WO2004101872A1 - Tissu contenant du basalte - Google Patents

Tissu contenant du basalte Download PDF

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Publication number
WO2004101872A1
WO2004101872A1 PCT/BE2003/000085 BE0300085W WO2004101872A1 WO 2004101872 A1 WO2004101872 A1 WO 2004101872A1 BE 0300085 W BE0300085 W BE 0300085W WO 2004101872 A1 WO2004101872 A1 WO 2004101872A1
Authority
WO
WIPO (PCT)
Prior art keywords
fabric
coating
basalt
product
advantageously
Prior art date
Application number
PCT/BE2003/000085
Other languages
English (en)
Inventor
Jean-Marie Nolf
Original Assignee
Groep Masureel Veredeling
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 Groep Masureel Veredeling filed Critical Groep Masureel Veredeling
Priority to EP03724677A priority Critical patent/EP1625248A1/fr
Priority to AU2003229147A priority patent/AU2003229147A1/en
Priority to PCT/BE2003/000085 priority patent/WO2004101872A1/fr
Publication of WO2004101872A1 publication Critical patent/WO2004101872A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D03D1/0035—Protective fabrics
    • D03D1/0041—Cut or abrasion resistant
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
    • 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
    • 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
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
    • D03D15/247—Mineral
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides

Definitions

  • Basalt fibers are sized at the filament extrusion step in order to improve some of their properties, like smoothening of the filament surface (i.e. filling possible surface micro cracks and hiding surface defects) to reduce the probability of filament breakage and decreasing the fiber friction coefficient to facilitate further processing steps as weaving, knitting, braiding, etc.
  • instability and vulnerability are mainly due to the low friction coefficient of the sized basalt fibers ; instability of the sewn fabric at the seam ; breakage problem when submitted to a sufficiently small curvature, with the consequence that the fabrics cannot be folded ; instability of the fabric due to its high friction coefficient and therefor for its non stitchability (low strength at the seam) ; high stiffness of basalt ; naked basalt fabric may irritate the skin when handled, due to the small diameter of the basalt filament ends and their stiffness ;
  • Applicant has also proposed in unpublished PCT/BE 03/00061 a flexible and stable fabric having a low flammability (less than Ml, preferably M0 according to the norm NF P92-503 : 1995 ; NF P92-507 : 1997) and a low smoke generation (less than FI, preferably F0 according to the norm NF XI 0-702-1 : 1995 and NF X 10- 702-3 : 1994, toxicity in accordance with NF X 70-100 : 1986), said fabric having advantageously furthermore an excellent abrasion resistance of more than 10,000 cycles, advantageously more than 20,000 cycles, preferably more than 40,000 cycles, most preferably more than 50,000 cycles, while maintaining good flexibility and advantageously good resistance to aging.
  • EP 323763 discloses a textile barrier for protection against mechanical and/or thermal attack, such as attack by fire, explosion, projectiles, bullets, vandalism, etc.
  • the textile is a non woven fabric made of aramide fibers.
  • the textile can be provided with a woven or netted metallic fabric.
  • Aramide fibers are expensive and provide a limited fire resistance.
  • the invention has thus for subject matter a product combining anti vandalism properties and fire resistance properties with a flammability of Ml or MO according to the norm NF P 92-503 : 1995, NF P 92-507 : 1997 and a smoke generation of FI or F0 according to the norm NF X 10-702-1 : 1995; NF X 10-702- 3 : 1994 and NF X 70-100 : 1986.
  • the invention relates to a product comprising at least a structure made of at least:
  • the metallic reinforcing element is adapted for ensuring a resistance to cuts and tears in a cutting or tearing direction, advantageously preventing tears and/or cuts, by means of a cardboard box cutter, said cutter being pushed into the structure and with application of a force in said cutting direction of more than 300 N, advantageously of more than 500 N, preferably of more than 600 N , such as more than 1000N or even more than 1500N and whereby said structure is at least provided with a coating layer covering at least partly the yarns containing basalt fibers, said coating being selected from the group consisting of polyester containing coating, polyurethane containing coating, silicone containing coating and mixture thereof, whereby the coated yarns containing basalt fibers are selected so as to ensure a flammability of Ml or M0 according to the norm NF P 92-503 : 1995, NF P 92-507 : 1997 and a smoke generation of FI or F0 according
  • the metallic reinforcement element can be made of metallic wire having sufficient mechanical properties for providing anti vandalism resistance, such as cut resistance to a knife.
  • Such metallic reinforcement element is for example an intermediate layer in the form of a steel wire network as disclosed in EP 190 064, a fabric comprising at least two layers of individual elements (advantageously differing from 90°) as disclosed in WO 02/090644 and WO 02/089617.
  • the metallic reinforcement combines at least one steel wire network as disclosed in EP 190 064 with one or more fabrics with two layers of individual elements as disclosed in WO 02/090644 and/or WO 02/089617.
  • the content of these documents EP 190 064, WO 02/090644 and WO 02/089617 is incorporated in the present specification by reference.
  • the metallic reinforcement wires and the yams containing basalt fibers can be combined together so as to form yams comprising metallic reinforcement wire(s) and basalt containing fibers, such as yams comprising a core comprising metallic reinforcement wire and a protection layer surrounding the core, said protection layer comprising basalt containing fibers.
  • the yams can possibly comprise several metallic wires.
  • the metallic wires and the basalt fibers are combined together so as to form the yams. Possibly the metallic wire(s) extend at the periphery of the yams or adjacent to said periphery.
  • Basalt weight means the weight of basalt present in the fabric.
  • the fabric is a tridimensional fabric or has a tridimensional stmcture, such as a closed stmcture, such as cylindrical stmcture, the weight per surface is determined after developing the tridimensional fabric in a plane.
