CN1241446A - 防火毯和其它含有蜜胺树脂的组合物和具有防火性质的产品 - Google Patents

防火毯和其它含有蜜胺树脂的组合物和具有防火性质的产品 Download PDF

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CN1241446A
CN1241446A CN99105881.XA CN99105881A CN1241446A CN 1241446 A CN1241446 A CN 1241446A CN 99105881 A CN99105881 A CN 99105881A CN 1241446 A CN1241446 A CN 1241446A
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G·M·肯特
K·L·约翰逊
A·萨马卡
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Abstract

用三聚氰胺树脂纤维、芳族聚酰胺纤维和/或改性聚丙烯酸纤维的混合物生产的组合物和产品,它们具有优异的防火特性,以及高强度,极好的加工性能,和使最终用户感到舒适的特性。

Description

防火毯和其它含蜜胺树脂的 组合物和具有防火性质的产品
本申请是1997年9月26日提出的申请号为08/938,525的共同未决美国申请的部分继续，这里将该美国申请的全部内容引入作为参考。
一般地说，本发明涉及含有三聚氰胺树脂的组合物的领域。具体地说，本发明体现在这样的产品上，该产品应用了三聚氰胺树脂纤维、芳族聚酰胺纤维和/或改性聚丙烯酸纤维的关键性混合物，并且该产品具有优异的防火特性，以及高强度，极好的加工性能，和使最终用户感到舒适的特性。
万一住宅、工作场所或车辆着火，那么此处的人们将被暴露在敞开的火舌和剧烈燃烧的火焰环境中，而目前市场上没有能够提供足够防火保护的毯式产品。历史上专业消防员装备中所使用的耐火织物用在消费者的防护器材例如防火毯(即，住宅、工业或车辆装置中的人员可以使用的防火及防止火对人员皮肤的有害作用的毯)上一直是太昂贵并且笨重。
专业消防员的装备所使用的材料例如PBI或Lenzing P-84是非常昂贵的。有些工业耐火织物使用玻璃纤维，人接触到玻璃纤维会感到不舒适。由于这些原因，即费用和舒适的原因，此类材料不适合用户友善的应用，例如住宅、工作场所、车辆和其它环境下作为防火毯。迄今，从消费者的市场观点看，防火纤维技术还没有制造出此类可行的产品。考虑到如此常见的住宅、工作场所和车辆着火中的一级、二级和三级烧伤而失去的生命和所造成的伤害，这是令人感到遗憾的。
根据本发明，用于消费者防护器材以及专业防护器材的经济可行的防火产品是由三聚氰胺树脂组合物制成。概括地说，本发明体现在这样的织物上，该织物包括三聚氰胺树脂纤维、芳族聚酰胺纤维和/或改性聚丙烯酸纤维的关键性组合，这样就得到了经济可行的防火产品，并且该产品具有高强度，极好的加工性能，以及使最终用户感到舒适的特性。
所开发的本发明的产品可以作为在任何紧急场所用于防护过热和敞开的火焰的主要防火材料。在住所、私立医院、宾馆、车辆、工业和工作场所以及任何其它存在火灾或极高表面温度的环境中，这些产品都具有挽救生命和防止严重烧伤的潜能。
仔细研究了下面优选实施方案的详细描述之后，本发明的这些和其它方面的情况及其优点将更清楚。
这里所用的术语“纤维”指的是不同长度的短纤维。
