WO2004031464A1 - Materiaux de garniture retardateurs de flamme - Google Patents

Materiaux de garniture retardateurs de flamme Download PDF

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Publication number
WO2004031464A1
WO2004031464A1 PCT/US2003/030750 US0330750W WO2004031464A1 WO 2004031464 A1 WO2004031464 A1 WO 2004031464A1 US 0330750 W US0330750 W US 0330750W WO 2004031464 A1 WO2004031464 A1 WO 2004031464A1
Authority
WO
WIPO (PCT)
Prior art keywords
fiber
fire blocking
fiber component
present
textile structure
Prior art date
Application number
PCT/US2003/030750
Other languages
English (en)
Inventor
Charles R. Mason
Kate Hale-Blackstone
Original Assignee
Freudenberg Nonwovens, L.P.
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 Freudenberg Nonwovens, L.P. filed Critical Freudenberg Nonwovens, L.P.
Priority to EP03754982A priority Critical patent/EP1546443A4/fr
Priority to AU2003272781A priority patent/AU2003272781A1/en
Publication of WO2004031464A1 publication Critical patent/WO2004031464A1/fr

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Classifications

    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose series
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/43—Acrylonitrile series
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—Composite fibres sheath-core
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43832—Composite fibres side-by-side
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • Y10T428/24339—Keyed
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24372—Particulate matter
    • Y10T428/24397—Carbohydrate
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y10T428/249964—Fibers of defined composition
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y10T428/249964—Fibers of defined composition
    • Y10T428/249965—Cellulosic
    • 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
    • Y10T442/2631—Coating or impregnation provides heat or fire protection
    • Y10T442/2656—Antimony containing
    • 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
    • Y10T442/2631—Coating or impregnation provides heat or fire protection
    • Y10T442/2713—Halogen containing
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/638—Side-by-side multicomponent strand or fiber material
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/642—Strand or fiber material is a blend of polymeric material and a filler material
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/682—Needled nonwoven fabric
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/682—Needled nonwoven fabric
    • Y10T442/684—Containing at least two chemically different strand or fiber materials
    • Y10T442/686—Containing polymeric and natural strand or fiber materials