  • the basalt fabric and the metallic reinforcement element do not form a single fabric, but are bound or connected together by means of one or more connecting or binding means, such as by sewing, by adhesion, by gluing, etc. or by combinations of such means.
  • the binding can be made by dot coating or dot sewing, so as to form local binding points.
  • the product comprises : - a fabric (woven such as satin, plain, etc., non woven, knitted, braided, , three dimensional, three axial (plane), etc. and combinations thereof) made at least of yams containing at least basalt fibers (preferably basalt continuous filament fibers or BCF fibers), said fabric having a weight comprised between 70 g/m 2 and 4000 g/m 2 , advantageously from 100 to 3500g/m 2 , preferably less than 2500g/m 2 ; advantageously a primer coating at least partly said yams or fibers of said fabric, said primer being suitable for the coating layer(s), the dry weight of primer being comprised between 10 and 200 g/m 2 , advantageously between 20 and 100 g/m 2 , preferably between 25 and 50 g/m 2 ; - at least a coating layer selected from the group consisting of polyester containing coating, polyurethane containing coating, silicone containing coating and mixture thereof, said layer coating at least
  • the total weight of the layer, i.e. with additives, solid particles, etc. is advantageously comprised between 50 and 1000g/m 2 ).
  • the fabric is a tridimensional fabric or has a tridimensional stmcture, such as a closed stmcture, such as cylindrical stmcture, the weight per surface is determined after developing the tridimensional fabric in a plane.
  • the presence of a primer coating is preferred as it ensures a better binding of polyester, polyurethane, polyester polyurethane, silicone on the yams containing basalt fibers. Polyester polyurethane and silicone are most preferred. Silicone is especially preferred.
  • the fabric containing basalt fibers and coated with at least a coating layer is adapted for providing a fire resistance with a flammability of Ml or M0 according to the norm NF P 92-503 : 1995, NF P 92-507 : 1997 and a smoke generation of FI or F0 according to the norm NF X 10-702-1 : 1995; NF X 10-702-3 : 1994 and NF X 70-100 : 1986 .
  • the stmcture comprising yams containing basalt fibers (especially in the form of a fabric), the metallic reinforcing element and the coating layer is adapted (by selection of the metallic reinforcing element, the yams, the coating layer and the possible binding means) for ensuring a fire resistance with a flammability of Ml or M0 (preferably M0) according to the norm NF P 92-503 : 1995, NF P 92-507 : 1997 and a smoke generation of FI or F0 (preferably F0) according to the norm NF X 10-702-1 : 1995; NF X 10-702-3 : 1994 and NF X 70- 100 : 1986 .
  • said wires are selected to be M0 or Ml, preferably M0, and F0 or FI, preferably F0.
  • the coating layer comprises advantageously less than 25% by weight of solid particles and possible additives.
  • the additives and solid particles are advantageously selected so as to be unapt to generate smoke (FI or preferably F0 according to norm NF XI 0-702-1 : 1995 and NF X 10-702-3 : 1994 (toxicity in accordance with NF X 70-100 : 1986)).
  • the weight ratio weight of the coating layer/weight of primer layer is comprised between 3 and 30, preferably between 5 and 20, most preferably between 10 and 20.
  • the coating layer on the basalt fibers or yams has an abrasion resistance of more than 10,000 cycles, advantageously more than 20,000 cycles, preferably more than 25,000 cycles, according to the Martindale test BS 5690; 1991. Most preferably, the coating layer on the basalt fibers or yams has an abrasion resistance of more than 40,000 cycles, preferably more than 50,000 cycles, according to the Martindale test BS 5690; 1991.
  • the basalt fabric used in the product of the invention has advantageously a flexibility (flexibility of the fabric without the metallic reinforcement) such that the coated face can be folded and pinched (pressing the folded face between fingers along the folding line), whereby two portions of the coated faces contact each other.
  • the folding is carried out with a radius of curvature of less than 2mm, advantageously of less than 1mm, substantially without visible breakage of basalt fibers or filaments on the coated face.
  • the folding of the fabric does not form visible broken basalt fibers or filament on the coated side of the fabric, while some broken fibers or filaments are visible along the folding line on the uncoated side.
  • the ratio number of visible broken fibers or filaments on the coated side along the folding line / number of visible broken fibers on the uncoated face along the folding line is advantageously less than 0.1, preferably less than 0.05, most preferably less than 0.01, especially less than 0.001, or even more.
  • the number of visible broken fibers or filaments even on the uncoated face along the folding line is in any case low due to the passage of some coating agent between adjacent filaments or fibers.
  • the portion of the face of the fabric coated with a coating layer has a coating weight distribution such that for each cm 2 of the portion of the coated fabric, the weight of coating layer varies between 60%> and 250% of the average coating weight, advantageously between 70% and 150%, preferably between 80% and 130%.
  • different silicone elastomers can be used for coating the two opposite faces of the fabric.
  • the same silicone elastomer is used for coating the two opposite faces of the fabric.
  • the portion of the coated face of the fabric (for example coated with a silicone elastomer coating ) has a coating weight distribution such that for each cm 2 of the portion of the coated fabric, the weight of coating layer varies between 60% and 250% of the average coating weight, advantageously between 10% and 150%, preferably between 80% and 130%.
  • a uniform distribution of the coating is advantageous for ensuring substantially uniform properties of the coated fabric (stability, resistance to breakage, flexibility, etc.).
  • the layer coating a face of the fabric has a maximum coating weight (wet stage) of 100g/m 2 , advantageously a maximum coating weight of 80g/m 2 , preferably a maximum coating weight of 70g/m 2 .
  • the said maximum coating weight at the wet stage can be higher than 100g/m 2 , such as 200g/m 2 or even more.
