C/zh not_active Expired - Lifetime
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---|---|
AU4287089A (en) | 1990-10-11 |
CA1331721C (en) | 1994-08-30 |
EP0391000A2 (en) | 1990-10-10 |
ATE115658T1 (de) | 1994-12-15 |
JP2564011B2 (ja) | 1996-12-18 |
KR930000627B1 (ko) | 1993-01-28 |
CN1046122A (zh) | 1990-10-17 |
KR900016543A (ko) | 1990-11-13 |
EP0391000A3 (en) | 1992-05-13 |
US5091243A (en) | 1992-02-25 |
EP0391000B1 (en) | 1994-12-14 |
DE68920026D1 (de) | 1995-01-26 |
DE68920026T2 (de) | 1995-06-08 |
AU617010B2 (en) | 1991-11-14 |
JPH02269881A (ja) | 1990-11-05 |
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