US20040063371A1 - Chemical resistant, water and dry particle impervious, flame resistant laminate - Google Patents
Chemical resistant, water and dry particle impervious, flame resistant laminate Download PDFInfo
- Publication number
- US20040063371A1 US20040063371A1 US10/687,814 US68781403A US2004063371A1 US 20040063371 A1 US20040063371 A1 US 20040063371A1 US 68781403 A US68781403 A US 68781403A US 2004063371 A1 US2004063371 A1 US 2004063371A1
- Authority
- US
- United States
- Prior art keywords
- laminate
- layer
- fire retardant
- fibers
- retardant additive
- 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.)
- Abandoned
Links
- 239000000126 substance Substances 0.000 title abstract description 12
- 239000002245 particle Substances 0.000 title description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title description 4
- 239000004744 fabric Substances 0.000 claims abstract description 34
- 239000003063 flame retardant Substances 0.000 claims abstract description 24
- 239000000654 additive Substances 0.000 claims abstract description 19
- 230000000996 additive effect Effects 0.000 claims abstract description 15
- 230000001681 protective effect Effects 0.000 claims abstract description 10
- 239000000835 fiber Substances 0.000 claims description 26
- 239000004745 nonwoven fabric Substances 0.000 claims description 11
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 9
- 239000004800 polyvinyl chloride Substances 0.000 claims description 9
- 239000000853 adhesive Substances 0.000 claims description 8
- 230000001070 adhesive effect Effects 0.000 claims description 8
- 229920000728 polyester Polymers 0.000 claims description 7
- 229920001131 Pulp (paper) Polymers 0.000 claims description 6
- 229910019142 PO4 Inorganic materials 0.000 claims description 5
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 claims description 5
- 230000002706 hydrostatic effect Effects 0.000 claims description 5
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 5
- 239000010452 phosphate Substances 0.000 claims description 5
- 229920003043 Cellulose fiber Polymers 0.000 claims description 3
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 claims description 3
- LFVGISIMTYGQHF-UHFFFAOYSA-N ammonium dihydrogen phosphate Chemical compound [NH4+].OP(O)([O-])=O LFVGISIMTYGQHF-UHFFFAOYSA-N 0.000 claims description 3
- 229910000387 ammonium dihydrogen phosphate Inorganic materials 0.000 claims description 3
- 235000019826 ammonium polyphosphate Nutrition 0.000 claims description 3
- 229920001276 ammonium polyphosphate Polymers 0.000 claims description 3
- 239000004202 carbamide Substances 0.000 claims description 3
- 235000019837 monoammonium phosphate Nutrition 0.000 claims description 3
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 3
- NSBGJRFJIJFMGW-UHFFFAOYSA-N trisodium;stiborate Chemical compound [Na+].[Na+].[Na+].[O-][Sb]([O-])([O-])=O NSBGJRFJIJFMGW-UHFFFAOYSA-N 0.000 claims description 3
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 claims description 3
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 3
- JJEPQBZQAGCZTH-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-[2-(2,3,4,5,6-pentabromophenoxy)ethoxy]benzene Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1OCCOC1=C(Br)C(Br)=C(Br)C(Br)=C1Br JJEPQBZQAGCZTH-UHFFFAOYSA-N 0.000 claims description 2
- FIAXCDIQXHJNIX-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-ethylbenzene Chemical compound CCC1=C(Br)C(Br)=C(Br)C(Br)=C1Br FIAXCDIQXHJNIX-UHFFFAOYSA-N 0.000 claims description 2
- OZHJEQVYCBTHJT-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-methylbenzene Chemical compound CC1=C(Br)C(Br)=C(Br)C(Br)=C1Br OZHJEQVYCBTHJT-UHFFFAOYSA-N 0.000 claims description 2
- YATIGPZCMOYEGE-UHFFFAOYSA-N 1,3,5-tribromo-2-[2-(2,4,6-tribromophenoxy)ethoxy]benzene Chemical compound BrC1=CC(Br)=CC(Br)=C1OCCOC1=C(Br)C=C(Br)C=C1Br YATIGPZCMOYEGE-UHFFFAOYSA-N 0.000 claims description 2
- VPCDIRXBJQNZNC-UHFFFAOYSA-N 1,3-dibromo-5-[2-[3,5-dibromo-4-(2,3-dibromopropyl)phenoxy]propan-2-yloxy]-2-(2,3-dibromopropyl)benzene Chemical compound C=1C(Br)=C(CC(Br)CBr)C(Br)=CC=1OC(C)(C)OC1=CC(Br)=C(CC(Br)CBr)C(Br)=C1 VPCDIRXBJQNZNC-UHFFFAOYSA-N 0.000 claims description 2
- OUCSIUCEQVCDEL-UHFFFAOYSA-N 2,3,4-tribromophenol Chemical class OC1=CC=C(Br)C(Br)=C1Br OUCSIUCEQVCDEL-UHFFFAOYSA-N 0.000 claims description 2
- JHJUYGMZIWDHMO-UHFFFAOYSA-N 2,6-dibromo-4-(3,5-dibromo-4-hydroxyphenyl)sulfonylphenol Chemical compound C1=C(Br)C(O)=C(Br)C=C1S(=O)(=O)C1=CC(Br)=C(O)C(Br)=C1 JHJUYGMZIWDHMO-UHFFFAOYSA-N 0.000 claims description 2
- VEORPZCZECFIRK-UHFFFAOYSA-N 3,3',5,5'-tetrabromobisphenol A Chemical compound C=1C(Br)=C(O)C(Br)=CC=1C(C)(C)C1=CC(Br)=C(O)C(Br)=C1 VEORPZCZECFIRK-UHFFFAOYSA-N 0.000 claims description 2
- 238000003855 Adhesive Lamination Methods 0.000 claims description 2
- 239000007983 Tris buffer Substances 0.000 claims description 2
- 229920002678 cellulose Polymers 0.000 claims description 2
- 239000001913 cellulose Substances 0.000 claims description 2
- WHHGLZMJPXIBIX-UHFFFAOYSA-N decabromodiphenyl ether Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1OC1=C(Br)C(Br)=C(Br)C(Br)=C1Br WHHGLZMJPXIBIX-UHFFFAOYSA-N 0.000 claims description 2
- CAYGQBVSOZLICD-UHFFFAOYSA-N hexabromobenzene Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1Br CAYGQBVSOZLICD-UHFFFAOYSA-N 0.000 claims description 2
- OJMHGSMSQZEBFH-UHFFFAOYSA-N hexabromodiphenyl ethers Chemical compound BrC1=CC(Br)=CC(Br)=C1OC1=CC(Br)=CC(Br)=C1Br OJMHGSMSQZEBFH-UHFFFAOYSA-N 0.000 claims description 2