  • the basalt fibers comprises a large number (such as more than 100, for example from 100 to 1000) of continuous basalt filaments having each a diameter comprised between 5 ⁇ m and 25 ⁇ m, preferably between 7 ⁇ m and 24 ⁇ m.
  • a coated face with a coating layer is provided with one or more further layers, such as by calendering, etc.
  • Said further layer can be a further silicone layer and/or a polyester polyurethane layer or a layer having various properties, such as a heat insulating layer, for example needle felt layer, basalt continuous filament fibers layer, etc.
  • the fabric is provided with successive silicone elastomer layers, preferably applied the one on another, for example by applying a new silicone elastomer layer after a at least partial curing of the previous silicone elastomer.
  • Said further layer(s) are advantageously selected so as to be Ml or MO, preferably MO, and FI or F0, preferably FO.
  • the portion of the fabric coated with a coating layer, especially a polyester polyurethane layer or with a silicone layer has a porosity made of pores of less than 50 ⁇ m, advantageously of less than 25 ⁇ m, preferably of less than lO ⁇ m. Said portion is most preferably substantially impermeable to liquids. Most of the times in clothing, some gas permeability is desired and/or even required.
  • At least a portion of a coating layer comprises at least one, for example one or more, pigments and/or coloring pigments and/or metallic pigments (such as aluminum powders, metallic microfibers, etc.) and/or luminescent compounds (such as fluorescent compound(s) and/or a phosphorescent compound(s)) and/or mixtures thereof.
  • pigments and/or coloring pigments and/or metallic pigments such as aluminum powders, metallic microfibers, etc.
  • luminescent compounds such as fluorescent compound(s) and/or a phosphorescent compound(s)
  • At least a face of the coated fabric (which can be for example a plain fabric or a satin fabric) is associated with a heat insulating layer and/or with a heat insulating layer on its both sides.
  • the coated fabric of the invention is used for covering one or both faces of a substrate, such as a non woven substrate.
  • the total weight of the layer, i.e. with additives, solid particles, etc. is advantageously comprised between 50 and 1000g/m 2
  • an intermediate layer is a metallic reinforcing element adapted for ensuring a resistance to cuts and tears in a cutting or tearing direction (advantageously in two orthogonal directions, as well as in any combinations thereof), advantageously preventing tears and/or cuts, by means of a cardboard box cutter, said cutter being pushed into the stmcture and with application of a force in said cutting direction of more than 300 N, advantageously of more than 500 N, preferably of more than 600 N
  • Connecting elements form bounds between the layer, such bounds can be connection created by chemical (glue, etc.), plastics, rubber, connection elements (sewing points, sewing lines, local connecting points, connection elements which are weaker than the reinforced layer, preferably weaker than at least one basalt containing fabric.
  • the product of the invention has various uses, such as for making inner layers, outer layers, intermediate layers, interliners in wall, floor, ceiling panels, fire resistance panels, covering laminates, such as for floor, seats, cushions, fire resistant mattresses, protective clothing, such as gloves, pancho's for forest fire fighters, tapes, canisters, tubes, heat protection envelopes (such as for pipes, valves, cables, electrical cables).
  • these possible uses are given here above as non limiting examples.
  • the product of the invention finds thus possible uses in various sectors, such as construction, transport (transport of persons, transport of goods), car industry, trains, furniture, protective clothes, plant, machinery and equipment, air plane and train seating, fire proof electrical cables or wires, telecommunication wires and cables (for example copper wires, copper cables, coaxial cables, etc.), signal transmission wires or cables, optical fiber optical fiber cables, truck tarpaulins, car soft tops or covers, canopies, tents, car covers, seat covers, tapes, etc.
  • additional finishing coatings are possible, such as coating for soft and continuous contact with the skin (for example obtained by flocking), further silicone coatings (for heat, weather and small impacts protection, elasticity),elastic layer, intumescent layer (for fire-heat insulation), etc.
  • Preferred silicone elastomers are silicone having a high density after curing, said density being measured for the cured silicone elastomer as such (i.e. free of charges or additives).
  • Preferred silicone elastomers are elastomers having a density after curing of at least 1.3 (g/cm 3 ), most preferably of at least 1.35, such as 1.4, 1.5 or even more. The density is measured at 23 °C in water according to the norm DIN
  • the silicone elastomer has moreover advantageously one or more further properties selected from the group consisting of : - Shore A hardness (DIN 53 505 - ISO 868) of at least 45, preferably of at least 50, most preferably of at least about 55 ;
  • a tensile strength (DIN 53 504-S 1 - ISO 37) comprised between 5 and 6.5 N/mm 2 ;
  • a tear resistance (ASTM D 624 B) comprised between 10 and 20 N/mm, preferably about 15 N/mm;
  • high resistance to hydrolysis and water for example resistance of at least 15 minutes in a boiling solution containing 4% by weight NaOH), i.e. a high resistance to aging; etc.
  • the invention relates also to a process for the preparation of a product of the invention, in which a basalt containing fabric is advantageously coated at least partly with a primer composition, whereby the fabric advantageously coated with the primer composition (possibly after a curing step of the primer coating) is coated at least partly with an aqueous dispersion of polyester and/or polyurethane and/or silicone elastomer, said aqueous dispersion containing at least 10% by weight of compound selected from the group consisting of polyester, polyurethane, silicone elastomer and mixture thereof, advantageously from 20 to 70% by weight, preferably from 30 to 50% by weight of said compound, whereby before and/or after the coating with an aqueous dispersion containing the compound, the basalt containing fabric is provided with a metallic reinforcement or comprises a metallic reinforcement.
  • the aqueous dispersion is free or substantially free of emulgators. Therefore, mineral pigments or particles, such as mineral powder, can be added to the coating dispersion before its application on the basalt fabric. Said pigments or other solid additives have advantageously a particle size of less than 2 ⁇ m, preferably of less than l ⁇ m, most preferably less than O.l ⁇ m.