本发明的混合纤维组合物包括三聚氰胺树脂纤维和有效量的芳族聚酰胺纤维和/或改性聚丙烯酸纤维。通常，混合纤维包括约15-约80重量份的三聚氰胺树脂纤维、约0-约80重量份的芳族聚酰胺纤维、和约0-约80重量份的改性聚丙烯酸纤维。本发明优选的实施方案由这样的混合纤维组成，该混合纤维中三聚氰胺树脂纤维的存在量为约20-约50重量份，芳族聚酰胺纤维的存在量为约20-约50重量份，和改性聚丙烯酸纤维的存在量为约20-50重量份。本发明另一种优选的实施方案由这样的混合纤维组成，该混合纤维中三聚氰胺树脂纤维的存在量为约30-约36重量份，芳族聚酰胺纤维的存在量为约30-约36重量份，和改性聚丙烯酸纤维的存在量为约30-36重量份。本发明还有一种优选的实施方案是由这样的混合纤维组成，该混合纤维中三聚氰胺树脂纤维的存在量为约33 1/3重量份，芳族聚酰胺纤维的存在量为约33 1/3重量份，和改性聚丙烯酸纤维的存在量为约33 1/3重量份。
根据本发明，可以使用混合纤维以生产具有优异的防火特性，以及高强度，极好的加工性能，和使最终用户感到舒适的特性的组合物。这些组合物可以用于毯(这里指的是“防火毯”)、私立医院和其它建筑的墙衬材料(例如，墙纸或墙幕)中，可以用于工业用途的焊接保护屏、热衬产品中，以及用于防火和/或高温的其它用途中。
可以用于本发明的三聚氰胺树脂纤维是由三聚氰胺—甲醛预缩合物的高浓度溶液生产的纤维，该纤维是这样生产的，即加入酸性固化剂后，旋转纺丝(rotospinning)、纺出、挤压或原纤化。所得到的纤维通常在拉伸或未拉伸的情况下预干燥，三聚氰胺树脂通常在120℃-250℃下固化。该纤维一般是约0.3-约8旦尼尔和约0.5-约8英寸长。尤其是，当三聚氰胺树脂中高达约30摩尔％，特别是约2-约20摩尔％的三聚氰胺被羟烷基三聚氰胺取代时，可以得到热稳定的纤维。此类纤维具有高达200℃，优选高达220℃的持续使用温度。另外，少量的三聚氰胺可以用取代的三聚氰胺、脲或苯酚代替。用于本发明的特别优选的三聚氰胺树脂纤维是商标为BASOFIL由BASF公司制造的市售产品。
可以用于本发明的芳族聚酰胺纤维是这样生产的纤维，即纺丝间苯二酸或对苯二酸与对或间苯二胺的缩聚产物在溶剂例如N-乙烯基吡咯烷酮和六甲基磷酰胺的混合物中的溶液。然后将所得到的连续纤维切成短纤维，其旦尼尔通常为约0.3-约8。优选的芳族聚酰胺纤维是基于同分异构的聚对苯基二甲酰对苯二胺的纤维。用于本发明的特别优选的芳族聚酰胺纤维是商标为KEVLAR由E.I.du Pontde Nemours & Company制造的市售产品，或商标为TWARON由Akzo Nobel制造的市售产品。
该申请中所使用的术语“改性聚丙烯酸纤维”通常指的是由低于约85％但至少约35重量％的丙烯腈单元〔CH2-CH(CN)-〕组成的任意长链的合成聚合物形成的纤维。可以用于本发明的合适的改性聚丙烯酸纤维包括(但不限于这些)由Kanebo，Ltd.(Tokyo，Japan)生产的改性聚丙烯酸纤维、由Solutia(Atlanta、Georgia)制造的自灭火的改性聚丙烯酸纤维和由Courtaulds Fibers Ltd.(U.K.)生产的INIDEX纤维。用于本发明的改性聚丙烯酸纤维特别优选的是商标为KANECARON由Kaneka Corporation制造的市售产品。
通常将本发明的三聚氰胺树脂纤维、芳族聚酰胺纤维和改性聚丙烯酸纤维在常规的纤维混合设备中进行混合。起始物一般是长度约1-约6英寸的常规长度的短纤维。也可以与纤维一起加入通常的添加剂例如填料、染料、颜料、金属粉末和/或褪光剂。起始物通常通过输送装置喂入盖板梳理机中并在其中进行预混合。然后通常在梳理机的工作辊和剥离梳理机(stripper card)中完成混合。然后用纺织工业中的普通加工方法将所得到的填絮进一步加工成纱或纤维网。然后根据应用领域，可以将这些纱、纤维网或织物进一步加工成各种织物或非织物结构。