Definitions

  • This invention relates to fire resistant needle punched materials and to their methods of preparation.
  • the invention has particular utility in the formation of fire blocking fabric as a liner under upholstery fabric and mattress ticking.
  • the invention also has utility for the production of fire resistant vertical lapped batting material.
  • U.S. Patent No. 4,702,861 describes a flame retardant composition for application as an aqueous working dispersion onto surfaces of combustible materials. Upon exposure to elevated temperatures and/or flame, the formulation reportedly creates a substantially continuous protective film generally encapsulating and/or enveloping the surface of the article onto which it is applied.
  • the film-forming materials are based upon an aqueous latex dispersion of polyvinylchloride-acrylic copolymer together with certain other film-forming and viscosity controlling components.
  • melamine and melamine/formaldehyde based resinous fibers are said to display desirable heat stability, solvent resistance, low flammabiTity and high-wear characteristics.
  • BasofilTM One form of melamine/formaldehyde fiber is marketed under the tradename BasofilTM.
  • aromatic poiyamide family or aramids reportedly have high strength, toughness, and thermal stability.
  • Aramid fibers are marketed under the tradenames NomexTM and KevlarTM.
  • acrylic fibers are well-known in the synthetic fiber and fabric industries, as are the modified acrylic fibers (modacrylic). Such modacrylics are relatively inexpensive, and have been used in various blends with the fibers noted above to provide fire-resistant fabric material.
  • One particular modacrylic fiber is sold under the tradename ProtexTM, which is available from Kaneka Corporation, Japan.
  • VisilTM flame retardant viscose fibers
  • a silicic acid containing viscose with a limiting oxygen index (i.e., the minimum concentration of oxygen necessary to support combustion) in the range of 0.27 - 0.35, depending upon a particular textile construction.
  • I punched material that can serve, among other things, as a protective liner material. More specifically, it is an object of the present invention to develop new types of needle punched materials that rely upon a foundation component of a modified acrylic type fiber that is based upon a copolymer of polyacrylonitrile and a halogen based monomer to provide an inexpensive fire blocking composition.
  • the present invention comprises a fire blocking non-woven needlepunched textile structure, comprising a first fiber component containing polyacrylonitrile copolymer with a halogen containing monomer and a second fiber component, wherein said second fiber component supports said first fiber component during burning, optionally including inorganic filler as a coating for said first and second fiber components.
  • the invention herein comprises a fire blocking non-woven textile structure, in the form of vertical lapped batting, comprising a first fiber component containing polyacrylonitrile copolymer with a halogen containing monomer and a second fiber component, wherein said second fiber component comprises a viscose fiber containing silicic acid and/or a melamine-formaldehyde polymer, and a third fiber component comprising a binder fiber having the capability to melt bond said first and second components wherein said first and second components are melt bonded together by said binder fiber.
  • the fire resistant non- woven material of the present invention which can be used as a protective liner material, is preferably manufactured from a needle- punched combination of modacrylic fiber with a second fiber component which may comprise a viscose fiber containing silicic acid and or a melamine/formaldehyde polymer.
  • a second fiber component which may comprise a viscose fiber containing silicic acid and or a melamine/formaldehyde polymer.
  • an inorganic filler such as vermiculate may be included as a coating.
  • Other inorganic fillers include those selected from the group consisting of graphite, fumed silica or silica dioxide, or titanium dioxide, and mixtures thereof.
  • the modacrylic fiber When the modacrylic is activated by heat, it apparently assists in the displacement of oxygen thereby reducing heat release and burn rate. Furthermore, the vermiculate coating may then serve to disperse the heat across the needlepunch fabric.
  • the invention herein is not limited to any particular theorized functionality of the individual components and relies upon the various combinations that are ultimately described in the appended claims.
  • the modacrylic fiber is preferably based upon a polyacrylonitrile copolymer with a halogen containing comonomer, and the halogen containing comonomer is preferably poly (vinyl chloride) or poly(vinylidine chloride).
  • a preferred modacrylic fiber is available form Kaneka Corporation, under the tradename ProtexTM.
  • the modacrylic employed herein is sold under the tradename ProtexTM M, at a specific gravity of 1.45 - 1.60 with a fiber denier of 2.2 dtex x 38 mm.
  • ProtexTM M is described as having the following chemical components: acrylonitrile, vinylidine chloride copolymer, antimony oxide.
  • a preferred viscose fiber containing silicic acid is sold under the tradename NisilTM, available from Sateri Oy Inc.
  • the Nisil fiber is type AP 33 3.5 dtex.x 50 mm. It is composed of 65-75% regenerated cellulose, 25-35% silicic acid, and 2-5% aluminum hydroxide.
  • a preferred melamine/formaldehyde fiber component is sold under the tradename BasofilTM, available from McKinnon-Land-Moran, LLC.