  • the invention relates also to the use of a product according to the invention, as fire protection layer with anti vandalism properties, such as for interliner for mattress or seats, mattress covering, seat covering.
  • the basalt fabric can be in direct contact with the skin.
  • objects of the invention are fire protection clothes, fingers, boots, mittens, gloves, cowls, helmets, pancho's, overcoats, etc., curtains, seat interliners, panel constructions, fire proof electrical cables or wires, communication wires, truck tarpaulins, car soft tops or covers, canopies, tents, car covers, seat covers, tapes, etc. comprising at least a product or an element of the invention.
  • Tapes can be used for wrapping, with partial overlapping (for example overlapping between 10 and 90%> of the width, advantageously between 10 and 50% of the width), around a tube, a container, a cable, an electrical cable, a telecommunication cable, a parcel, signal transmission wire or cable, etc.
  • Such a tape can be provided with adhesion means such as gluing means, so as to ensure a good adhesion of the tape on the tube, cable, container, etc.
  • adhesion means such as gluing means, so as to ensure a good adhesion of the tape on the tube, cable, container, etc.
  • a silicone or polyurethane glue can be used.
  • Figure 1 is an upper (enlarged) view of a portion of an upper face of a fire resistant and anti vandalism structure of the invention
  • Figure 2 is a downside view of the stmcture of Figure 1 ;
  • Figure 3 is a cross section view of the structure of Figure 1 along the line III-III ;
  • Figure 4 is a cross section view of a stmcture provided with a coated fabric on both of its faces ;
  • Figure 5 is an upper view of a specific embodiment similar to the embodiment of
  • Figure 7 is a schematic view of a process for manufacturing a coated stmcture of the invention .
  • Figures 8 to 10 are schematic views of other processes for manufacturing a coated fabric of the invention.
  • Figure 12 is an upper view of the stmcture of figure 11 ;
  • Figure 13 is a schematic view showing a stmcture with a dot coating for obtaing dot connecting points ;
  • Figure 14 is a schematic view of a portion of a possible embodiment of a structure of the invention.
  • Fig 1 is a schematic view of the upper face of a stmcture of the invention having fire resistance and anti vandalism properties.
  • Said upper face consists of a coated basalt fabric.
  • the basalt fabric 1 has a weight of about 200g/m 2 to 400g/m 2 and is made of warp yams 1A and weft yams IB, said weft yams being crossed with respect to the warp yams for example so as to pass once above and once under said warp yams (plain binding).
  • the density of yams is 10 yams/centimeter for the warp yams and 8 yams/centimeter for the weft yams.
  • the thickness E of the fabric before its coating is about 190 ⁇ m.
  • the yams are made from continuous basalt filament with a diameter comprised between 7 and 2 l ⁇ m, for example about 9 ⁇ m, about 13 ⁇ m, about 20 ⁇ m, and combinations thereof, said yams weigh about 117 tex and comprise about 100 to 1500 filaments, for example about 500 filaments.
  • the basalt filaments are made from acid type basalt, with a SiO 2 content higher than 43%, advantageously higher than 46%>, for example higher than 50% by weight.
  • a torsion is carried out on the yams so as improve the cohesion of the filaments the one with respect to the other, for example, the torsion is such that the yam is submitted to a torsion from 5 to 150 times per meter, for example from 70 to 120 times per meter, preferably about 100 times.
  • the primer coating quantity represents about 25 g/m 2 of fabric.
  • the primer forms a thin continuous or not continuous layer (preferably substantially continuous) on the face of the yams directed towards the face to be provided with the silicone elastomer coating.
  • the silane ester used is ethenyl triacetate silane with trimethoxyl-3-propyl ester.
  • a coating 2 is provided on the upper face of the fabric 1, face which is provided with the primer coating, as well as on its downside face.
  • Said coating is a silicone elastomer coating, for example a coating prepared from Elastosil ® Liquid rubber sold by Wacker Chemie.
  • the coating 2 is applied on the fabric as an aqueous dispersion at a silicone elastomer rate of about 300g/m 2 (on dry basis), meaning that the thickness of the coating 2 is less than about 220 ⁇ m, as part of the coating dispersion flows in between filaments of yams.
  • the coated fabric has a total thickness of about 400-500 ⁇ m.
  • the coating layer is regularly applied so that the thickness of the coating layer varies between 50% and 200%>, advantageously from 80%) to 130% of the average coating thickness. The thickness of the coating layer is higher in the valley portions of the fabric.
  • the face 3 of the fabric of Fig 1 is coated so as to form a protection for the metallic reinforcement element 50, as well as partly connecting means between the reinforcement element 50 and the coated fabric 1.
  • the reinforcement element is a knitted fabric of thin steel wire 51,51 A, etc. as disclosed in figure 4 of EP 190 064.
  • the knitting is operated so that the distance L between the base of two adjacent wires 51, 51A is comprised between 1mm and 20mm, advantageously between 2mm and 12mm, such as 3mm, 4mm, 5mm, 6mm and 8mm.
  • the number of connections or links between two adjacent wires is for example comprised between 1 to 20 for a length of 3cm of adjacent wires. This number is for example substantially adapted so that the distance H between two adjacent connections or links corresponds substantially to the distance L.
  • the pitch of the knitted fabric is for example comprised between 5 and 9mm.
  • the knitted fabric is not coated, in the present example, the knitted fabric 50 is coated with a primer PI and with a silicone composition 2C, advantageously compatible with the composition used for coating the fabric 1 , preferably substantially the same composition as used for coating the fabric.
  • the fabric 1 and the knitted fabric 50 are bound together by silicone bindings or links
  • the knitted fabric has the form of a textile with a slidable binding.
