US20130149926A1 - Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof - Google Patents

Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof Download PDF

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Publication number
US20130149926A1
US20130149926A1 US13/714,062 US201213714062A US2013149926A1 US 20130149926 A1 US20130149926 A1 US 20130149926A1 US 201213714062 A US201213714062 A US 201213714062A US 2013149926 A1 US2013149926 A1 US 2013149926A1
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US
United States
Prior art keywords
fire retardant
nonwoven
panel
moisture resistant
further including
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
Application number
US13/714,062
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English (en)
Inventor
Ritesh Mehbubani
Brian Taylor
Stephen Yanchek
Ali Khosroshahi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Federal Mogul Powertrain LLC
Original Assignee
Federal Mogul Powertrain LLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Federal Mogul Powertrain LLC filed Critical Federal Mogul Powertrain LLC
Priority to US13/714,062 priority Critical patent/US20130149926A1/en
Publication of US20130149926A1 publication Critical patent/US20130149926A1/en
Assigned to CITIBANK, N.A., AS COLLATERAL TRUSTEE reassignment CITIBANK, N.A., AS COLLATERAL TRUSTEE SECURITY INTEREST Assignors: FEDERAL-MOGUL CHASSIS LLC, A DELAWARE LIMITED LIABILITY COMPANY, FEDERAL-MOGUL CORPORATION, A DELAWARE CORPORATION, FEDERAL-MOGUL IGNITION COMPANY, A DELAWARE CORPORATION, FEDERAL-MOGUL POWERTRAIN, INC., A MICHIGAN CORPORATION, FEDERAL-MOGUL PRODUCTS, INC. , A MISSORI CORPORATION, FEDERAL-MOGUL WORLD WIDE, INC., A MICHIGAN CORPORATION
Assigned to FEDERAL-MOGUL POWERTRAIN, INC. reassignment FEDERAL-MOGUL POWERTRAIN, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: YANCHEK, Stephen, KHOSROSHAHI, Ali, MEHBUBANI, RITESH, TAYLOR, BRIAN
Assigned to FEDERAL-MOGUL POWERTRAIN LLC. reassignment FEDERAL-MOGUL POWERTRAIN LLC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: FEDERAL-MOGUL POWERTRAIN, INC.
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • B27N1/006—Pretreatment of moulding material for increasing resistance to swelling by humidity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N9/00—Arrangements for fireproofing
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • 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
    • Y10T442/2213—Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant

Definitions

  • This invention relates generally to nonwoven panels, and more particularly to flame retardant, moisture resistant nonwoven structural panels and to their method of construction.
  • structural panels meaning those capable of functioning as a structural member, such as office divider panels, for example, from fiberglass composites via bonding fiberglass with resin.
  • the resins used to construct fiberglass panels include high levels of formaldehyde, which can be harmful to persons, and due to a new regulation CAL1350, which calls for the levels of formaldehydes to be below 0.04 ppm, the fiberglass panels are unacceptable.
  • the fiberglass panels are not environmentally friendly given they have a relatively high carbon footprint in manufacture and are made from materials that are typically not renewable.
  • a nonwoven, fire retardant, moisture resistant panel includes a bonded nonwoven sheet of bast fibers bonded with polymeric binding fibers. Further, the panel includes a single coating of a dried and cured solution. The dried and cured coating includes a binder, a Ph stabilizer and a single flame retardant. The binder is cross-linked with the bast fibers to form a moisture resistant barrier that reduces the moisture absorption of the bast fibers.
  • the panel meets the requirements of regulation CAL1350 calling for levels of formaldehydes to be below 0.04 ppm.
  • the panel is formed as an office divider panel that passes an ASTM E-84 flame test.
  • the mixture includes between 50-80 wt % of bast fibers fiber and between 15-50 wt % of polymeric binding fiber.
  • the bonded nonwoven web is between 150 gsm and 1500 gsm.
  • the dried and cured coating has between 30 gsm and 300 gsm dry pickup weight.
  • a formaldehyde free scrim layer is bonded to at least one side of the panel.
  • a method of constructing a nonwoven, fire retardant, moisture resistant panel includes forming a homogenous mixture of bast fibers and polymeric binding fiber; forming a web of the homogenous mixture; melting the polymeric binding fiber and bonding the bast fibers with the material of the polymeric binding fiber to form a bonded nonwoven sheet; saturating the bonded nonwoven sheet in a solution including a binder, a Ph stabilizer and a flame retardant; cross-linking the binder with the bast fibers by drying the saturated, bonded nonwoven sheet and curing the solution; and compressing the nonwoven sheet.
  • the method includes maintaining the levels of formaldehydes in the panel below 0.04 ppm.
  • the method includes compressing the nonwoven sheet while curing the solution.
  • the method includes cooling the nonwoven sheet while being compressed.
  • the method includes using a modified polycarboxylic acid with a polyol for the binder.
  • the method includes providing the fire retardant as a single fire retardant.
  • the method includes bonding a formaldehyde free scrim layer to at least one side of the panel.
  • FIG. 1 is a process flow diagram showing the steps of constructing a panel in accordance with one aspect of the invention.
  • FIG. 1 illustrates a nonwoven, fire retardant, moisture resistant panel, referred to hereafter as panel 10 , 10 ′, 10 ′′, constructed in accordance with the invention, as well as a method of construction of the panel 10 , 10 ′, 10 ′′ in accordance with another aspect of the invention.
  • the panel 10 , 10 ′, 10 ′′ includes a bonded nonwoven sheet 12 and a dried and cured coating 14 formed from a single solution 16 ( FIG. 2 ) that is dried and cured in a single process, thereby minimizing the space requirements and process steps in manufacture.
  • the sheet 12 is formed from a mixture of bast fibers 18 and polymeric binding fiber 20 bonded with one another via a process that melts, at least partially, the polymeric binding fiber 20 .
  • the solution 16 includes a solution-based binder, a Ph stabilizer and a single flame retardant.
  • the binder from the solution 16 is cross-linked with the bast fibers 18 to form an impervious or substantially impervious moisture resistant barrier that greatly reduces the tendency of the bast fibers 18 to absorb moisture.
  • the structural integrity of the bast fibers 18 and the panel 10 , 10 ′, 10 ′′, constructed in part therefrom, is maintained in use, even in the presence of moisture, which allows the panel 10 , 10 ′, 10 ′′ to meet stringent requirements required for office divider tackable board under ASTM E-84 Class A, and further, to pass humidity shock and board stiffness tests.
  • the panel 10 , 10 ′, 10 ′′ has a high strength and high stiffness, and as such, is suitable for use as a structural member, such as an office divider panel, for example.
  • the panel 10 , 10 ′, 10 ′′ is environmentally friendly, in that the materials used to construct the panel 10 , 10 ′, 10 ′′ can be reclaimed, are renewable, are mostly natural and biodegradable, and further, contain less than 0.04 ppm levels of formaldehydes, referred to hereafter as “very low levels of formaldehyde”, and thus, the panel 10 , 10 ′, 10 ′′ is suitable for use in applications needing to pass regulation CAL 1350, which requires formaldehyde contents in office divider boards to contain less than 0.04 ppm formaldehyde.
  • the bast fibers 18 can be provided from a variety of natural fibers, such as jute, kenaf, hemp, flax or mixture thereof, by way of example and without limitation.
  • the bast fibers 18 are generally provided having a content between about 50-85 wt %, and in one example was provided as 80 wt % kenaf.
  • the polymeric binding fiber 20 can be provided from a variety of thermally bonding materials, including polypropylene, polyethylene, copolyesters, nylons, polyactic acid (PLA), and bicomponent fibers (sheath/core fibers, wherein the sheath is typically a low melt polymeric material and the core is a higher temperature polymeric material), by way of example and without limitation.
  • the polymeric binding fiber 20 is generally provided having content between 15-50 wt %, and in the example, was provided as 20 wt % bicomponent, including a polyester core and a modified polyester sheath.
  • the solution-based binder was provided as a modified polycarboxylic acid with a polyol diluted with water.