也可以用本领域普通技术人员显而易见的常规方法和设备将本发明的混合纤维染色。例如，可以使用连续浸轧/汽蒸染色法，其中混合纤维以织物形式平幅浸渍。然后使织物通过约120°F的蒸箱，停留时间约(12)分钟。随后使织物经过水洗。用醋酸控制PH约为4。
本发明的混合纤维可以作为纱被加工成织物，例如防火毯，该防火毯与由各个纤维组分单独制成的其它织物相比具有极好防火特性并且更经济。
为了由本发明优选的芳族聚酰胺纤维含量约20-约50重量％的混合纤维生产织物，可以把梳理机工作辊和剥离梳理机(stripper carding)中得到的填絮进行交叉铺网和针刺。例如可以用所得到的纤维网制造防火产品。
根据本发明，可以把针刺的非织造织物剪成适当的尺寸并包装成毯，或如果需要可以将其折边。
通过下面非限定性的实施例可以进一步理解本发明。实施例
根据本发明优选的实施方案，把相同份数的三聚氰胺树脂纤维(BASOFIL)、对(para)芳族聚酰胺纤维(KEVLAR)和改性聚丙烯酸纤维(KANECARON)开松，并在纺织短纤维生产线中混合在一起。所得到的混合纤维含有约33 1/3重量份三聚氰胺树脂纤维、约33 1/3重量份芳族聚酰胺纤维和约33 1/3重量份改性聚丙烯酸纤维。
把纤维输送到纺织梳理机中，在此将纤维进一步混合并定向成毛层或填絮。然后将该毛层或填絮交叉铺网至所需的重量，并进一步混合。然后将交叉铺网的毛层或填絮喂入针刺机，该针刺机缠结纤维产生足够结实到可以用作毯的非织造织物。每平方码的最终重量约为6盎司。
把所得到的非织造织物制成四块毯子用于在热的人体模型上进行实验。所有的实验(下面称热人体模型实验，该实验公开在序号为08/938,525的共同未决美国专利申请中，该申请的全部内容显然已经被引入作为参考)都用2卡/cm2-秒的热通量进行。每次暴露的持续时间是4秒。
对四块实验毯中的每一块都分别这样进行实验，用每块毯子将人体模型的躯干包裹1.5遍，然后将被包裹的人体模型暴露在控制的火焰中4秒钟。用热传感器测定温度数据，将该数据通过计算机处理。计算机控制实验过程，从装备仪器的人体模型上获得数据，计算入射的热通量并预测烧伤情况，以及作出每个实验的报告，其结果列于表1中。表1  热人体模型试验结果
  样品   重量(kg) 暴露时间(秒) 预测烧伤(％)2级，3级，总和
    1     0.79     4     25     13     38
    2     0.80     4     34     8     42
    3     0.79     4     47     9     56
    4     0.79     4     39     11     50
  平均     0.79     4     36     10     46
为了比较，按照上述方法对Nomex IIIA工业工作服进行实验，所得到的实验结果列于表2，它是对Nomex IIIA工业工作服进行的三次热人体模型实验的平均值。表2热人体模型试验结果
    物品 暴露时间(秒)   预测烧伤(％)2级3级，总和
Nomex IIIA工业工作服     4     38     26     64
如上述实验结果所示，本发明具有意想不到的优异的防火能力(例如防烧伤)。当暴露在热通量为2卡/cm2-秒中，本发明的织物可以为人体模型提供防护，预测将产生低至约25％的二级烧伤(被覆盖的人体模型表面面积的25％将遭受二级烧伤)和约13％的三级烧伤(被覆盖的人体模型表面面积的13％将遭受三级烧伤)。Nomex IIIA工业工作服的更高的实验结果说明了本发明意想不到的防火特性。
目前已经描述了本发明最实用和优选的实施方案，但是，应当理解，本发明不限于所公开的方案，正相反，本发明意欲包括权利要求的精神和范围内的各种改进的和等效的方案。