  • the knitted metallic fabric is prepared from metallic wires coated with a silicone layer prior the knitting operation.
  • the manufacture of the stmcture of figure 1 can for example be operated as follows.
  • the basalt fabric is coated on his both faces with a primer layer P. After curing of said primer layer, one of its faces is coated with a silicone composition, so as to obtain after curing a thin silicone coating on said coated face.
  • the knitted fabric is treated with a primer composition, cured, and thereafter coated with a silicone containing composition.
  • the wire of the knitted fabric is provided with a silicone layer.
  • the metallic wire has for example a diameter comprised between 50 ⁇ m and 500 ⁇ m, while the primer coating has a thickness for example comprised between lO ⁇ m and 75 ⁇ m.
  • the silicone coating has for example a thickness comprised between 50 ⁇ m and 300 ⁇ m.
  • the silicone coated metallic fabric is applied on the face of the basalt fabric not coated with a silicone layer.
  • a silicone composition is then applied so as to coat the face of the basalt fabric in contact with the coated knitted metallic fabric, whereby forming after curing, silicone binds or links between the knitted fabric and the basalt fabric.
  • a same silicone composition is used for coated the metallic fabric and the basalt fabric.
  • the two opposite faces of the basalt fabric are coated with a silicone layer, before being contacted with the silicone coated metallic knitted fabric.
  • Figure 4 is a view of a structure similar to that shown in figures 1 to 3.
  • Said figure 4 is cross section view.
  • the stmcture comprises three layers LA1,LA2 and L A3.
  • the layer LAl is a basalt fabric 1 (yams 1A,1B) provided with a primer coating P and with a silicone coating 2A,2B on its both opposite faces.
  • the layer LA3 is similar to the layer LAI.
  • the layer LA2 an intermediate layer located between the layer LAI and LA3, comprises a metallic reinforcement element, such as a metallic knitted fabric as disclosed for the embodiment of figures 1 to 3. Said knitted fabric is coated with a primer coating, before being embedded in a silicone layer 54 forming a link between the two basalt fabrics and the knitted fabric 50.
  • a metallic reinforcement element such as a metallic knitted fabric as disclosed for the embodiment of figures 1 to 3.
  • Said knitted fabric is coated with a primer coating, before being embedded in a silicone layer 54 forming a link between the two basalt fabrics and the knitted fabric 50.
  • the knitted metallic fabric 50 can be not be coated with a primer coating.
  • FIG 5 is an upper view of an embodiment similar to the embodiment of figure 1.
  • the basalt fabric 1 is a knitted fabric instead of being a woven fabric.
  • the use of a knitted fabric 1 is advantageous for increasing the flexibility of the stmcture.
  • the pitch of the knitted basalt fabric is for example comprised between 0.5mm and 5mm.
  • Figure 13 is an exploded view of a stmcture similar to that shown in figure 1.
  • the basalt fabric 1 is provided on its both faces with a silicone layer 2, said silicone layer being cured.
  • the metallic reinforcing element 50 is provided with a primer coating suitable for creating binds with silicone.
  • the cured basalt fabric is provided with a pattern of uncured silicone points or dots or local area. After placement of said local silicone area, the metallic reinforcing element is pressed against the face of the basalt fabric provided with local uncured silicone points 59. The assembly consisting of basalt fabric and metallic reinforcing element is then passed through a chamber for curing the silicone points 59.
  • the so obtained structure comprises local binding points between the basalt fabric and the metallic reinforcing element 50, which enables a higher flexibility between the basalt fabric and the metallic reinforcing element.
  • the metallic wires are connected only on their face directed towards the basalt fabric by local silicone bindings.
  • the wire shown in figure 6 can then be used for forming a fabric, a woven fabric, a knitted fabric, a braided fabric, etc. possibly with basalt fibers not associated to a metallic wire.
  • the wire of figure 6 can advantageously be used for preparing woven fabric having slidable binding and/or bindings suitable to be easily broken for enabling a slidability of wires the one with respect to others.
  • the coating is stable and is resistant to UN aging, as well as to temperature aging ;
  • the coating does not degrade the basalt fibers or filaments, nor their properties, during the application of the coating, as well as during its burning ; - the coating does not catch fire with propagating flame, nor produces toxic fumes (coated fabric classified as M0 in accordance to the norm ⁇ F P92-503: 1995 and NF P92-507 : 1997), the coating disappears when burning in non toxic fumes (coated fabric classified as F0 in accordance to the norm NF X10- 702-1 : 1995, NF X10-702-3 : 1994 and NF X 70-100 : 1986); r the coated face is non irritating (for example due to the absence of naked basalt filament ends) ; excellent resistance to flames after the disappearance of the coating without degradation of the basalt fabric due to the coating process;
  • coated fabric can conform to complex or variable form of substrates, such as seats, etc. ;
  • Figure 7 is a schematic view of a process for manufacturing a coated fabric of Figure 1.
  • a knitted metallic fabric 50 is provided from a roll W and is moved towards the roll B.
  • the naked basalt fabric 1 is provided from a roll A, is applied on the metallic fabric 50, and is pulled by a stenter in the dryer 16 and taken by the roll B on which the coated basalt fabric attached to the metallic fabric is enrolled.
  • the naked basalt fabric placed on the metallic fabric 50 passes through a pair of brake rollers 10 with a torque motor regulated so as to exert a low braking (for example torque motor regulated to less than 15%, advantageously less than 10% > of the full braking capacity).
  • the naked fabric 1 passes then in a knife over air system 11 comprising two support rollers 12,13 between which the fabric 1 extends substantially horizontally.
  • a knife 14 contacts a portion of the fabric located between the two rollers 12,13, said knife 14 distributing an aqueous dispersion of silicone elastomer 15.
  • the wet coated fabric Ibis enters in a dryer 16.
