WO2008006395A1 - Process of manufacturing a laminated flame-retardant fabric - Google Patents

Process of manufacturing a laminated flame-retardant fabric Download PDF

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Publication number
WO2008006395A1
WO2008006395A1 PCT/EP2006/006921 EP2006006921W WO2008006395A1 WO 2008006395 A1 WO2008006395 A1 WO 2008006395A1 EP 2006006921 W EP2006006921 W EP 2006006921W WO 2008006395 A1 WO2008006395 A1 WO 2008006395A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
flame
powder
retardant
coating
Prior art date
Application number
PCT/EP2006/006921
Other languages
French (fr)
Inventor
Luc Regis Leon Carlier
Original Assignee
Ctf 2000 N.V.
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 Ctf 2000 N.V. filed Critical Ctf 2000 N.V.
Priority to PCT/EP2006/006921 priority Critical patent/WO2008006395A1/en
Publication of WO2008006395A1 publication Critical patent/WO2008006395A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
    • B32B23/10—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/03—Powdery paints
    • C09D5/033—Powdery paints characterised by the additives
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/18—Fireproof paints including high temperature resistant paints
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0013—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using multilayer webs
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0063—Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D06N3/0093—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by applying resin powders; by sintering
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
    • D06N3/183—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials the layers are one next to the other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant