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical compound OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 claims description 2
- 238000003475 lamination Methods 0.000 claims description 2
- SVHOVVJFOWGYJO-UHFFFAOYSA-N pentabromophenol Chemical compound OC1=C(Br)C(Br)=C(Br)C(Br)=C1Br SVHOVVJFOWGYJO-UHFFFAOYSA-N 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 125000003011 styrenyl group Chemical class [H]\C(*)=C(/[H])C1=C([H])C([H])=C([H])C([H])=C1[H] 0.000 claims description 2
- AUHHYELHRWCWEZ-UHFFFAOYSA-N tetrachlorophthalic anhydride Chemical compound ClC1=C(Cl)C(Cl)=C2C(=O)OC(=O)C2=C1Cl AUHHYELHRWCWEZ-UHFFFAOYSA-N 0.000 claims description 2
- 239000004114 Ammonium polyphosphate Substances 0.000 claims 2
- WVMYSOZCZHQCSG-UHFFFAOYSA-N bis(sulfanylidene)zirconium Chemical compound S=[Zr]=S WVMYSOZCZHQCSG-UHFFFAOYSA-N 0.000 claims 2
- 235000013877 carbamide Nutrition 0.000 claims 2
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 claims 2
- 229910000476 molybdenum oxide Inorganic materials 0.000 claims 2
- PQQKPALAQIIWST-UHFFFAOYSA-N oxomolybdenum Chemical compound [Mo]=O PQQKPALAQIIWST-UHFFFAOYSA-N 0.000 claims 2
- GRPTWLLWXYXFLX-UHFFFAOYSA-N 1,1,2,2,3,3-hexabromocyclodecane Chemical compound BrC1(Br)CCCCCCCC(Br)(Br)C1(Br)Br GRPTWLLWXYXFLX-UHFFFAOYSA-N 0.000 claims 1
- GRZZXOIUHGCCCK-UHFFFAOYSA-N BrC1=C(C(=C(C2(C1(C1=CC=CC=C1)O2)Br)Br)Br)Br Chemical compound BrC1=C(C(=C(C2(C1(C1=CC=CC=C1)O2)Br)Br)Br)Br GRZZXOIUHGCCCK-UHFFFAOYSA-N 0.000 claims 1
- 150000008064 anhydrides Chemical class 0.000 claims 1
- 239000012188 paraffin wax Substances 0.000 claims 1
- 239000000463 material Substances 0.000 description 11
- 238000000034 method Methods 0.000 description 8
- 239000007787 solid Substances 0.000 description 5
- 230000003068 static effect Effects 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 102100026816 DNA-dependent metalloprotease SPRTN Human genes 0.000 description 4
- 101710175461 DNA-dependent metalloprotease SPRTN Proteins 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 4
- 230000004888 barrier function Effects 0.000 description 4
- QGJOPFRUJISHPQ-UHFFFAOYSA-N Carbon disulfide Chemical compound S=C=S QGJOPFRUJISHPQ-UHFFFAOYSA-N 0.000 description 3
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 3
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 239000004814 polyurethane Substances 0.000 description 3
- -1 vapor Substances 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 239000004772 Sontara Substances 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical class OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 2
- 239000004327 boric acid Chemical class 0.000 description 2
- 239000012943 hotmelt Substances 0.000 description 2
- 239000002650 laminated plastic Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- LNOPIUAQISRISI-UHFFFAOYSA-N n'-hydroxy-2-propan-2-ylsulfonylethanimidamide Chemical compound CC(C)S(=O)(=O)CC(N)=NO LNOPIUAQISRISI-UHFFFAOYSA-N 0.000 description 2
- LQNUZADURLCDLV-UHFFFAOYSA-N nitrobenzene Chemical compound [O-][N+](=O)C1=CC=CC=C1 LQNUZADURLCDLV-UHFFFAOYSA-N 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 238000010561 standard procedure Methods 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- ACRQLFSHISNWRY-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-phenoxybenzene Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1OC1=CC=CC=C1 ACRQLFSHISNWRY-UHFFFAOYSA-N 0.000 description 1
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- CPELXLSAUQHCOX-UHFFFAOYSA-M Bromide Chemical compound [Br-] CPELXLSAUQHCOX-UHFFFAOYSA-M 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- 229920002284 Cellulose triacetate Polymers 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 239000005696 Diammonium phosphate Substances 0.000 description 1
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 description 1
- 229920000433 Lyocell Polymers 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- CYTYCFOTNPOANT-UHFFFAOYSA-N Perchloroethylene Chemical group ClC(Cl)=C(Cl)Cl CYTYCFOTNPOANT-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- QHWKHLYUUZGSCW-UHFFFAOYSA-N Tetrabromophthalic anhydride Chemical compound BrC1=C(Br)C(Br)=C2C(=O)OC(=O)C2=C1Br QHWKHLYUUZGSCW-UHFFFAOYSA-N 0.000 description 1
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 1
- NNLVGZFZQQXQNW-ADJNRHBOSA-N [(2r,3r,4s,5r,6s)-4,5-diacetyloxy-3-[(2s,3r,4s,5r,6r)-3,4,5-triacetyloxy-6-(acetyloxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6s)-4,5,6-triacetyloxy-2-(acetyloxymethyl)oxan-3-yl]oxyoxan-2-yl]methyl acetate Chemical compound O([C@@H]1O[C@@H]([C@H]([C@H](OC(C)=O)[C@H]1OC(C)=O)O[C@H]1[C@@H]([C@@H](OC(C)=O)[C@H](OC(C)=O)[C@@H](COC(C)=O)O1)OC(C)=O)COC(=O)C)[C@@H]1[C@@H](COC(C)=O)O[C@@H](OC(C)=O)[C@H](OC(C)=O)[C@H]1OC(C)=O NNLVGZFZQQXQNW-ADJNRHBOSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- GHPGOEFPKIHBNM-UHFFFAOYSA-N antimony(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Sb+3].[Sb+3] GHPGOEFPKIHBNM-UHFFFAOYSA-N 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- 229920002301 cellulose acetate Polymers 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 description 1
- 229910000388 diammonium phosphate Inorganic materials 0.000 description 1
- 235000019838 diammonium phosphate Nutrition 0.000 description 1
- HPNMFZURTQLUMO-UHFFFAOYSA-N diethylamine Chemical compound CCNCC HPNMFZURTQLUMO-UHFFFAOYSA-N 0.000 description 1