  • Said heater 16 comprises the stenter 17 exerting a force on the lateral edges of the fabric so as to limit the lateral or transversal stretching of the basalt fabric to less than 10%), advantageously to less than 2%o, preferably so as to avoid or to prevent substantially any transversal stretching during the drying, most preferably so as to exert a kind of negative stretching during the drying.
  • the fabric 1 is moved with a speed for example lower than 40m/minute, such as a speed comprised between 10 and 25m/minute.
  • the dryer 16 is advantageously using a direct gas heating or steam heating or oil heating, for example heated gas with a temperature comprised between 120°C and 250°C, preferably with a temperature of about 160°C when contacting the fabric to be dried (water evaporation and curing).
  • heated gas is for example combustion gas, but can also be heated air.
  • the fabric is prewetted with an aqueous medium or with water.
  • the coating is made in a vacuum chamber.
  • the silicone elastomer coating is applied on the basalt fabric after a pretreatment step, namely the formation of a primer layer directly applied on the basalt fiber.
  • the primer is advantageously applied as an aqueous dispersion and is at least partly cured (preferably only partly cured) before the application of the silicone elastomer liquid dispersion.
  • the device disclosed in figure 7 is provided with a further coating system, preferably a coating system similar to the system 11.
  • rollers are provided so as to turn the lower face of the fabric upwards so as to enable the coating thereof with a system similar to the system 11.
  • silicone elastomer dispersions examples are given hereafter, said dispersions being used at room temperature for the coating.
  • Dispersion 1 aqueous dispersion silicone elastomer ( Elastosil Liquid Rubber® 3001/55 A B with a platinum catalyst ) with a silicone elastomer content of 40%)
  • Dispersion 2 aqueous dispersion silicone elastomer ( Elastosil Liquid Rubber® 3001/55 A/B with a platinum catalyst) with a silicone elastomer content of 45%
  • Dispersion 3 aqueous dispersion silicone elastomer ( Elastosil Liquid Rubber® 3001/55 A B with a platinum catalyst) with a silicone elastomer content of 20%
  • Dispersion 5 aqueous dispersion silicone elastomer ( Elastosil Liquid Rubber® 3001/55 A/B with a platinum catalyst ) with a silicone elastomer content of 20% and with pigment content of 20% (for example kaolin, etc.)
  • Dispersion 6 aqueous dispersion silicone elastomer ( Elastosil Liquid Rubber® 3001/55 A/B with a platinum catalyst) with a silicone elastomer content of 20% and with a fluorescent pigment content of 5%
  • Dispersion 7 aqueous dispersion silicone elastomer ( Elastosil Liquid Rubber® 3001/55 A/B with a platinum catalyst) with a silicone elastomer content of 5% and with a fluorescent pigment content of 5%>
  • Dispersion 9 aqueous dispersion silicone elastomer (Elastosil Liquid rubber
  • silane ester ethenyl triacetate silane with trimethoxyl-3-propyl ester
  • silane ester ethenyl triacetate silane with trimethoxyl-3-propyl ester
  • silane ester ethenyl triacetate silane with trimethoxyl-3-propyl ester
  • Figure 8 shows a specific process for the manufacture of a double coated basalt fabric.
  • the naked basalt fabric 1 enters in a bath 20 containing a primer solution or a primer dispersion.
  • the naked fabric provided with a primer coating is then passing between nip rolls 21 so as to remove excess primer composition.
  • the naked fabric can then be moved, if necessary, in a dryer 22 or a system for accelerating the curing of the primer on the naked fabric.
  • the basalt fabric is submitted to a treatment for removing at least partly the sizing agent (such as silane and/or paraffin) possibly used for coating the basalt filament
  • the drying or curing of the primer is for example made by hot air, IR heating, heat nitrogen gas, CO gas, microwave, etc., the primer being for example heated or cured at a temperature from 50°C up to 200°C.
  • the fabric 1 with a primer coating is then passing through the bath 24 containing an aqueous dispersion of silicone elastomer.
  • the coated fabric Before its passage in the bath 24, the coated fabric is associated with a metallic reinforcement element 50.
  • the basalt fabric and the element 50 are then moved together in the bath 24 (containing a silicone dispersion), before passing through nip rolls 25 for removing excess silicone elastomer.
  • a knife coater such as a knife over air enduction ,26 is then used for coating the upper face of the fabric with a sufficient and regular amount of silicone elastomer. Said coater distributes silicone elastomer on the upper face of the fabric.
  • the so " coated fabric is then moved in a heating chamber or in a curing chamber 27 for enabling a quick cure of the silicone elastomer.
  • the drying or curing of the silicone elastomer is for example made by hot air, IR heating, heat nitrogen gas, CO 2 gas, microwave, etc., the primer being for example heated or cured at a temperature from 50°C up to 250°C.
  • the so obtained fabric is provided with a thick upper silicone elastomer layer and with lower silicone elastomer layer with a thickness which can vary.
  • the reinforcement element 50 is added to the basalt fabric, so that the element lays on the upper face of the basalt fabric, the air knife system ensuring a control of the thickness.
  • the thickness is adapted so that the reinforcement element 50 is embedded in a silicone layer bound to the basalt fabric.
  • the fabric has to be provided with two thick silicone elastomer layers, one on its lower face and another on its upper face, it is possible to use a system for reversing the fabric after coating the upper face of the fabric with a silicone elastomer with a knife coater, whereby the lower face becomes the upper face which can then be further treated with a knife coater for distributing uniformly a silicone elastomer.
  • the basalt fabric and the reinforcement element are separately treated with a silicone dispersion or with different silicone dispersions, the treated basalt fabric and the treated reinforcement element being thereafter contacted together and pressed together, before being cured together.
  • Said method is exemplified in figure 10, in which the same reference have been used as in the methods of figures 7 and 8.
