EP0419560B1 - Tissu textile enduit - Google Patents
Tissu textile enduit Download PDFInfo
- Publication number
- EP0419560B1 EP0419560B1 EP89907540A EP89907540A EP0419560B1 EP 0419560 B1 EP0419560 B1 EP 0419560B1 EP 89907540 A EP89907540 A EP 89907540A EP 89907540 A EP89907540 A EP 89907540A EP 0419560 B1 EP0419560 B1 EP 0419560B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- coating
- textile fabric
- fabric
- set forth
- carpet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Images
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/045—Vinyl (co)polymers
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/045—Vinyl (co)polymers
- D06N2203/047—Arromatic vinyl (co)polymers, e.g. styrene
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/045—Vinyl (co)polymers
- D06N2203/048—Polyvinylchloride (co)polymers
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/04—Foam
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2209/00—Properties of the materials
- D06N2209/06—Properties of the materials having thermal properties
- D06N2209/067—Flame resistant, fire resistant
Definitions
- This invention relates to textile fabrics, such as carpets and upholstery fabrics, which have both good flame spread resistance and low smoke generating properties.
- FR-A-1 491 223 describes a felt which is rendered fire resistant by applying thereto a composition comprising a synthetic resin and a fire resistant filler.
- EP-A-0 183 393 discloses a combustible carrier, e.g. a textile, having applied thereto a sodium silicate which is heat foamble to produce an element which resists the passage of fire thesethrough.
- carpets used as floor coverings in buildings and upholstery fabric should be resistant to the spread of a fire and should have relatively low smoke generating properties. Indeed, carpets and upholstery fabric are subject to various building codes and fire codes which define the permissible limits of flammability and smoke generation.
- DOC FFI-70 Pill Test
- the flooring radiant panel test (ASTM Standard Test Method E648) was developed to measure the flame spread or flame propagation properties of a floor covering system when exposed to a more fully developed fire. In particular, it measures the flame propagation properties of the floor covering under conditions which simulate the influence of a large fire source in the room.
- ASTM Standard Test Method E662 was developed to measure the amount of smoke produced during a fire and is informative in showing the magnitude of the smoke problem.
- flame retardant additives in the face fibers of the carpet, as described, for example, in US-A- 4,012,546, 4,097,630 and 4,193,911.
- Another approach has been to apply flame retardant after treatments to the fibers, as described, for example, in US-A- 4,173,671, 4,504,546, 4,610,905 and 4,618,522.
- Another approach has involved incorporating a flame retardant additive in the latex coating which binds the pile yarns to the primary backing as described, for example, in US-A- 3,663,345 and 4,689,256.
- Exemplary flame retardant additives have included antimony oxide, antimony chloride, phosphates and borates of alkali metals, alkaline earth metals and aluminum hydrates.
- smoke suppressant compounds must also be added to the carpet or carpet coatings.
- Exemplary compounds utilized as smoke suppressants include mixtures of certain nickel, bismuth, zinc, copper, iron or molybdenum compounds as described in US-A- 3,975,359, 4,055,537 and 4,143,030.
- the present invention advantageously improves both the flame spread resistant and also the smoke suppressant properties of a textile fabric.
- the present invention is a departure from conventional approaches to imparting flame resistance to a fabric.
- a textile material is provided with a coating which includes an inorganic filler material which functions as a flame blocker and a radiant energy reflector.
- the coating composition upon exposure to heat or flame forms a heat reflective ceramic barrier or mantle which effectively reduces the amount of flame spread and also the amount of smoke.
- the coating of the present invention comprises a film-forming polymer binder and a heat reflective filler material selected from the group consisting of natural and synthetic silicates, barites, talcs, and silicas.
- the filler material is dispersed in and bound to the fabric by the film-forming polymer binder.
- mica is used as the inorganic filler material and the film-forming polymer binder is derived from at least one monomer selected from the group consisting of acrylic, vinyl, chlorinated vinyl, styrene, butadiene and ethylene monomers and copolymers or blends thereof.
- the coating is applied to the rear surface of the primary backing of the carpet.
- a secondary backing such as a foamed or unfoamed polyvinylchloride layer, is bonded to the coated rear surface of the primary backing.
- the coating is applied to the rear surface of the fabric, and forms a flame retardant, smoke suppressant, heat reflective barrier for protecting underlying cushioning materials.