- 239000004715 ethylene vinyl alcohol Substances 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000007756 gravure coating Methods 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- RZXDTJIXPSCHCI-UHFFFAOYSA-N hexa-1,5-diene-2,5-diol Chemical compound OC(=C)CCC(O)=C RZXDTJIXPSCHCI-UHFFFAOYSA-N 0.000 description 1
- 229920001477 hydrophilic polymer Polymers 0.000 description 1
- 238000007759 kiss coating Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000000575 pesticide Substances 0.000 description 1
- 239000002798 polar solvent Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 239000004627 regenerated cellulose Substances 0.000 description 1
- 238000005067 remediation Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229950011008 tetrachloroethylene Drugs 0.000 description 1
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
- A41D31/08—Heat resistant; Fire retardant
- A41D31/085—Heat resistant; Fire retardant using layered materials
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
- A41D31/10—Impermeable to liquids, e.g. waterproof; Liquid-repellent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/04—Cellulosic plastic fibres, e.g. rayon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2327/00—Polyvinylhalogenides
- B32B2327/06—PVC, i.e. polyvinylchloride
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2437/00—Clothing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2571/00—Protective equipment
- B32B2571/02—Protective equipment defensive, e.g. armour plates or anti-ballistic clothing
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- Y10S428/92—Fire or heat protection feature
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- Y10S428/921—Fire or flameproofing
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- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2631—Coating or impregnation provides heat or fire protection
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- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2631—Coating or impregnation provides heat or fire protection
- Y10T442/2713—Halogen containing
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- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2762—Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
- Y10T442/277—Coated or impregnated cellulosic fiber fabric
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- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2762—Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
- Y10T442/277—Coated or impregnated cellulosic fiber fabric
- Y10T442/2787—Coating or impregnation contains a vinyl polymer or copolymer
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- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
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- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
- Y10T442/2869—Coated or impregnated regenerated cellulose fiber fabric
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- Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet
- Y10T442/676—Vinyl polymer or copolymer sheet or film [e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, etc.]
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/68—Melt-blown nonwoven fabric
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/681—Spun-bonded nonwoven fabric
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/689—Hydroentangled nonwoven fabric
Definitions
- U.S. Pat. No. 5,491,022 relates to a product having a plastic laminate formed by coextruding at least two layers of polymeric sheets with an intermediate layer of a polar resin or hydrophilic polymer. The plastic laminate is then adhered to a fabric scrim formed of polyester and cellulosic fibers treated with fire retardant and antistatic agents.
- the product described in the '022 patent has a thickness of at least 125 mils, and is, therefore, undesirably thick and heavy.
- An object of the invention is to provide a material that is fire retardant.
- Another object of the invention is to provide a material that is resistant to chemicals.
- Another object of the invention is to provide a material that is relatively light weight and has structural integrity sufficient to form a protective garment.
- a laminate containing a first layer of a nonwoven fabric having a fire retardant additive applied thereto; and a second layer containing a polymeric film.
- a laminate having a first layer of a nonwoven fabric containing cellulose and manmade fibers, the first layer having a fire retardant additive applied thereto; and a second layer of a polyvinyl chloride film.
- the barrier film may have at least some degree of flame resistance or may contain a fire retardant additive.
- the resulting material referred to herein as a “laminate,” is resistant to certain chemicals in liquid, vapor, or solid form, and is also flame resistant.
- the laminate is also impervious to water and dry particles.
- flame resistant refers to the ability of the fabric to pass at least one flame resistance test set forth by the National Fire Protection Association in “NFPA 701 Standard Methods of Fire Tests for Flame-Resistant Textiles and Films,” 1996 Ed. and “NFPA 701 Standard Methods of Fire Tests for Flame-Resistant Textiles and Films,” 1989 Ed. The entire contents of each of those publications are incorporated herein by reference,
- the laminate has a first layer that is a nonwoven fabric.
- nonwoven fabrics include spunbond fabrics, resin bonded fabrics, thermal bonded fabrics, air-laid pulp fabrics, and stitchbonded fabrics.
- the nonwoven fabric is a spunlace fabric made from a combination of cellulosic and manmade fibers.