  • the silicone elastomer used in said process is preferably halogen free.
  • the invention has also for subject matter a product as disclosed in WO 02/090644 and in WO 02/089617, in which the metallic wires are connected to at least a basalt fabric, preferably coated with a polyester polyurethane and/or with a silicone.
  • the invention has thus also for subject matter : - a fabric comprising at least two layers and/or two directions of individual elements of which at least one individual element is a reinforcing element comprising a metal component, preferably a steel component, which elements are not interwoven or interwoven, but have only an indirect connection created by chemicals, plastics, bbers or by a connection elements which are weaker than the individual reinforcing element(s), in which the individual elements are connected by means of a fabric layer, said fabric layer being a basalt containing fabric, the yams of which are coated with a polyester polyurethane and/or with a silicone; fabric as disclosed hereabove having one or more characteristics mentioned in anyone of the claims 2 to 23 of WO 02/089617.
  • Figure 11 is a schematic exploded view of a stmcture comprising such a layer of individual elements, while figure 12 is an upper view of said stmcture.
  • the stmcture comprises : - an upper basalt fabric 70 made of basalt containing yams, both faces of said fabric being coated with a silicone and/or polyester polyurethane layer; an lower basalt fabric 71 made of basalt containing yams, both faces of said fabric being coated with a silicone and/or polyester polyurethane layer;
  • an intermediate layer 72 comprising three series of metallic reinforcement wires (carbon steel wire with a diameter of 150 ⁇ m) 73,74,75, the wires of the first series extending in a first direction, while the wires of the second series extend in a second direction, the wires of the third series extending in a third direction, said second direction forming an angle of +30° with respect to the first direction, while the third direction forms an angle of -30° with respect to the first direction (an angle of 60° being defined between the second and third directions), the wires of the three series crossing each other at crossing points CP, the number of reinforcement wires being two or three per cm in each direction,
  • the yams used for said connecting lines CL can be made in various materials, advantageously materials which do not emit toxic fumes, preferably materials having a good fire resistance, materials not suitable for propagating fire, etc.
  • the yams can be glass containing yams, basalt containing yams, aramide yams, etc.
  • the yams forms connecting points between wires of different series, said connecting points being weaker than the reinforcing wires, so that when a cutter is moved onto the stmcture, connecting points can be broken, whereby giving a slidability to reinforcing wires therebetween.
  • the wire can also be made in a material resistant to a high temperature, such as at temperature higher than 300°C, advantageously higher than 400°C, preferably greater than 500°C, so as to ensure a good connection between the basalt fabric and the metallic reinforcing element.
  • a material resistant to a high temperature such as at temperature higher than 300°C, advantageously higher than 400°C, preferably greater than 500°C, so as to ensure a good connection between the basalt fabric and the metallic reinforcing element.
  • One or more wires are connected to a electrical power source so as to emit a signal when one or more wires are contacted together due to the action of the knife or cutter, especially a cardboard box cutter, i.e. a cutter used for opening cardboard box.
  • Figure 14 is a view in cross-section of a portion of a layered stmcture comprising :
  • first insulating layer 60 for example made of basalt fibers, such as a mat of basalt fibers, said insulating layer being located between the upper basalt fabric 1 and the intermediate metallic reinforcing element 50;
  • bonds along edges of the stmcture are advantageous as it enables great movement of the metallic reinforcing element 50 with respect to the basalt fabrics.
  • the lower insulating layer 61 is associated to one or more distinct electrically conductive elements, such as an aluminum film 63.
  • Said film 63 is for example connected to the ground or to a terminal of an electrical power source, while the wires of the metallic reinforcing elements are connected to one or several electrical power source, whereby when the end of a blade of a cutter traverse the upper layer, the metallic reinforcing element and partly the lower insulating layer, an electrical contact is made between the wire and the aluminum film, whereby an alarm signal can be emitted.
  • An assembly can be obtained (see figure 15) with a pattern combining adjacent cushions with a stmcture similar to the structure shown in figure 14, except that the insulating layer is a compressible insulating layer and that the insulating layers are also sewn with the basalt fabrics and the metallic reinforcing element.
  • Dispersion 2 aqueous dispersion polyester polyurethane ( Impranil DLN ®) with a polyester polyurethane content of 45%)
  • Dispersion 3 aqueous dispersion polyester polyurethane ( Impranil DLN ®) with a polyester polyurethane content of 20%>
  • Dispersion 5 aqueous dispersion polyester polyurethane ( Impranil DLN ®) with a polyester polyurethane content of 20% and with pigment content of 20%> (for example kaolin, etc.)
  • Dispersion 6 aqueous dispersion polyester polyurethane ( Impranil DLN ®) with a polyester polyurethane content of 20%> and with a fluorescent pigment content of 5%
  • Dispersion 7 aqueous dispersion polyester polyurethane ( Impranil DLN ®) with a polyester polyurethane content of 5% and with a fluorescent pigment content of 5%
  • fabrics examples include woven fabric with binding such as plain, sateen, twill, etc., knitted flat fabric, three dimensional fabrics, etc., such as knitted tubes, braided fabrics such as in tubes, non woven fabric, needlefelt fabrics, etc.
  • the product of the invention can have various uses, such as for making inner layers in wall, floor, ceiling panels, fire resistance panels, covering laminates, such as for car floor, seats, cushions, fire resistant mattresses, protective clothing, such as gloves, pancho's for forest fire fighters, tapes, canisters, tubes, heat protection envelope (such as for pipe, valves, cables, electrical cables, cutting resistant luggage, cutting resistant parcel or package, cutting resistant upholstery fabric, for seats, chairs, etc.