- a pile carpet construction typically comprises a primary backing 10, pile yarns 15 extending through the primary backing, a precoat layer 20 applied to the rear surface of the primary backing 10 of the carpet as a "tuftlock" coating and a secondary backing 25.
- the secondary backing may typically comprise a foamed or unfoamed polymer composition such as polyvinyl chloride, polyethylene or polyurethane.
- An upholstery fabric construction as shown in Figure 5, comprises an outer upholstery layer 30 of a woven, knitted or nonwoven textile fabric bonded to an underlying foam or padding layer 35.
- a coating which, in addition to its function as a precoat layer for use with pile carpet fabric or an adhesive layer for use with upholstery fabric also provides improved flame spread resistance and smoke suppressant properties to the textile fabric.
- the coating in either latex or plastisol form, comprises a film-forming polymer binder and an inorganic material which forms a heat reflective ceramic barrier upon combustion which is dispersed in and bound to the fabric by the film-forming polymer binder.
- the amount of the heat reflective material in relation to the polymer binder is typically from about 25 to about 200 parts by weight per 100 parts of polymer binder.
- Exemplary film-forming polymer binders may be derived from at least one monomer selected from the group consisting of acrylic, vinyl, chlorinated vinyl, styrene, butadiene and ethylene monomers and copolymers or blends thereof. Particularly useful binders include polyvinylidene chloride and vinyl acetate ethylene.
- the inorganic heat-reflective material includes natural and synthetic silicates and barites.
- a preferred silicate is mica which is a general name for a group of hydrous potassium-aluminum silicate minerals which may contain Mg, Fe(II), Mn, Li, Fe(III) and Ti as major or minor constituents.
- the mica also may have some impurities such as FeSO4 which add to the flame retardant properties of the mica.
- Mica is characterized by a structure based on sheets of linked (SiAl)O4 tetrahedrons, the geometry of which accounts for the characteristic cleavage of the mica into sheets or platelets.
- the inorganic filler material Upon exposure of the textile side of the carpet by a radiant heat source such as a flame located close to the carpet, the inorganic filler material, and particularly mica, functions as a flame spread resistance agent by blocking the heat from the flame from the highly flammable secondary backing portion of the carpet. Ninety to ninety-five percent or more of the heat energy is reflected from the heat source. As illustrated in Figures 2 and 4, the inorganic filler material, when subjected to a flame, forms a charred ceramic barrier 12 characterized by a highly porous net-like appearance. This barrier 12 is disposed between the heat source above the textile fabric and the highly flammable secondary backing 25.
- the ceramic barrier reduces the amount of smoke generated by serving to promote more complete combustion of the combustible vapors which are evolved from the backing 25.
- the charred ceramic barrier 12 appears to function much like the mantle of a gas lantern. Any smoke or vapors that are evolved from the backing 25 pass through the small openings of the barrier and are burned.
- the coating may also advantageously include hydrated inorganic filler material such as calcium carbonate or aluminum trihydrate.
- the amount may be varied as desired depending upon the nature of the secondary backing and the degree of flame and smoke suppressing desired. Particularly good results are observed when the hydrated filler is used in amounts equal to the amounts of ceramic barrier forming inorganic filler material present.
- the coating may also include an intumescent material. The intumescent particles expand and swell when exposed to high heat, thus further reducing the amount of smoke escaping from the layers of the carpet that may be burning. Further, the particles, when exposed to high heat, release water that reduces the propensity of the carpet to flame.
- Exemplary intumescent compounds may include compounds having a polyhydric source of carbon such as starch or pentaerthritol in combination with a source of hydrochloric acid or phosphoric acid such as monoammonium phosphate.
- the coating is particularly effective for improving the flame spread resistance properties of the textile fabric.
- Flame spread resistance is measured in accordance with ASTM Standard Test Method E662 for Critical Radiant Flux of Floor-Covering Systems Using a Radiant Heat Energy Source. This test is designed to simulate a likely set of conditions which may lead to fire spread in a carpet system. The test method determines a critical radiant flux, measured in watts per square centimeter, and is a measurement of the lowest level of radiant energy necessary for a fire to continue to burn and spread.
- the actual test uses a horizontally mounted floor covering sample which is exposed to radiant energy from a gas-air fueled radiant panel mounted above one end of the sample at an angle of 30°.
- the radiant panel generates a radiant flux profile along the length of the sample ranging from a maximum of 1.1 watts/cm2 immediately under the panel to approximately 0.1 watts/cm2 at the end of the sample remote from the panel.