- Cellulosic fibers that may be used to form the spunlace fabric include woodpulp fibers, cotton fibers, regenerated cellulose fibers such as Rayon® (obtained from DuPont) or Lyocell® (obtained from DuPont, cellulose acetate fibers, cellulose triacetate fibers, jute, hemp and any bast, leaf, or stem fibers.
- woodpulp fibers are used.
- Manmade fibers that may be used to form the spunlace fabric include polyester, nylon, or acrylic fibers.
- the cellulosic and manmade fibers are in the form of flat layers.
- the celluosic fibers are in the form of sheets of paper and the manmade fibers are in the form of an air-laid web of staple fibers or a nonwoven sheet of substantially continuous filaments.
- the webs or sheets may be bonded or nonbonded.
- the weight ratio of the cellulosic fibers to manmade fibers ranges from 75:25 to 25:75, more preferably from 65:35 to 50:50.
- the weight of the spunlace fabric used in the laminate is determined by the degree of dimensional stability needed as well as wear durability needed in protective apparel applications.
- a preferred weight range for the spunlace fabric is 1.0 osy to 4.0 osy.
- An example of a spinlace woodpulp/polyester fabric that can be used to form the laminate is sold by DuPont under the tradename Sontara®.
- the nonwoven fabric used in the laminate is preferably formed by a spunlace process.
- spunlace processing are well known in the art.
- a pulp containing cellulosic fibers may be applied to one side of a batt of carded manmade fibers.
- the material is then passed under a plurality of water jets, which entangle the manmade and cellulosic fibers to form a fabric.
- Methods of making the spunlace fabric are described in U.S. Pat. No. 4,442,161, the entire contents or which are incorporated herein by reference.
- a fire retardant additive is applied to the spunlace fabric, at a preferred dry solids add-on ranging from about 5 to about 45 percent by weight of the spunlace fabric. Preferably, the dry solids add-on ranges from about 15 to about 25 percent by weight of the spunlace fabric.
- Any well-known inorganic fire retardant additives can be used, including ammonium polyphosphates, ammonium dihydrogen phosphate, antimony trioxide, sodium antimonate, zinc borate, zirconium oxides, diammonium phosphate, sulfamic acid, salts of sulfamic acid, boric acid, salts of boric acid, and hydrated alumina.
- organic fire retardant additives that may be used include urea polyammonium phosphate, chlorinated paraffins, tetrabromobisphenol-A and oligomers thereof, decabromodiphenyl oxide, hexabromodiphenyl oxide, pentabromodiphenyl oxide, pentabromotoluene, pentabromoethylbenzene, hexabromobenzene, pentabromophenol, tribromophenol derivatives, perchloropentanecyclodecane, hexabromocyclodecone, tris(2,3-dibromopropyl-1)isocyanurate, tetrabromobisphenol-S and derivatives thereof, 1,2-bis(2,3,4,5,6-pentabromophenoxy)ethane, 1,2-bis-(2,4,6-tribromophenoxy)ethane, brominated styrene oligomers, 2,2-bis(2,3,4,5,
- fire retardant additives may be used.
- a preferred fire retardant additive is a phosphate, such as Spartan 880® sold by Spartan Flame Retardants.
- the fire retardant additive may be applied to the spunlace fabric by any conventional method such as spraying, contacting the spunlace fabric with a saturation pad or saturation roller, a dip/nip saturation process, gravure coating, or kiss coating.
- the nonwoven fabric is laminated to a polymeric film which serves as a barrier against liquids, solids, and gases.
- the polymeric film may be selected so that by itself it has at least some degree of flame resistance. This property of flame resistance for the polymeric film may be measured by flame testing or by determining its limiting oxygen index.
- the polymeric film may be made from halogenated films such as polyvinyl chloride, polyvinyl bromide, or polyvinylidene chloride.
- a polymeric film may be used which, by itself, is not flame resistant, but is rendered flame resistant by the application of fire retardant additives.
- a preferred polymeric film is polyvinyl chloride.
- Polymeric film thickness could range from about 0.1 mils to about 8.0 mils, with the preferred range being about 0.2 mils to about 6.0 mils.
- the polymeric film thickness depends on the end use, and may be optimized to control the laminate's strength, abrasion resistance, and barrier properties for an intended end use while being cost effective.
- the weight of the polymeric film is determined by the degree and type of chemical resistance needed, as well as the needed cost fit to the specific end use.
- the weight of the polymeric film ranges from about 0.05 to about 10.0 ounces per square yard.
- a more preferred weight for the polymeric film ranges from about 0.15 to about 5.0 ounces per square yard.
- the film and the fabric can be attached to one another in many ways, including ultrasonic lamination, R.F. sealing, adhesive lamination, and heat bonding with pressure. Proper bonding may enhance the laminate's ability to hinder the propagation of a flame.
- the nonwoven fabric is bonded to the polymeric film via a moisture curable polyurethane adhesive.
- a polyurethane adhesive is XPU 51018M PUR® which may be obtained from ATO Findley, Inc.
- the adhesive may be applied to a surface of either the spunlace fabric or the polymeric film by a hot met slot coater. Generally, the adhesive is applied at temperatures ranging from about 150 to about 250° F. The temperature may be controlled to optimize the viscosity of the adhesive for proper flow through the slot dies.
- Other adhesives that may be used include, for example, pressure sensitives, polyesters, polyamides, polyolefins and thermoplastic polyurethanes.
- the laminate may also contain additional layers.
- the chemical resistance of the laminate may be enhanced by the addition of another layer of a dissimilar polymeric film.
- An additional polyethylene layer may be added to enhance protection against polar solvents, i.e., solvents having relatively high dielectric strengths.
- a layer of a conventional ethylene vinyl alcohol may be added to improve further the solvent repellancy of the laminate.