Definitions

  • the invention relates to a process of manufacturing a laminated flame-retardant treated fabric comprising a front fabric layer and a flame-retardant back-layer.
  • the fabric more especially upholstery fabric has been provided with a back coating based upon a collapsible foam, a half collapsible foam, a stable foam, or a paste, either low or high viscosity paste, in which the applied coating contains at least one flame-retardant compound.
  • lik-roll coating such as a kiss roll
  • knife coating such as knife over air or knife over roll
  • screen coating any other commonly known coating method.
  • the coating can be done by so-called padding (Foulard).
  • Foard Fooulard
  • the chemicals come into direct contact with the front side of the fabric which makes the method less attractive.
  • the chemicals used in the coating need to be dried and fixed to the fabric, which can be done by guiding the coated fabric through an over (Stenter) in which the fabric is submitted to temperatures of at least 120 0 C up till temperatures of about 200 0 C.
  • the length of the oven determines the speed of drying and fixing to the fabric. This operation requires a good air exhaustion system with sophisticated filtration equipment to reduce the emission.
  • halogen containing coatings are commonly used because they are more efficient and more economical. However mostly they only achieve low or no water resistances like in the soaking test BS. It is therefore difficult to achieve permanent systems which allow a wash ability of the fabric and it is also difficult to achieve high flame retardant standards like BS 5852 part XX Crib 5 or 7 on 100% synthetic materials. With halogen the recycling of water generates an additional problem.
  • EP-A-O 752 458 there is described another system and process for producing flame retardant fabric.
  • this is called a lamination process in which a non-woven fabric is provided with a thermal glue layer and the flame retardant powder is sprayed over this glue layer. Subsequently an additional glue layer may be applied over this first glue layer or another protective layer can be applied.
  • the thermal glue layer can be of the type PES, PP, TPU ot mixtures thereof whereas as flame retardant compound use can be made of graphite particles.
  • the obtained fabric can be any within a wide range of fabrics such as upholstery, carpets, mattress ticking, curtains, black-out and dim-out curtains, sun protection fabrics, gardening furniture fabrics, wall paper fabrics, protective clothing, automotive applications, decoration fabrics, banners and all kind of technical fabrics.
  • the end fabric maintains mainly its original flexibility, its air permeability, its hand touch which is even improved by giving a full soft body, and its appearance of the original front fabric which has the behaviour to be flame-retardant without any direct flame-retardant composition being present on both the front and rear face of the end fabric. This has the advantage that people working with this type of fabric have no direct contact with any chemical composition thereby avoiding a number of environmental problems. It is also possible to use lighter front fabrics than usually, as the total strength and other characteristics of the ultimate fabric will be provided by the combination of the front and back layer bound together.
  • thermo-adhesive pre-treated flame retardant fabric will be composed as follows:
  • Part i A blend mainly of cellulose containing fibres and a defined percentage of synthetic fibres is assembled in a non-woven fabric produced by hydro jet.
  • the weight of this fabric will vary between 15g/m 2 and 100 g/m 2 . This does not exclude the use of 100% cellulose containing fibres and of different types of weavings like non-woven, woven, knitted
  • a stable or semi-stable or unstable coating or even a non foam able coating which is produced of flame-retardant raw-materials, binders , special additives.
  • special additives like anti-bacterial, anti dust mite, anti-waves, temperature reflex ion,....
  • the scattered mix of powders can be a mono product or blends of flame retardant compounds such as vermiculite, powder thermo glue like PES, PP, PA, or mixtures thereof, and chemical powders which can provide all kind of properties like anti-bacterial, anti-dust mite,...
  • Those powders can have particle sizes ranging from the 50 ⁇ to 500 ⁇ .
  • the fabric (part 1) is installed in a coating line (knife over air) or a printing line (CT4) which all provides the possibility to apply stable foam, semi stable foam and unstable foam and paste (non foam able).
  • the special flame-retardant coating (part 2) is applied on the fabric (part 1).
  • the powders (part 3) are scattered above the coating (part 2) before entering the stenter (oven).
  • the powders fall Jn and on the front side of the coating.
  • a second method of application of the powders on the coatings is to use the technology of flocking . This has for advantage that it attracts and fix better the powder in the coating and gives a stronger fixation between the powder and the coating.
  • the coating (part 2) and the powders (part 3) can be dried and fixed at a temperature between 90 0 C and 160 0 C. In the case of stable foam or semi-stable foam , the fabric will be crushed just after the oven.
  • thermo-adhesive pre-treated flame retardant fabric The end result is a back layer thermo-adhesive pre-treated flame retardant fabric .
  • thermo-adhesive pre-treated flame retardant fabric is ready to be sold, shipped and applied by the end customer which can be a manufacturer of normal woven or non woven front fabric composed of synthetic fibres (smelting/splitting type).
  • thermo-adhesive pre-treated flame retardant fabric with a classical laminator from the type Kleverik, Reliant, ...and even with existing material like heated calendars. This will provide a low cost, easy to apply, flexible solution to synthetic fabrics with flame retardant properties.
  • the back layer (part 1 ) and the coating (part 2) are prepared as described above but without the application of the mix of powders containing the flam retardant powder and the thermal glue powder.
  • an adequate amount of a powder mix (part 3 ) is supplied to the end user together with the back layer. This allows the end user to apply the scattered mix of powder to the back layer and in the same process adhere the front layer to the back layer provided with the scattered mix of powder.
  • Thickness : 0,62 mm
  • Thickness : 0,54 mm Max tensile strength
  • Thickness : 0,70 mm
  • Thickness 0, 70 mm Quality D:
  • Type of treatment foamable coating or paste coating
  • Type of treatment padding coating Weight of dry add on: 40-50 g/m 2
  • Type of treatment Foamable coating or paste coating Weight of dry add on : 40- 50 g/m 2
  • Type of treatment Padding coating Weight of dry add on : 20 g/m 2
  • Type of treatment Padding coating Weight of dry add on : 10-15g/m 2
  • Material composition EVA glue powder + Vermiculite powder
  • Material composition Polyurethane glue powder + Vermiculite powder
  • Material composition mixture in different ratio's of all A/B/C/D/E powders+ Vermiculite powder
  • Types of fabrics non-woven and woven Flat and short and medium length pile fabrics
  • Types of fabrics non-woven and woven Flat and short and medium length pile
  • Types of fabrics non-woven and woven Flat and short and medium length pile
  • Types of fabrics non-woven and woven Flat and short and medium length pile
  • Types of fabrics non-woven and woven Flat and short and medium length pile
  • Material composition Mixtures of all above listed products, A 1 B 1 C 1 D 1 E must be splitting when flame is burning material)
  • Types of fabrics non-woven and woven Flat and short and medium length pile

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)

Abstract

A process of manufacturing a laminated flame-retardant treated fabric comprising a front fabric layer and a flame-retardant back-layer, in which that one surface of a back-layer is provided with a flame-retardant powder and a thermal glue powder, and the back-layer is connected to the front fabric layer by heat treatment of the superimposed layers. Preferably the mixture of flame-retardant powder and thermal glue powder is applied in a scattered way.