  • the non-woven material will also have a basis weight of 100-500 g/m 2 , including all increments therebetween at lg/m 2 variation.
  • the above referenced fire blocking non-woven textile therefore may preferably contain the modacrylic ⁇ polymer component (e.g., polyacrylonitrile copolymer with poly(vinylidine chloride)), at levels of about 50-80% (wt), and correspondingly, the second fiber component which supports the modacrylic component may be present at about 20-50% (wt.).
  • the modacrylic component is present at about 80% (wt.) and the second fiber component is preferably a viscose fiber containing silicic acid and/or a melamine/formaldehyde polymer which is present at about 20% (wt.).
  • all increments therebetween are included, at 1% (wt) variation.
  • the second fiber component serves to support the first fiber component during burning.
  • support it is meant that the second fiber maintains the first fiber component in place thereby reducing the tendency of the first fiber component to undergo shrinkage during burning, which shrinkage will sacrifice considerably the fire blocking performance.
  • the above non-woven include an inorganic filler, e.g. vermiculite as a coating component.
  • Nermiculate is reference to one of the mica groups that are used as granular fillers, and comprise a crystalline layer silicate material. However, some of the silicon atoms are replaced with aluminum, producing a negative charge that is neutralized by the interlayer cations, mostly magnesium.
  • the vermiculite particles are. of a planer structure consisting of platelets that have a minimum 400:1 xy plane to z plane ratio.
  • the level of vermiculate herein, as a coating in the non- woven is about 20-40g/m , including all increments therebetween at 1.0 g/m variation.
  • the fire blocking non-woven material is preferably of a thickness of: 1.5 - 25 mm, including all increments therebetween at 1.0 mm variation.
  • the above non- woven textile is further modified, in the sense that the concentration of the first and second fiber components are reduced in favor of the use of a binder polymer fiber.
  • a binder polymer fiber has the capability to melt bond with the first and second fiber components.
  • the preferred binder fiber is 4d x 2" from either Nan Ya or Sam Yang in Korea with the outer layer having a melting point of 150°C which melting point is lower than the melting point of the inner layer of this particular binder fiber material.
  • the first component modacrylic fiber is first blended with the second fiber component (viscose fiber containing silicic acid and/or melamine/formaldehyde polymer) as well as the bicomponent polymer fiber noted above.
  • the three fibers are blended together, formed into a web which is then vertically lapped and then bonded in a hot air oven as the final process.
  • the binder fiber outer layer melts and flows onto the other fibers which bonds the structure together.
  • the binder fibers of the present invention may include one or plurality of polymer components.
  • the binder fiber may be in the form of a sheath/core, side by side, or monofiliment configuration.
  • the modacrylic fiber component is present at a level of about 50-70% (wt.)
  • the second fiber component is present at a level of about 10-20% (wt.)
  • the binder fiber is present at a level of about 10-30% (wt.).
  • all increments therebetween are included at 1% (wt) variation.
  • such composition preferably is prepared at a basis weight of 100-500 g/m 2 , and at all 1.0 g/m 2 increments.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne une structure textile aiguilletée non tissée retardatrice de flamme comprenant un premier composant fibreux contenant un copolymère de polyacrylonitrile et un monomère contenant un halogène, et un deuxième composant fibreux. Ledit deuxième composant fibreux est sélectionné de sorte qu'il supporte le premier composant fibreux pendant une combustion. La structure peut éventuellement comprendre une charge inorganique utilisée comme revêtement des premier et deuxième composants fibreux. Dans un autre mode de réalisation, l'invention concerne une structure textile non tissée retardatrice de flamme contenant les premier et second composants fibreux précités mélangés avec un troisième composant fibreux de liant sous forme d'une structure non tissée superposée verticalement.
PCT/US2003/030750 2002-10-01 2003-09-30 Materiaux de garniture retardateurs de flamme WO2004031464A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP03754982A EP1546443A4 (fr) 2002-10-01 2003-09-30 Materiaux de garniture retardateurs de flamme
AU2003272781A AU2003272781A1 (en) 2002-10-01 2003-09-30 Flame blocking liner materials

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/262,133 US20040062912A1 (en) 2002-10-01 2002-10-01 Flame blocking liner materials
US10/262,133 2002-10-01

Publications (1)

Publication Number Publication Date
WO2004031464A1 true WO2004031464A1 (fr) 2004-04-15

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2003/030750 WO2004031464A1 (fr) 2002-10-01 2003-09-30 Materiaux de garniture retardateurs de flamme

Country Status (4)

Country Link
US (1) US20040062912A1 (fr)
EP (1) EP1546443A4 (fr)
AU (1) AU2003272781A1 (fr)
WO (1) WO2004031464A1 (fr)

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WO2015050702A1 (fr) * 2013-10-04 2015-04-09 Dreamwell, Ltd. Panneau résistant au feu et procédés pour conférer des propriétés pare-feu à un article

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EP1546443A4 (fr) 2008-07-02
AU2003272781A1 (en) 2004-04-23
EP1546443A1 (fr) 2005-06-29
US20040062912A1 (en) 2004-04-01

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