- the formed laminate therefore has a preferred thickness of about 0.001 to about 0.5 inches, more preferably about 0.005 to about 0.05 inches.
- the formed laminate's weight may range from about 0.5 to about 10.0 ounces per square yard, and more preferably, from about 1.0 to about 8.0 ounces per square yard.
- a phosphate fire retardant additive sold as Spartan 880®, was applied to a 2.13 osy Sontara®) DuPont spunlace wood pulp/polyester fabric. The fabric was then dried on a pin tenter. The dry solids add-on of the Spartan 880° was 27 percent by weight of the fabric.
- a 0.5 mil polyvinyl chloride film was then bonded to the woodpulp side of the spunlace fabric by application of 3.0 gsm add-on of a hot melt moisture curable urethane to form a laminate. The urethane was applied using a hot melt slot coater maintained at a temperature from 150 to 250° F. The finished basis weight of the laminate was approximately 2.95 osy.
- a laminate was formed by the same method described in Example 1, except a 2.0 mil polyvinyl chloride film was used as the polymeric film. Properties of the laminate are shown below in Table 2. All data shown in Table 2 is the calculated mean. TABLE 2 Physical Properties of Laminate Having 2.0 Mil PVC Layer Cured Bond Cured Bond Grab Grab Basis Strength- Strength- Tensile Tensile Weight Thickness MD XD MD XD Static Static (oz/sq.
- Laminates were made by the same method of Example 1 having a 0.5 mil polyvinyl chloride layer and a 2.0 mil polyvinyl chloride layer. The chemical penetration resistance for each laminate was tested by the method taught in ASTM F903-87.
- the laminates described herein should be useful for protective garments used in heavy Industry (e.g. welding, equipment manufacturing), hazardous chemical remediation, general laboratory work, electrical utilities (rainware, fire protection), the petrochemical industry, pesticide applications, and painting.
- protective garments formed by the laminate include gloves, headgear, jackets, trousers, and shoes.
- the laminates described herein may be formed into protective covers for machinery or equipment, Regardless of the specific end use, the laminate may be used by Itself or in conjunction with other protective materials.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Textile Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
Abstract
Disclosed is a laminate having flame and chemical resistance, which may be used to form protective fabrics. The laminate contains a first layer of a spunlace fabric having a fire retardant additive applied thereto; and a second layer of a polymeric film.
Description
- Our discovery relates to laminates which may be used for garments, which are chemical and flame resistant, and are impervious to dry particles.
- With multiple safety concerns, coupled with hazards and liabilities that are associated with today's industrial working environment, there is a need for a material that is impervious to water and dry particles, resistant to chemical breakthrough, and resistant to flames. Typically, available materials have only some of the above-mentioned properties, or are constructed of very heavy and expensive materials. Existing products normally target one area of industrial protection. For example, DuPont's Tychem® is described by the manufacturer as a high-performance protective material for garments. While Tychem® may provide protection against various liquid chemicals, it is not a flame resistant material. In fact, Tychem®) is sold with a warning that the product should not be used around heat, flames, sparks, or in potentially flammable or explosive environments.
- Although some products may be both flame and chemical resistant, those products are generally costly to make and/or have other disadvantages. For example, U.S. Pat. No. 5,491,022 relates to a product having a plastic laminate formed by coextruding at least two layers of polymeric sheets with an intermediate layer of a polar resin or hydrophilic polymer. The plastic laminate is then adhered to a fabric scrim formed of polyester and cellulosic fibers treated with fire retardant and antistatic agents. The product described in the '022 patent, however, has a thickness of at least 125 mils, and is, therefore, undesirably thick and heavy.
- An object of the invention is to provide a material that is fire retardant.
- Another object of the invention is to provide a material that is resistant to chemicals.
- Another object of the invention is to provide a material that is relatively light weight and has structural integrity sufficient to form a protective garment.
- To achieve these and other objectives, and in accordance with the purpose of our invention as embodied and broadly described herein, in one aspect we describe a laminate containing a first layer of a nonwoven fabric having a fire retardant additive applied thereto; and a second layer containing a polymeric film.
- In another aspect, we describe a laminate having a first layer of a nonwoven fabric containing cellulose and manmade fibers, the first layer having a fire retardant additive applied thereto; and a second layer of a polyvinyl chloride film.
- We have found that the desired physical properties can be obtained by combining a fire retardant finished nonwoven fabric with a barrier film. The barrier film may have at least some degree of flame resistance or may contain a fire retardant additive. The resulting material, referred to herein as a “laminate,” is resistant to certain chemicals in liquid, vapor, or solid form, and is also flame resistant. The laminate is also impervious to water and dry particles.
- As used herein, “flame resistant” refers to the ability of the fabric to pass at least one flame resistance test set forth by the National Fire Protection Association in “NFPA 701 Standard Methods of Fire Tests for Flame-Resistant Textiles and Films,” 1996 Ed. and “NFPA 701 Standard Methods of Fire Tests for Flame-Resistant Textiles and Films,” 1989 Ed. The entire contents of each of those publications are incorporated herein by reference,
- Preferably, the laminate has a first layer that is a nonwoven fabric. Examples of nonwoven fabrics include spunbond fabrics, resin bonded fabrics, thermal bonded fabrics, air-laid pulp fabrics, and stitchbonded fabrics. More preferably, the nonwoven fabric is a spunlace fabric made from a combination of cellulosic and manmade fibers. Cellulosic fibers that may be used to form the spunlace fabric include woodpulp fibers, cotton fibers, regenerated cellulose fibers such as Rayon® (obtained from DuPont) or Lyocell® (obtained from DuPont, cellulose acetate fibers, cellulose triacetate fibers, jute, hemp and any bast, leaf, or stem fibers. Preferably, woodpulp fibers are used.