Description

Process of manufacturing a laminated flame-retardant fabric.
The invention relates to a process of manufacturing a laminated flame-retardant treated fabric comprising a front fabric layer and a flame-retardant back-layer.
In the prior art several methods have been described for producing laminated flame-retardant treated fabrics.
In a first method the fabric, more especially upholstery fabric has been provided with a back coating based upon a collapsible foam, a half collapsible foam, a stable foam, or a paste, either low or high viscosity paste, in which the applied coating contains at least one flame-retardant compound.
The application of such a coating is commonly done by means of lik-roll coating (such as a kiss roll), knife coating (such as knife over air or knife over roll), screen coating or any other commonly known coating method.
In some cases, especially for flat fabrics, the coating can be done by so-called padding (Foulard). However in this system the chemicals come into direct contact with the front side of the fabric which makes the method less attractive.
When using one of the above cited methods the chemicals used in the coating need to be dried and fixed to the fabric, which can be done by guiding the coated fabric through an over (Stenter) in which the fabric is submitted to temperatures of at least 1200C up till temperatures of about 2000C. The length of the oven determines the speed of drying and fixing to the fabric. This operation requires a good air exhaustion system with sophisticated filtration equipment to reduce the emission.
As these technologies are well known for years they offer a number of advantages in that a wide scope of applications are available. It is therefore possible with this method to coat synthetic and natural fibres. Furthermore a substantial number of coating equipment is available in the market and present in vertically integrated companies. A disadvantage of this process however is that the equipment to be used is relatively expensive and requires high investment costs, the equipment is large requiring substantial space and must be handled by skilled people.
In this type of process halogen containing coatings are commonly used because they are more efficient and more economical. However mostly they only achieve low or no water resistances like in the soaking test BS. It is therefore difficult to achieve permanent systems which allow a wash ability of the fabric and it is also difficult to achieve high flame retardant standards like BS 5852 part XX Crib 5 or 7 on 100% synthetic materials. With halogen the recycling of water generates an additional problem.
In EP-A-O 752 458 there is described another system and process for producing flame retardant fabric. In general terms this is called a lamination process in which a non-woven fabric is provided with a thermal glue layer and the flame retardant powder is sprayed over this glue layer. Subsequently an additional glue layer may be applied over this first glue layer or another protective layer can be applied. The thermal glue layer can be of the type PES, PP, TPU ot mixtures thereof whereas as flame retardant compound use can be made of graphite particles.
For this process it is needed to have a heated laminator (e.g. of the type Kleverik or Reliant), allowing the assemblage of the front and back fabric, whereas further one or two scatters must be available in order to apply the flame retardant and the thermal glue powder powder.
By using this system and process it became possible to have halogen free flame retardant powders and reach high standards on synthetic fabrics like Crib 5 or Crib 7. Furthermore there is a wash ability of 5 to 10 times depending upon the synthetic fabrics and the thermal glue used. Moreover the type of machine to be used is much cheaper and smaller than in the previous method as no oven is needed. Otherwise the system has some very specific disadvantages. The investment for a laminator is still important as is the cost for scattering equipment as the application is difficult in view of the static electricity. During confection there are still particles leaving the fabric. Graphite is containing heavy metals (chromium) so that there is pollution problem and it is a expensive product that can only produced in circumstances which are environmentally unfriendly. In some application also the colour of the graphite constitutes a problem.
It is therefore an object of the invention to provide a process for manufacturing a laminated flame-retardant fabric in which the above mentioned problems and disadvantages have been avoided.