  • the polyol is used primarily as a crosslinking agent while the modified polycarboxylic acid is compatible with the natural fibers of the bast fibers 18 and forms a good crosslink between the natural fibers and the melted resin of the polymeric binding fiber 20 , thereby facilitating formation of an impervious or substantially impervious barrier that greatly reduces the tendency of the bast fibers 18 to absorb moisture.
  • the binder content can range from between 10-20 wt %, and in the example, 14 wt % binder content was used.
  • the flame retardant is provided as a single flame retardant and applied in a single process, thereby minimizing the complexity and cost of the manufacture process.
  • the flame retardant can be provided as boron-based, phosphorous-based, or sulfur-based constituent, by way of example.
  • a Ph stabilizer is used to blend the fire retardant in the binder.
  • the fire retardant used in the example was disodium octaborate tetrahydrate, by way of example and without limitation.
  • the amount of fire retardant content can be provided between about 5-25 wt %, and in the example, 15 wt % content was used based on a 30 wt % dry pick-up from the chemical solids.
  • the process of constructing the panel 10 includes the following steps: forming a homogenous mixture of bast fibers 18 and polymeric binding fiber 20 , shown generally at 22 ; forming a web 24 of the homogenous mixture 22 ; heating the web 24 and melting the polymeric binding fiber 20 at least partially and bonding the bast fibers 18 with the melted material of the polymeric binding fiber 20 to form a bonded nonwoven sheet 12 ; providing a solution 16 including a binder, a Ph stabilizer and a flame retardant; saturating the bonded nonwoven sheet 12 with the solution 16 ; cross-linking the binder in the solution 16 with the bast fibers 18 by drying the saturated, bonded nonwoven sheet 12 ; curing the solution and compressing the nonwoven sheet 12 , and optionally, if desired to provide enhanced stiffness and change of color from that of the natural fibers, the method further includes bonding a formaldehyde free scrim layer 25 to at least one side (panel 10 ′) or both sides (panel 10 ′′) of the sheet
  • the process includes blending the bast fibers 18 and polymeric binding fiber 20 in a mixer and then fine openers until the mixture 22 is homogenous.
  • the homogeneity provides the uniform distribution of the polymeric binding fiber 20 needed to obtain maximum and uniform stiffness throughout the entirety of the finished panel 10 .
  • the mixture 22 is processed in a web forming machine to create the nonwoven web 24 .
  • the weight of the web 24 can be varied from about 150 gsm (grams per square meter) up to about 1500 gsm, wherein the weight of the sample was formed around 700 gsm.
  • the web 24 is heated, such as in an oven identified generally at 26 , to a temperature suitable to at least partially melt the polymeric binding fiber 20 , thereby bonding the bast fibers 18 and polymeric binding fiber 20 together to form the bonded nonwoven sheet 12 .
  • the bonded nonwoven sheet 12 is saturated with the solution 16 , such as by being passed through a bath of the solution 16 identified generally at 28 , that includes the solution-based binder, which has a low Ph; a Ph stabilizer to offset the low Ph of the binder, and a flame retardant, as described above, and further being diluted with water, if not used as the Ph stabilizer.
  • the amount of saturation is performed to provide about a 10-40% dry-pick-up of the solution 16 , wherein the total binder pick-up in the example was about 30% dry pick-up; the total disodium octaborate tetrahydrate pick-up is between about 5-25 wt % based on a 30% dry pick-up from the chemical solids.
  • the saturated, bonded nonwoven sheet 12 is heated sufficiently to dry the sheet 12 and cure the solution 16 , such as in a continuous compression belt oven 30 , by way of example and without limitation.
  • the water from the solution 16 is first substantially evaporated to leave about 8-10% moisture content in the bonded nonwoven sheet 12 .
  • the temperature is increased to about 180-200 degrees Celsius, at which temperature the binder of the solution 16 is cured and cross-linked with the bast fibers 18 .
  • the bonded sheet 12 is compressed under a force F to a predetermined finished thickness, such as between a pair of high compression belts 32 , by way of example and without limitation.
  • the resulting panel 10 is cooled, wherein the heating, compression and cooling can all be performed within the continuous compression belt oven 30 .
  • the cooled and compressed panel 10 can then be further processed by laminating at least one formaldehyde free scrim layer 25 , such as fiberglass or polypropylene, by way of example and without limitation, to one side or both sides of the respective panel 10 ′, 10 ′′ via a scrim laminator 34 .
  • the resulting finished panel 10 , 10 ′, 10 ′′ meets the Class A rating for flame as per ASTM E-84, while the panel 10 ′, 10 ′′ also attains enhanced board stiffness, even in the presence of moisture, due to the synergies provided by the solution-based binder, binding fibers 20 , and scrim layer(s) 25 , and also has a very low formaldehyde content.
  • the panel 10 can remain free of the scrim layer 25 , though this will result in the panel 10 having a diminished strength relative to the panels 10 ′, 10 ′′.
  • the sheet 12 remains a continuous piece of material from the beginning of the process until after compressing, curing and cooling, or if a lamination scrim layer(s) 25 , until after lamination.
  • the desired length of panel 10 , 10 ′, 10 ′′ can be cut via a cutting operation 36 , shown as being after compression and after lamination, if performed.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Nonwoven Fabrics (AREA)
  • Building Environments (AREA)
US13/714,062 2011-12-13 2012-12-13 Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof Abandoned US20130149926A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US13/714,062 US20130149926A1 (en) 2011-12-13 2012-12-13 Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201161569975P 2011-12-13 2011-12-13
US201261703613P 2012-09-20 2012-09-20
US13/714,062 US20130149926A1 (en) 2011-12-13 2012-12-13 Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof

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US20130149926A1 true US20130149926A1 (en) 2013-06-13

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US13/714,062 Abandoned US20130149926A1 (en) 2011-12-13 2012-12-13 Non-Woven, Flame Retardant, Moisture Resistant Panel and Method of Construction Thereof

Country Status (7)

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US (1) US20130149926A1 (pt)
EP (1) EP2790882B1 (pt)
JP (1) JP2015504015A (pt)
KR (1) KR20140102260A (pt)
CN (1) CN104114342A (pt)
BR (1) BR112014014381A2 (pt)
WO (1) WO2013090525A1 (pt)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3033449A4 (en) * 2013-08-16 2017-03-01 Georgia-Pacific Consumer Products LP Entangled substrate of short individualized bast fibers

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101656398B1 (ko) * 2016-05-30 2016-09-09 한국건설기술연구원 불연성 섬유강화플라스틱(frp) 시트 제조 장치 및 방법
KR101754907B1 (ko) * 2016-06-10 2017-07-06 김진규 기능성 셀룰로오스 복합 섬유판 및 이의 제조방법

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US20050214534A1 (en) * 2004-03-29 2005-09-29 Adamo Joseph R Extended curable compositions for use as binders
US20060178064A1 (en) * 2001-11-07 2006-08-10 Balthes Garry E Fire retardant panel composition and methods of making the same
US20080250741A1 (en) * 2007-04-13 2008-10-16 University Of Maine System Board Of Trustees Fire resistant fibrous composite articles
US20100146887A1 (en) * 2008-11-14 2010-06-17 Wiker Anthony L Fire and Sag Resistant Acoustical Panel and Substantially Clear Coating Therefor
US20100301256A1 (en) * 2007-08-03 2010-12-02 Knauf Insulation Limited Binders
US20110060095A1 (en) * 2009-08-20 2011-03-10 Georgia-Pacific Chemicals Llc Modified binders for making fiberglass products

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060178064A1 (en) * 2001-11-07 2006-08-10 Balthes Garry E Fire retardant panel composition and methods of making the same
US20050214534A1 (en) * 2004-03-29 2005-09-29 Adamo Joseph R Extended curable compositions for use as binders
US20080250741A1 (en) * 2007-04-13 2008-10-16 University Of Maine System Board Of Trustees Fire resistant fibrous composite articles
US20100301256A1 (en) * 2007-08-03 2010-12-02 Knauf Insulation Limited Binders
US20100146887A1 (en) * 2008-11-14 2010-06-17 Wiker Anthony L Fire and Sag Resistant Acoustical Panel and Substantially Clear Coating Therefor
US20110060095A1 (en) * 2009-08-20 2011-03-10 Georgia-Pacific Chemicals Llc Modified binders for making fiberglass products

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3033449A4 (en) * 2013-08-16 2017-03-01 Georgia-Pacific Consumer Products LP Entangled substrate of short individualized bast fibers

Also Published As

Publication number Publication date
EP2790882B1 (en) 2015-07-29
JP2015504015A (ja) 2015-02-05
CN104114342A (zh) 2014-10-22
EP2790882A1 (en) 2014-10-22
BR112014014381A2 (pt) 2017-06-13
WO2013090525A1 (en) 2013-06-20
KR20140102260A (ko) 2014-08-21

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