- a gas fired pilot burner is used to initiate the ignition on the floor covering sample immediately below the radiant panel and the test is continued until the flooring system ceases to burn. The distance the flooring system burns to extinguishment is converted to watts per square centimeter from a calibration graph.
- the result of the test is reported as the critical radiant flux. This is the minimum radiant energy a fire needs to sustain flame propagation in the flooring system. In this test, the lower the number, the greater is the tendency of the system to spread flame. Conversely, the higher the number, the more resistant the material is to flame propagation.
- Oak flooring has a critical radiant flux value of about 0.35 to 0.40 watts/cm2 and carpet using conventional coatings has a critical radiant flux value of about 0.36 to 0.45 watts/cm2.
- the present invention provides a pronounced improvement in this property and carpet using the present coating has a critical radiant flux value of from about 0.50 to 0.70 watts/cm2.
- the coating is also an effective smoke suppressant.
- Smoke suppressant properties are measured using ASTM Standard Test Method E662 entitled "Specific Optical Density of Smoke Generated By Solid Materials.” The test measures the specific optical density of smoke generated by the solid materials and measures the concentration of smoke. A lower value is desired.
- Carpet coated with conventional flame retardants have a smoke density value of about 360 to 460, whereas the coating of the present invention provides a smoke density value of from 260 to 350.
- pile carpets comprise a primary backing 10 and pile yarns 15 extending from the primary backing to form pile tufts.
- the pile yarn 15 is inserted into the backing by tufting needles and to maintain the yarn tufts permanently in place in the backing a coating 20 such as that of the present invention is applied to the rear surface of the primary backing 10 to lock the tufts in place.
- the primary backing may be formed of natural fibers such as jute, or of synthetic fibers such as polypropylene, polyethylene, or polyester, for example.
- the pile carpet also typically includes a secondary backing 25 bonded to the primary backing 10 using the thermoplastic properties of the present coating.
- the secondary backings 25 may be formed of woven or nonwoven materials similar to those used as the primary backing.
- the secondary backing may be formed of natural fibers, such as jute or of synthetic fibers such as polypropylene, polyethylene or polyester.
- the secondary backing may comprise a foamed or unfoamed polymer sheet.
- Suitable polymer compositions include urethane polymers, polymers and copolymers of ethylene, propylene, isobutylene, and vinyl chloride. These compositions, however, are typically flammable and emit potentially dangerous smoke when burned.
- the upholstery fabric may be a sheet or film such as vinyl or synthetic leather, or a woven, nonwoven or knitted fabric, formed of natural fibers, synthetic fibers or blends thereof. Particularly desirable is a fabric construction which provides a pleasing hand to the upholstery layer and permits patterns and grains to be incorporated therein for aesthetic appeal.
- the upholstery fabric is shown as being used in a laminate form which includes an outer upholstery layer 30 and an inner foam layer 35 to provide cushioning and a rear fabric or scrim layer 40 which facilitates securement of the laminate to an underlying substrate.
- the inner foam layer 35 and the outer upholstery layer 30 can be bonded together using the coating layer 20 of the present invention.
- Suitable foam compositions for the foam layer 35 include urethane polymers, polymers and copolymers of ethylene, propylene, isobutylene, and vinyl chloride with urethane polymers being preferred.
- the first step of the method of producing a pile carpet having flame spread resistance and smoke suppressant properties comprises applying to the rear surface of the primary backing of the carpet and in contact with the pile yarns extending through the rear surface of the backing, an aqueous latex coating comprising a dispersion of a film-forming polymer binder and an inorganic heat-reflective material such as natural and synthetic silicates and barites.
- the rear surface of the backing is then heated to dry the coating and to bind the heat-reflective material to the pile yarns.
- the secondary backing is bonded to the primary backing.
- a carpet coating was compounded having the following ingredients: The compounded coating had a pH of 5 and a viscosity at 20 rpm of 3000 cps. The coating was mixed in an electric drum mixer until all of the solid material was dispersed. The coating was then coated on sections of carpet made from different nylon 66 fibers designated as "A", "B” and "C” at approximate coating levels of 7 g/m2 (24 oz/sq yds). A polyvinylchloride secondary backing was then applied to the back of the carpet.
- a carpet coating was compounded having the following ingredients: The compound coating had a pH of 5.5 and a viscosity at 20 rpm of 3000 cps. The coating was then mixed and coated on sections of carpet made from nylon 66 fibers the same as in Example 1 at coating levels of 7 g/m2 (24 oz/sq yds). A polyvinylchloride backing was then applied to the back of the carpet.