This object is achieved by means of the process according to claim 1.
The obtained fabric can be any within a wide range of fabrics such as upholstery, carpets, mattress ticking, curtains, black-out and dim-out curtains, sun protection fabrics, gardening furniture fabrics, wall paper fabrics, protective clothing, automotive applications, decoration fabrics, banners and all kind of technical fabrics. The end fabric maintains mainly its original flexibility, its air permeability, its hand touch which is even improved by giving a full soft body, and its appearance of the original front fabric which has the behaviour to be flame-retardant without any direct flame-retardant composition being present on both the front and rear face of the end fabric. This has the advantage that people working with this type of fabric have no direct contact with any chemical composition thereby avoiding a number of environmental problems. It is also possible to use lighter front fabrics than usually, as the total strength and other characteristics of the ultimate fabric will be provided by the combination of the front and back layer bound together.
In the following a number of examples of front and back layers will be described as well as possible combinations thereof. Moreover in the following description different methods for applying the thermal glue particles will be described. In most circumstances the back layer thermo-adhesive pre-treated flame retardant fabric will be composed as follows:
Part i : A blend mainly of cellulose containing fibres and a defined percentage of synthetic fibres is assembled in a non-woven fabric produced by hydro jet. The weight of this fabric will vary between 15g/m2 and 100 g/m2. This does not exclude the use of 100% cellulose containing fibres and of different types of weavings like non-woven, woven, knitted
Part 2:
A stable or semi-stable or unstable coating or even a non foam able coating which is produced of flame-retardant raw-materials, binders , special additives. IN addition it is possible to add other special additives like anti-bacterial, anti dust mite, anti-waves, temperature reflex ion,....
Part 3:
The scattered mix of powders can be a mono product or blends of flame retardant compounds such as vermiculite, powder thermo glue like PES, PP, PA, or mixtures thereof, and chemical powders which can provide all kind of properties like anti-bacterial, anti-dust mite,...
Those powders can have particle sizes ranging from the 50μ to 500 μ.
The method of production is characterized in that it comprises the following steps:
The fabric (part 1) is installed in a coating line (knife over air) or a printing line (CT4) which all provides the possibility to apply stable foam, semi stable foam and unstable foam and paste (non foam able). The special flame-retardant coating (part 2) is applied on the fabric (part 1). The powders (part 3) are scattered above the coating (part 2) before entering the stenter (oven). The powders fall Jn and on the front side of the coating. A second method of application of the powders on the coatings is to use the technology of flocking . This has for advantage that it attracts and fix better the powder in the coating and gives a stronger fixation between the powder and the coating. After this operation, the coating (part 2) and the powders (part 3) can be dried and fixed at a temperature between 900C and 1600C. In the case of stable foam or semi-stable foam , the fabric will be crushed just after the oven.
The end result is a back layer thermo-adhesive pre-treated flame retardant fabric .
This back layer thermo-adhesive pre-treated flame retardant fabric is ready to be sold, shipped and applied by the end customer which can be a manufacturer of normal woven or non woven front fabric composed of synthetic fibres (smelting/splitting type).
The customer can laminate this layer thermo-adhesive pre-treated flame retardant fabric with a classical laminator from the type Kleverik, Reliant, ...and even with existing material like heated calendars. This will provide a low cost, easy to apply, flexible solution to synthetic fabrics with flame retardant properties.
In a third method the back layer (part 1 ) and the coating (part 2) are prepared as described above but without the application of the mix of powders containing the flam retardant powder and the thermal glue powder. However apart from the back layer an adequate amount of a powder mix (part 3 ) is supplied to the end user together with the back layer. This allows the end user to apply the scattered mix of powder to the back layer and in the same process adhere the front layer to the back layer provided with the scattered mix of powder.