- Manmade fibers that may be used to form the spunlace fabric include polyester, nylon, or acrylic fibers. When combining the manmade fibers and cellulosic fibers to form the spunlace fabric, it is convenient for the cellulosic and manmade fibers to be in the form of flat layers. Preferably, the celluosic fibers are in the form of sheets of paper and the manmade fibers are in the form of an air-laid web of staple fibers or a nonwoven sheet of substantially continuous filaments. The webs or sheets may be bonded or nonbonded. Preferably, the weight ratio of the cellulosic fibers to manmade fibers ranges from 75:25 to 25:75, more preferably from 65:35 to 50:50.
- The weight of the spunlace fabric used in the laminate is determined by the degree of dimensional stability needed as well as wear durability needed in protective apparel applications. A preferred weight range for the spunlace fabric is 1.0 osy to 4.0 osy. An example of a spinlace woodpulp/polyester fabric that can be used to form the laminate is sold by DuPont under the tradename Sontara®.
- As mentioned, the nonwoven fabric used in the laminate is preferably formed by a spunlace process. Examples of spunlace processing are well known in the art. For example, a pulp containing cellulosic fibers may be applied to one side of a batt of carded manmade fibers. The material is then passed under a plurality of water jets, which entangle the manmade and cellulosic fibers to form a fabric. Methods of making the spunlace fabric are described in U.S. Pat. No. 4,442,161, the entire contents or which are incorporated herein by reference.
- A fire retardant additive is applied to the spunlace fabric, at a preferred dry solids add-on ranging from about 5 to about 45 percent by weight of the spunlace fabric. Preferably, the dry solids add-on ranges from about 15 to about 25 percent by weight of the spunlace fabric. Any well-known inorganic fire retardant additives can be used, including ammonium polyphosphates, ammonium dihydrogen phosphate, antimony trioxide, sodium antimonate, zinc borate, zirconium oxides, diammonium phosphate, sulfamic acid, salts of sulfamic acid, boric acid, salts of boric acid, and hydrated alumina.
- Exemplary organic fire retardant additives that may be used include urea polyammonium phosphate, chlorinated paraffins, tetrabromobisphenol-A and oligomers thereof, decabromodiphenyl oxide, hexabromodiphenyl oxide, pentabromodiphenyl oxide, pentabromotoluene, pentabromoethylbenzene, hexabromobenzene, pentabromophenol, tribromophenol derivatives, perchloropentanecyclodecane, hexabromocyclodecone, tris(2,3-dibromopropyl-1)isocyanurate, tetrabromobisphenol-S and derivatives thereof, 1,2-bis(2,3,4,5,6-pentabromophenoxy)ethane, 1,2-bis-(2,4,6-tribromophenoxy)ethane, brominated styrene oligomers, 2,2-bis-(4(2,3-dibromopropyl)3,5-dibromophenoxy)propane, tetrachlorophthalic anhydride, and tetrabromophthalic anhydride.
- Any combination of fire retardant additives, whether inorganic or organic, may be used. A preferred fire retardant additive is a phosphate, such as Spartan 880® sold by Spartan Flame Retardants. The fire retardant additive may be applied to the spunlace fabric by any conventional method such as spraying, contacting the spunlace fabric with a saturation pad or saturation roller, a dip/nip saturation process, gravure coating, or kiss coating.
- The nonwoven fabric, either before or after it is treated with a fire retardant, is laminated to a polymeric film which serves as a barrier against liquids, solids, and gases. The polymeric film may be selected so that by itself it has at least some degree of flame resistance. This property of flame resistance for the polymeric film may be measured by flame testing or by determining its limiting oxygen index. Accordingly, the polymeric film may be made from halogenated films such as polyvinyl chloride, polyvinyl bromide, or polyvinylidene chloride. As an alternative, a polymeric film may be used which, by itself, is not flame resistant, but is rendered flame resistant by the application of fire retardant additives.
- A preferred polymeric film is polyvinyl chloride. Polymeric film thickness could range from about 0.1 mils to about 8.0 mils, with the preferred range being about 0.2 mils to about 6.0 mils. The polymeric film thickness depends on the end use, and may be optimized to control the laminate's strength, abrasion resistance, and barrier properties for an intended end use while being cost effective. Similarly, the weight of the polymeric film is determined by the degree and type of chemical resistance needed, as well as the needed cost fit to the specific end use. The weight of the polymeric film ranges from about 0.05 to about 10.0 ounces per square yard. A more preferred weight for the polymeric film ranges from about 0.15 to about 5.0 ounces per square yard.
- The film and the fabric can be attached to one another in many ways, including ultrasonic lamination, R.F. sealing, adhesive lamination, and heat bonding with pressure. Proper bonding may enhance the laminate's ability to hinder the propagation of a flame.
- Preferably, the nonwoven fabric is bonded to the polymeric film via a moisture curable polyurethane adhesive. An example of a polyurethane adhesive is XPU 51018M PUR® which may be obtained from ATO Findley, Inc. The adhesive may be applied to a surface of either the spunlace fabric or the polymeric film by a hot met slot coater. Generally, the adhesive is applied at temperatures ranging from about 150 to about 250° F. The temperature may be controlled to optimize the viscosity of the adhesive for proper flow through the slot dies. Other adhesives that may be used include, for example, pressure sensitives, polyesters, polyamides, polyolefins and thermoplastic polyurethanes.
- The laminate may also contain additional layers. For example, the chemical resistance of the laminate may be enhanced by the addition of another layer of a dissimilar polymeric film. An additional polyethylene layer may be added to enhance protection against polar solvents, i.e., solvents having relatively high dielectric strengths. As another example, a layer of a conventional ethylene vinyl alcohol may be added to improve further the solvent repellancy of the laminate.