- a carpet coating was compounded having the following ingredients: The compounded coating had a pH of 5 and a viscosity at 20 rpm of 3000 cps. The coating was mixed and coated on sections of carpet made from nylon 66 fibers designated as "A" at approximate coating levels of 7 g/m2 (24 oz/sq yds). A polyvinylchloride secondary backing was then applied to the back of the carpet.
- a conventional coating without any mica was prepared having the following ingredients: The compound coating had a pH of 5.5 and a viscosity at 20 rpm of 3000 cps. The coating was then mixed and coated on sections of carpet made from nylon 66 fibers as in Example 1 at coating levels of 7 g/m2 (24 oz/sq yds). A polyvinylchloride backing was then applied to the back of the carpet.
- a textile fabric having a coating comprising a film-forming polymer binder and an inorganic filler material which forms a heat reflective barrier upon combustion and has improved flame spread resistance and smoke suppressant properties as compared to carpets having a conventional coating thereon.
- the fibers coated with the present coating and having a polyvinylchloride backing still exhibit acceptable smoke density value despite the fact that the polyvinylchloride secondary backing usually results in poor, unacceptable values because of the great amount of smoke polyvinylchloride polymers tend to give off upon combustion.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Carpets (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Chemical Or Physical Treatment Of Fibers (AREA)
Abstract
Claims (14)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US20768188A | 1988-06-16 | 1988-06-16 | |
US207681 | 1988-06-16 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0419560A1 EP0419560A1 (fr) | 1991-04-03 |
EP0419560B1 true EP0419560B1 (fr) | 1992-08-12 |
Family
ID=22771564
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP89907540A Expired - Lifetime EP0419560B1 (fr) | 1988-06-16 | 1989-06-07 | Tissu textile enduit |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP0419560B1 (fr) |
JP (1) | JPH03505105A (fr) |
WO (1) | WO1989012715A1 (fr) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5868969A (en) * | 1996-10-03 | 1999-02-09 | Fi-Ban, Inc. | Solid polyhalon impregnation of objects for fire-suppression |
AU751644B2 (en) * | 1998-04-15 | 2002-08-22 | Akro-Fireguard Products, Inc. | Low smoke, low toxicity carpet |
US6706362B2 (en) * | 2002-01-30 | 2004-03-16 | Textile Rubber & Chemical Co., Inc. | Sodium silicate coating process and products incorporating same |
GB2522255A (en) * | 2014-01-20 | 2015-07-22 | Clark Wright Ltd | An insulating apparatus |
JP2016125163A (ja) * | 2014-12-29 | 2016-07-11 | 株式会社クラレ | ポリエーテルイミド系繊維およびポリエーテルイミド系繊維集合体 |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0183393A2 (fr) * | 1984-10-31 | 1986-06-04 | Digital Equipment Corporation | Matériaux résistant au feu |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE519395A (fr) * | ||||
US2428282A (en) * | 1944-01-29 | 1947-09-30 | Sloane Blabon | Fire-resistant linoleum product |
FR1491223A (fr) * | 1965-12-14 | 1967-08-11 | Matériau susceptible de servir d'élément de revêtement pour des murs ou plancherspar exemple | |
JPS5522089A (en) * | 1978-07-27 | 1980-02-16 | United Merchants & Mfg | Treating composition and method of fabric |
GB2122232B (en) * | 1982-06-19 | 1986-08-28 | British Vita | Fire retardant materials |
US4513042A (en) * | 1984-07-23 | 1985-04-23 | Glenoit Mills, Inc. | Nonflammable sliver knit high pile fabric |
-
1989
- 1989-06-07 JP JP50691189A patent/JPH03505105A/ja active Pending
- 1989-06-07 EP EP89907540A patent/EP0419560B1/fr not_active Expired - Lifetime
- 1989-06-07 WO PCT/US1989/002494 patent/WO1989012715A1/fr active IP Right Grant
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0183393A2 (fr) * | 1984-10-31 | 1986-06-04 | Digital Equipment Corporation | Matériaux résistant au feu |
Also Published As
Publication number | Publication date |
---|---|
EP0419560A1 (fr) | 1991-04-03 |
JPH03505105A (ja) | 1991-11-07 |
WO1989012715A1 (fr) | 1989-12-28 |
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