The present invention will now be explained by means of a number of examples, in which connection it should be noted, however, that the present invention is by no means limited to such a special example: Q
Examples of trials:
Types of tested back fabrics:
1. Flat non woven
Quality A:
Material name : Jet non-woven
Material composition : 60% Polyester/40% Viscose
Weight: : 45g/m2 Thickness: : 0,65 mm
Max tensile strength
Longitudinal : 79 N/5cm Transversal: : 74 N/5cm Elongation at max tensile strength Longitudinal : 40 %
Transversal : 54 %
Quality B:
Material name : Jet non-woven Material composition : 100% Viscose
Weight: : 45g/m2
Thickness: : 0,62 mm
Max tensile strength
Longitudinal : 76 N/5cm Transversal: : 61 N/5cm
Elongation at max tensile strength Longitudinal : 31 % Transversal : 47 %
Quality C:
Material name : jet non-woven
Material composition : 35% Polyester/65% Viscose
Weight: : 50g/m2
Thickness: : 0,54 mm Max tensile strength
Longitudinal : 74 N/5cm Transversal: : 24 N/5cm
Elongation at max tensile strength Longitudinal : 30 % Transversal : 120 %
Quality D
Material name :wall papers backing Material composition : 100% cellulose Weight : 100g/m2
Quality E
Material name : glass fiber non-woven
Material composition :glass fiber Weight : 100 g/m2
2. Flat woven fabrics: Quality A:
Material composition: 100 % Co Weight: :100 g/m2
Thickness: : 0,70 mm
Quality B:
Material composition: 95% Co + 5% Elastane Weight : 100 g/m -.22
Thickness : 0,75 mm
Quality C:
Material composition : 65%Co + 35% Pes Weight : 100 g/m2
Thickness : 0, 70 mm Quality D:
Material composition :100% glass fibre Weight : 100 g/m2
Thickness : 0,80 mm
Quality E:
Material composition: 100% basalt Weight : 120 g/m 2
Thickness : 0,9 mm
Types of tested coatings or glues for the treatment of the back fabric:
Quality A: Material composition : Bromine/Antimony /binder/+additives compound
Type of treatment : foamable coating or paste coating
Weight of dry add on: 40-50 g/m2
Quality B:
Material composition : Bromine/Antimony /binder/+additives compound
Type of treatment : padding coating Weight of dry add on: 40-50 g/m2
Quality C:
Material composition : Phosphore/Nitrogen/binder /+ additives compound
Type of treatment : Foamable coating or paste coating Weight of dry add on : 40- 50 g/m2
Quality D:
Material composition : Phosphore/Nitrogen/binder / additives compound y
Type of treatment : Padding coating Weight of dry add on : 20 g/m2
Quality E: Material composition : Phosphore/Nitrogen/crosslinker
Type of treatment : Padding coating Weight of dry add on : 10-15g/m2
Types of powder glue and flame retardant powder mixtures (scattering application or Flock application technique):
Quality A:
Material composition: EVA glue powder + Vermiculite powder
Quality B:
Material composition: Polyurethane glue powder + Vermiculite powder
Quality C:
Material composition : polyamide glue powder +Vermiculite powder
Quality D
Material composition : Polyolefin glue powder + Vermiculite powder
Quality E : Material composition : Polyester glue powder + Vermiculite powder
Quality F and :
Material composition : mixture in different ratio's of all A/B/C/D/E powders+ Vermiculite powder
Those mixtures are possibly used for both type of flame retardant rolls, first in the case of use of a flame retardant treated back fabric which is assembled by scattering and lamination and second as powder which must be glued in the flame retardant coating composed of see here above.
Types of front fabrics which have given good results on FR Standards:
Quality A:
Material composition: 100% Polyester
Types of fabrics : non-woven and woven Flat and short and medium length pile fabrics
Quality B:
Material composition: 100% Trevira
Types of fabrics : non-woven and woven Flat and short and medium length pile
Quality C:
Material composition: 100% Polyamide
Types of fabrics : non-woven and woven Flat and short and medium length pile
Quality D:
Material composition: 100% Polypropylene
Types of fabrics : non-woven and woven Flat and short and medium length pile
Quality E:
Material composition: 100% acrylic
Types of fabrics : non-woven and woven Flat and short and medium length pile
Quality F and ....
Material composition: Mixtures of all above listed products, A1B1C1D1E must be splitting when flame is burning material) Types of fabrics : non-woven and woven Flat and short and medium length pile
It has been found that all combinations of the above cited materials in a product according to the invention has resulted in a product with good flame retardant properties and easy to handle process.