- The formed laminate therefore has a preferred thickness of about 0.001 to about 0.5 inches, more preferably about 0.005 to about 0.05 inches. The formed laminate's weight may range from about 0.5 to about 10.0 ounces per square yard, and more preferably, from about 1.0 to about 8.0 ounces per square yard.
- A phosphate fire retardant additive, sold as Spartan 880®, was applied to a 2.13 osy Sontara®) DuPont spunlace wood pulp/polyester fabric. The fabric was then dried on a pin tenter. The dry solids add-on of the Spartan 880° was 27 percent by weight of the fabric. A 0.5 mil polyvinyl chloride film was then bonded to the woodpulp side of the spunlace fabric by application of 3.0 gsm add-on of a hot melt moisture curable urethane to form a laminate. The urethane was applied using a hot melt slot coater maintained at a temperature from 150 to 250° F. The finished basis weight of the laminate was approximately 2.95 osy.
- Properties of the laminate are shown below in Table 1. In both Tables 1 and 2 below, the basis weight was determined by INDA Standard Test 130.1-92, the thickness was determined by IST 120.1-92, the cured bond strengths by IST 110.2-82, the grab tensile strengths by IST 110.3-92, the static decays by IST 40.2-92, the trap tears by IST 100.2-92, the resistivity by AATCC 76-1978, the flame char lengths by NFPA 701-1989, the flame weight loss by NFPA 701-1996, the Mullen Burst by ASTM D3786-87 and Suter Hydrostatic by INDA IST 80.4(95), and the Taber Abrasion by ASTM D3884-80. All data shown in Table 1 is the calculated mean.
TABLE 1 Physical Properties of Laminate Having 0.5 Mil PVC Layer Cured Bond Cured Bond Grab Grab Basis Strength Strength- Tensile- Tensile Weight Thickness MD XD MD XD Static Static (oz/sq. yd.) (in.) (grams/in) (grams/in.) (lb.) (lb.) Decay-MD Decay-XD 2.92 9.014 238 245 34.2 25.2 0.01 0.00 Flame Flame Char Flame Char Weight Mullen Taber Trap Trap Length- Length- Loss- Burst Abrasion Suter Tear-MD Tear-XD Resistivity MD (in.) XD (in.) MD (%) (lb.f/sq. in.) (cycles) Hydrostatic 7.2 7.9 3.55E+14 4.1 4.0 23.7 27.2 500 >50 cm - A laminate was formed by the same method described in Example 1, except a 2.0 mil polyvinyl chloride film was used as the polymeric film. Properties of the laminate are shown below in Table 2. All data shown in Table 2 is the calculated mean.
TABLE 2 Physical Properties of Laminate Having 2.0 Mil PVC Layer Cured Bond Cured Bond Grab Grab Basis Strength- Strength- Tensile Tensile Weight Thickness MD XD MD XD Static Static (oz/sq. yd.) (in.) (grams/in.) (grams/in.) (lb.) (lb.) Decay-MD Decay-XD 4..25 0.015 94 126 43.5 33.6 0.01 0.00 Flame Flame Char Flame Char Weight Mullen Taber Trap Trap Length- Length- Loss Burst Abrasion Suter Tear-MD Tear-XD Resistivity MD (in.) XD (in.) MD (%) (lb.f/sp. in.) (cycles) Hydrostatic 7.2 10.3 31.0E+12 4.6 4.3 23.6 33.0 500 >100 cm - Laminates were made by the same method of Example 1 having a 0.5 mil polyvinyl chloride layer and a 2.0 mil polyvinyl chloride layer. The chemical penetration resistance for each laminate was tested by the method taught in ASTM F903-87. Procedure C and the results are shown in Table 3 below,
TABLE 3 Chemical Penetration of Laminates Laminate Having Laminate Having 0.5 mil PVC Layer 2.0 mil PVC Layer Acetone Pass Pass Acetonitrite Pass Pass Carbon Disulfide Pass Pass Dichloromethane Fail Fail Diethylamine Fail Pass Dimethylformamide Fail Fail Ethyl acetate Pass Pass Hexane Pass Pass Methanol Pass Pass Nitrobenzene Fail Fail Sodium hydroxide Pass Pass Sulfuric Acid Fail Fail Tetrachloroethylene Pass Pass Tetrahydrofuran Fail Fail Toluene Pass Pass - The laminates described herein should be useful for protective garments used in heavy Industry (e.g. welding, equipment manufacturing), hazardous chemical remediation, general laboratory work, electrical utilities (rainware, fire protection), the petrochemical industry, pesticide applications, and painting. Examples of protective garments formed by the laminate include gloves, headgear, jackets, trousers, and shoes.
- Additionally, the laminates described herein may be formed into protective covers for machinery or equipment, Regardless of the specific end use, the laminate may be used by Itself or in conjunction with other protective materials.
- It will be apparent to those skilled in the art that various modifications and variations can be made in the laminate and methods disclosed above without departing from the spirit of our discovery. Thus, it is intended that our description covers the modifications and variations of this invention provided that they come within the scope of the appended claims and their equivalents.
Claims (23)
1. A laminate comprising:
(a) a first layer of a nonwoven fabric having a fire retardant additive applied thereto; and
(b) a second layer containing a flame resistant polymeric film.
2. The laminate of claim 1 , wherein the nonwoven fabric is spunlace fabric.
3. The laminate of claim 2 , wherein the spunlace fabric comprises cellulose fibers and manmade fibers.
4. The laminate of claim 2 , wherein the spunlace fabric comprises cellulose fibers and polyester fibers.
5. The laminate of claim 2 , wherein the spunlace fabric comprises wood pulp fibers and polyester fibers.
6. The laminate of claim 1 , wherein the laminate has a thickness ranging from about 0.001 to about 0.5 inches.
7. The laminate of claim 1 , wherein the first and second layer are joined together by an adhesive.
8. The laminate of claim 1 , wherein the first and second layers are joined together by ultrasonic lamination, R.F. sealing, adhesive lamination, or heat bonding with pressure.