Claims (26)

1、一种混合纤维，该混合纤维包括包括约15-约80重量份的三聚氰胺树脂纤维、约0-约80重量份的芳族聚酰胺纤维、和约0-约80重量份的改性聚丙烯酸纤维。
2、权利要求1的混合纤维，其中芳族聚酰胺纤维是对芳族聚酰胺纤维。
3、权利要求1的混合纤维，其中三聚氰胺树脂纤维的存在量为约30-约36重量份。
4、权利要求1的混合纤维，其中芳族聚酰胺纤维的存在量为约30-约36重量份。
5、权利要求1的混合纤维，其中改性聚丙烯酸纤维的存在量为约30-36重量份。
6、权利要求1的混合纤维，其中三聚氰胺树脂纤维的存在量为约30-约36重量份，芳族聚酰胺纤维的存在量为约30-约36重量份，改性聚丙烯酸纤维的存在量为约30-36重量份。
7、权利要求1的混合纤维，其中，三聚氰胺树脂纤维的存在量为约33 1/3重量份，芳族聚酰胺纤维的存在量为约33 1/3重量份，和改性聚丙烯酸纤维的存在量为约33 1/3重量份。
8、权利要求6或7的混合纤维，其中芳族聚酰胺纤维是对—芳族聚酰胺纤维。
9、由权利要求1-8任意一项的混合纤维得到的纱。
10、由权利要求1-8任意一项的混合纤维得到的毯。
11、由权利要求1-8任意一项的混合纤维得到的毯。
12、权利要求11的毯，其中该毯是织造物或非织造物。
13、由权利要求1-8任意一项的混合纤维得到的建筑材料。
14、权利要求1的混合纤维，其中三聚氰胺树脂纤维包括三聚氰胺—甲醛缩合物，其中约2-约20摩尔％的三聚氰胺被羟烷基三聚氰胺代替。
15、权利要求1的混合纤维，其中芳族聚酰胺纤维包括间苯二酸或对苯二酸与对或间苯二胺的缩聚产物。
16、权利要求1的混合纤维，芳族聚酰胺纤维包括同分异构的聚(对-苯二甲酰对苯二胺)。
17、权利要求1的混合纤维，其中混合纤维是染色散纤维。
18、一种通过混合成品纤维产权利要求1的混合纤维的方法，其中该混合物包括约15-约100重量份的三聚氰胺树脂纤维、约0-约100重量份的芳族聚酰胺纤维、和约0-约80重量份的改性聚丙烯酸纤维。
19、一种防火毯，它包括约15-约100重量份的三聚氰胺树脂纤维、约0-约100重量份的芳族聚酰胺纤维、和约0-约80重量份的改性聚丙烯酸纤维。
20、权利要求19的防火毯，其中芳族聚酰胺纤维是对—芳族聚酰胺纤维。
21、权利要求19的防火毯，其中三聚氰胺树脂纤维的存在量为约30-约36重量份。
22、权利要求19的防火毯，其中芳族聚酰胺纤维的存在量为约30-约36重量份。
23、权利要求19的防火毯，其中改性聚丙烯酸纤维的存在量为约30-36重量份。
24、权利要求19的防火毯，三聚氰胺树脂纤维的存在量为约30-约36重量份，其中芳族聚酰胺纤维的存在量为约30-约36重量份，改性聚丙烯酸纤维的存在量为约30-36重量份。
25、权利要求19的防火毯，其中，三聚氰胺树脂纤维的存在量为约33 1/3重量份，芳族聚酰胺纤维的存量为约33 1/3重量份，和改性聚丙烯酸纤维的存在量为约33 1/3重量份。
26、权利要求24或25的防火毯，其中其中芳族聚酰胺纤维是对—芳族聚酰胺纤维。
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