Claims

1. A process of manufacturing a laminated flame-retardant treated fabric comprising a front fabric layer and a flame-retardant back-layer, characterized in that one surface of a back-layer is provided with a flame- retardant powder and a thermal glue powder, and the back-layer is connected to the front fabric layer by heat treatment of the superimposed layers.
2. A process according to claim 1 , characterized in that the front fabric layer is a non-woven fabric layer.
3. A process according to claims 1 or 2, characterized in that the back layer is a non-woven fabric layer.
4. A process according to any one of the claims 1 - 3, characterized in that the front fabric layer comprises 100 % by weight of synthetic fabrics.
5. A process according to any one of the claims 1 - 4, characterized in that the back-layer is made of pure cellulose fibres or a mixture of cellulose and polyester fibres.
6. A process according to any one of the proceeding claims, characterized in that, the flame-retardant powder and the thermal glace powder are applied to the surface of the back-layers as a scattered mix of powders.
7. A process according to anyone of the claims 1-5, characterized in that the flame retardant powder and the thermal glue powder are applied to the surface of the back-layer by means of a flock process.
8. A process according to claim 7, characterized in that the surface of the back-layer is coated with a stable foam or a non foam able coating and the scattered mix of powder is applied while the stable foam or the non foam able coating is still in a wet condition.
9. A process according to any one of the preceding claims, characterized in that the back-layer is provided with a coating containing at least a flame- retardant.
10. Back layer to be used with a front layer characterized in that one surface of the black layer is provided with a scattered mix of powders containing a flame-retardant powder and a thermal glue powder.
11. Back layer according to claim 10, characterized in that the back layer comprises a fabric layer one surface of being provided with a coating containing at least one flame retardant component.
12. Assembly comprising an amount of back layer comprising a fabric layer of which one surface being provided with a coating comprising a flame retardant component, and a package contained a mixture of a flame retardant powder and a thermal glue powder.
PCT/EP2006/006921 2006-07-14 2006-07-14 Process of manufacturing a laminated flame-retardant fabric WO2008006395A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/EP2006/006921 WO2008006395A1 (en) 2006-07-14 2006-07-14 Process of manufacturing a laminated flame-retardant fabric

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2006/006921 WO2008006395A1 (en) 2006-07-14 2006-07-14 Process of manufacturing a laminated flame-retardant fabric

Publications (1)

Publication Number Publication Date
WO2008006395A1 true WO2008006395A1 (en) 2008-01-17

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
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Country Status (1)

Country Link
WO (1) WO2008006395A1 (en)

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CN102876258A (en) * 2012-10-18 2013-01-16 义乌市新彩虹工艺地毯有限公司 Preparation method of microcapsule elastic glue for carpet
CN103082827A (en) * 2012-12-11 2013-05-08 东华大学 Coffee carbon polyester fiber elastic carpet and preparation method thereof
CN103534404A (en) * 2011-05-17 2014-01-22 Ctf2000有限公司 Method for fireproofing textiles
CN105804352A (en) * 2016-03-15 2016-07-27 苏州迪恩斯纺织服饰有限公司 Environment-friendly wall cloth with self-contained adhesives and preparation method thereof
US11207863B2 (en) 2018-12-12 2021-12-28 Owens Corning Intellectual Capital, Llc Acoustic insulator
US11666199B2 (en) 2018-12-12 2023-06-06 Owens Corning Intellectual Capital, Llc Appliance with cellulose-based insulator

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CN103534404A (en) * 2011-05-17 2014-01-22 Ctf2000有限公司 Method for fireproofing textiles
CN102876258A (en) * 2012-10-18 2013-01-16 义乌市新彩虹工艺地毯有限公司 Preparation method of microcapsule elastic glue for carpet
CN103082827A (en) * 2012-12-11 2013-05-08 东华大学 Coffee carbon polyester fiber elastic carpet and preparation method thereof
CN103082827B (en) * 2012-12-11 2016-07-06 东华大学 A kind of coffee carbon polyester fiber elastic carpet and preparation method thereof
CN105804352A (en) * 2016-03-15 2016-07-27 苏州迪恩斯纺织服饰有限公司 Environment-friendly wall cloth with self-contained adhesives and preparation method thereof
US11207863B2 (en) 2018-12-12 2021-12-28 Owens Corning Intellectual Capital, Llc Acoustic insulator
US11666199B2 (en) 2018-12-12 2023-06-06 Owens Corning Intellectual Capital, Llc Appliance with cellulose-based insulator

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