9. The laminate of claim 1 , wherein the polymeric film is halogenated.
10. The laminate of claim 1 , wherein the polymeric film comprises polyvinyl chloride.
11. The laminate of claim 1 , wherein the polymeric film has a thickness ranging from about 0.3 to about 8.0 mils.
12. The laminate of claim 1 , wherein the fire retardant additive is ammonium polyphosphate, ammonium dihydrogen phosphate, urea polyammonium phosphate, antimony trioxide, sodium antimonate, zinc borate, a zirconium oxide, a molybdenum oxide, a zirconium sulfide, or a molybdenum sulfide.
13. The laminate of claim 1 , wherein the fire retardant additive is a chlorinated paraffin, tetrabromobisphenol-A, decabromodiphenyl oxide, hexabromodiphenyl oxide, pentabromobiphenyl oxide, pentabromotoluene, pentabromoethylbenzene, hexabromobenzene, pentabromophenol, tribromophenol derivatives, perchloropentanecyclodecane, hexabromocyclodecane, tris(2,3-dibromopropyl-1)isocyanurate, tetrabromobisphenol-S, 1,2-bis(2,3,4,5,6-pentabromophenoxy)ethane, 1,2-bis(2,4,6-tribromophenoxy)ethane, a brominated styrene oligomer, 2,2-bis-(4(2,3-dibromopropyl)-3,5-dibromophenoxy)propane, tetrachlorophthalic anhydride, and tetrabrornophthalic anhydride.
14. The laminate of claim 1 , wherein the fire retardant additive is applied to the first layer at about 5 to about 45 percent by weight of the first layer.
15. The laminate of claim 1 , that passes NFPA 701-1989, has at least 12.0 lbs of grab tensile according to INDA IST 110.3-92, and a Suter hydrostatic head of at least 50 cm.
16. A protective garment formed of the laminate of claim 1 .
17. A laminate comprising:
(a) a first layer of a spunlace fabric containing cellulose and manmade fibers, the first layer having a fire retardant additive applied thereto;
(b) a second layer of a polyvinyl chloride film.
18. The laminate of claim 17 , wherein said first and second layers are joined together by an adhesive.
19. The laminate of claim 17 , wherein the laminate has a thickness ranging from about 0.001 to about 0.5 inches.
20. The laminate of claim 17 , wherein the fire retardant additive is ammonium polyphosphate, ammonium dihydrogen phosphate, urea polyammonium phosphate, antimony trioxide, sodium antimonate, zinc borate, a zirconium oxide, a molybdenum oxide, a zirconium sulfide, or a molybdenum sulfide.
21. The laminate of claim 17 , wherein the fire retardant additive is applied to the first layer at about 5 to about 45 percent by weight of the first layer.
22. The laminate of claim 17 , that passes NFPA 701-1989, has at least 12.0 lbs. of grab tensile according to INDA IST 110.3-92, and a Suter hydrostatic head of at least 50 cm.
23. A protective garment formed of the laminate of claim 17.
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US10/687,814 US20040063371A1 (en) | 1998-04-20 | 2003-10-20 | Chemical resistant, water and dry particle impervious, flame resistant laminate |
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US8233098P | 1998-04-20 | 1998-04-20 | |
US09/294,056 US6713411B2 (en) | 1998-04-20 | 1999-04-19 | Chemical resistant, water and dry particle impervious, flame resistant laminate |
US10/687,814 US20040063371A1 (en) | 1998-04-20 | 2003-10-20 | Chemical resistant, water and dry particle impervious, flame resistant laminate |
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US09/294,056 Division US6713411B2 (en) | 1998-04-20 | 1999-04-19 | Chemical resistant, water and dry particle impervious, flame resistant laminate |
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US09/294,056 Expired - Lifetime US6713411B2 (en) | 1998-04-20 | 1999-04-19 | Chemical resistant, water and dry particle impervious, flame resistant laminate |
US10/687,814 Abandoned US20040063371A1 (en) | 1998-04-20 | 2003-10-20 | Chemical resistant, water and dry particle impervious, flame resistant laminate |
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US09/294,056 Expired - Lifetime US6713411B2 (en) | 1998-04-20 | 1999-04-19 | Chemical resistant, water and dry particle impervious, flame resistant laminate |
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US (2) | US6713411B2 (en) |
AU (1) | AU4197100A (en) |
WO (1) | WO2000063011A1 (en) |
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US20090181588A1 (en) * | 2008-01-15 | 2009-07-16 | Brookwood Companies, Inc. | Breathable, Fire Resistant Fabric Having Liquid Barrier and Water-Repellant Properties |
US7666802B2 (en) | 2008-01-15 | 2010-02-23 | Brookwood Companies, Inc. | Breathable, fire resistant fabric having liquid barrier and water-repellant properties |
US8156576B1 (en) | 2008-07-21 | 2012-04-17 | Kappler, Inc. | Flash fire and chemical resistant fabric and garments |
US8359675B2 (en) | 2008-07-21 | 2013-01-29 | Kappler, Inc. | Flash fire and chemical resistant fabric and garments |
USRE46443E1 (en) | 2008-07-21 | 2017-06-20 | Kappler, Inc. | Flash fire and chemical resistant fabric and garments |
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Also Published As
Publication number | Publication date |
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US20030129901A1 (en) | 2003-07-10 |
AU4197100A (en) | 2000-11-02 |
US6713411B2 (en) | 2004-03-30 |
WO2000063011A1 (en) | 2000-10-26 |
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