  • protective clothing such as gloves, pancho's for forest fire fighters, tapes, canisters, tubes, heat protection envelope (such as for pipe, valves, cables, electrical cables, cutting resistant luggage, cutting resistant parcel or package, cutting resistant upholstery fabric, for seats, chairs, etc.
  • construction wall, floor and ceiling paneling for building-in fire resistance, fire curtains such as automatically falling down to segment buildings, manufacturing halls, storage areas, tunnel, electrical wire insulation, fire blocking interliners with a thermal insulation function, etc. in case of fire ;
  • furniture fire resistant mattresses, fire blocking interliners in mattresses, plane seats, train seats, bus seats, etc.
  • protective clothes especially sewn protective clothes : overcoats, gloves, boots, etc. for example for fire fighter, forest fire fighter ;
  • the coating with the silicone elastomer is advantageously carried out substantially just after the treatment of the basalt fabric with the primer composition.
  • the silicone elastomer coating is carried out less than 30minutes, advantageously less than 15 minutes, most preferably less than 5 minutes after the end of the treatment of the basalt fabric with the primer composition.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

La présente invention concerne un produit comportant au moins une structure constituée d'au moins : des fils contenant des fibres de basalte, et un élément de renforcement métallique, lesdits fils et l'élément de renforcement étant liés les uns aux autres, et l'élément de renforcement métallique étant conçu pour conférer une résistance aux coupures et aux déchirures.
PCT/BE2003/000085 2003-05-16 2003-05-16 Tissu contenant du basalte WO2004101872A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP03724677A EP1625248A1 (fr) 2003-05-16 2003-05-16 Tissu contenant du basalte
AU2003229147A AU2003229147A1 (en) 2003-05-16 2003-05-16 Basalt containing fabric
PCT/BE2003/000085 WO2004101872A1 (fr) 2003-05-16 2003-05-16 Tissu contenant du basalte

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/BE2003/000085 WO2004101872A1 (fr) 2003-05-16 2003-05-16 Tissu contenant du basalte

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WO2004101872A1 true WO2004101872A1 (fr) 2004-11-25

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EP (1) EP1625248A1 (fr)
AU (1) AU2003229147A1 (fr)
WO (1) WO2004101872A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006006039A1 (fr) * 2004-07-06 2006-01-19 Paolo Cappellari Vetement pour motocycliste
WO2008066946A2 (fr) 2006-05-01 2008-06-05 Federal-Mogul Corporation Matériau isolant et résistant au feu fait de filaments continus de basalte ; manchons et procédés de construction de celui-ci
WO2011110220A1 (fr) * 2010-03-09 2011-09-15 Mep-Olbo Gmbh Bande transporteuse
ITTO20111208A1 (it) * 2011-12-23 2013-06-24 Bridgestone Corp Mescola di gomma per pneumatici
FR3015104A1 (fr) * 2013-12-13 2015-06-19 Nexans Enveloppe de protection thermique pour proteger un cable et/ou un accessoire pour cable
EP3042761A1 (fr) * 2015-01-12 2016-07-13 Schmitz-Werke GmbH + Co. KG Tissu textile pour vehicules cabriolets
WO2022106839A1 (fr) * 2020-11-20 2022-05-27 Brennan Enterprise Limited Barrière anti-feu flexible pour bâtiments

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1043277A1 (fr) * 1999-04-09 2000-10-11 N.V. Bekaert S.A. tissu tricoté à surfaces avant et arrière differentes
WO2002086213A1 (fr) * 2001-04-19 2002-10-31 Groep Masureel Veredeling Etoffe contenant du basalte

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1043277A1 (fr) * 1999-04-09 2000-10-11 N.V. Bekaert S.A. tissu tricoté à surfaces avant et arrière differentes
WO2002086213A1 (fr) * 2001-04-19 2002-10-31 Groep Masureel Veredeling Etoffe contenant du basalte

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006006039A1 (fr) * 2004-07-06 2006-01-19 Paolo Cappellari Vetement pour motocycliste
WO2008066946A2 (fr) 2006-05-01 2008-06-05 Federal-Mogul Corporation Matériau isolant et résistant au feu fait de filaments continus de basalte ; manchons et procédés de construction de celui-ci
EP2013388A2 (fr) * 2006-05-01 2009-01-14 Federal-Mogul Corporation Matériau isolant et résistant au feu fait de filaments continus de basalte ; manchons et procédés de construction de celui-ci
EP2013388A4 (fr) * 2006-05-01 2012-07-11 Federal Mogul Corp Matériau isolant et résistant au feu fait de filaments continus de basalte ; manchons et procédés de construction de celui-ci
WO2011110220A1 (fr) * 2010-03-09 2011-09-15 Mep-Olbo Gmbh Bande transporteuse
ITTO20111208A1 (it) * 2011-12-23 2013-06-24 Bridgestone Corp Mescola di gomma per pneumatici
WO2013093897A1 (fr) * 2011-12-23 2013-06-27 Bridgestone Corporation Composé de pneumatique en caoutchouc
FR3015104A1 (fr) * 2013-12-13 2015-06-19 Nexans Enveloppe de protection thermique pour proteger un cable et/ou un accessoire pour cable
EP2892057A2 (fr) 2013-12-13 2015-07-08 Nexans Enveloppe de protection thermique pour protéger un câble et/ou un accessoire pour câble
EP2892057A3 (fr) * 2013-12-13 2015-10-28 Nexans Enveloppe de protection thermique pour protéger un câble et/ou un accessoire pour câble
EP3042761A1 (fr) * 2015-01-12 2016-07-13 Schmitz-Werke GmbH + Co. KG Tissu textile pour vehicules cabriolets
WO2022106839A1 (fr) * 2020-11-20 2022-05-27 Brennan Enterprise Limited Barrière anti-feu flexible pour bâtiments

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EP1625248A1 (fr) 2006-02-15

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