CA1274161A - Fire barrier fabrics - Google Patents
Fire barrier fabricsInfo
- Publication number
- CA1274161A CA1274161A CA000547652A CA547652A CA1274161A CA 1274161 A CA1274161 A CA 1274161A CA 000547652 A CA000547652 A CA 000547652A CA 547652 A CA547652 A CA 547652A CA 1274161 A CA1274161 A CA 1274161A
- Authority
- CA
- Canada
- Prior art keywords
- fabric
- vinyl
- fire barrier
- glass
- copolymers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000004744 fabric Substances 0.000 title claims abstract description 182
- 230000004888 barrier function Effects 0.000 title claims abstract description 32
- 239000003365 glass fiber Substances 0.000 claims abstract description 51
- 238000000576 coating method Methods 0.000 claims abstract description 41
- 239000011248 coating agent Substances 0.000 claims abstract description 39
- 239000011521 glass Substances 0.000 claims abstract description 32
- 239000000835 fiber Substances 0.000 claims abstract description 9
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 9
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 9
- 238000005299 abrasion Methods 0.000 claims abstract 3
- 230000001464 adherent effect Effects 0.000 claims abstract 3
- 229920002554 vinyl polymer Polymers 0.000 claims description 59
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 57
- 239000000463 material Substances 0.000 claims description 25
- 229920002635 polyurethane Polymers 0.000 claims description 22
- 239000004814 polyurethane Substances 0.000 claims description 22
- 229920001577 copolymer Polymers 0.000 claims description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 239000011230 binding agent Substances 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 8
- 229920000642 polymer Polymers 0.000 claims description 8
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 claims description 7
- 229910052736 halogen Inorganic materials 0.000 claims description 7
- 150000002367 halogens Chemical class 0.000 claims description 7
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 5
- 239000005977 Ethylene Substances 0.000 claims description 5
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical compound O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 claims description 5
- 229910000410 antimony oxide Inorganic materials 0.000 claims description 4
- VTRUBDSFZJNXHI-UHFFFAOYSA-N oxoantimony Chemical compound [Sb]=O VTRUBDSFZJNXHI-UHFFFAOYSA-N 0.000 claims description 4
- LGXVIGDEPROXKC-UHFFFAOYSA-N 1,1-dichloroethene Chemical compound ClC(Cl)=C LGXVIGDEPROXKC-UHFFFAOYSA-N 0.000 claims description 3
- 229920012485 Plasticized Polyvinyl chloride Polymers 0.000 claims description 3
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 3
- 229920000800 acrylic rubber Polymers 0.000 claims description 3
- 238000010030 laminating Methods 0.000 claims description 3
- 239000011253 protective coating Substances 0.000 claims description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 claims description 2
- 239000006087 Silane Coupling Agent Substances 0.000 claims 1
- 238000012360 testing method Methods 0.000 description 25
- 239000006260 foam Substances 0.000 description 15
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 11
- 239000000779 smoke Substances 0.000 description 10
- 239000000203 mixture Substances 0.000 description 9
- 239000004816 latex Substances 0.000 description 8
- 229920000126 latex Polymers 0.000 description 8
- 239000000123 paper Substances 0.000 description 8
- 239000004014 plasticizer Substances 0.000 description 8
- 230000003292 diminished effect Effects 0.000 description 7
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 6
- 239000002131 composite material Substances 0.000 description 6
- 238000010276 construction Methods 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 6
- 229920005830 Polyurethane Foam Polymers 0.000 description 5
- 239000000945 filler Substances 0.000 description 5
- 239000003063 flame retardant Substances 0.000 description 5
- 230000035515 penetration Effects 0.000 description 5
- 229920001084 poly(chloroprene) Polymers 0.000 description 5
- 239000011496 polyurethane foam Substances 0.000 description 5
- 239000002987 primer (paints) Substances 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- 239000008199 coating composition Substances 0.000 description 4
- 230000006378 damage Effects 0.000 description 4
- 239000000839 emulsion Substances 0.000 description 4
- 238000001125 extrusion Methods 0.000 description 4
- 239000004088 foaming agent Substances 0.000 description 4
- -1 for example Substances 0.000 description 4
- 239000011120 plywood Substances 0.000 description 4
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 3
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 3
- 229910019142 PO4 Inorganic materials 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 235000011114 ammonium hydroxide Nutrition 0.000 description 3
- 125000003118 aryl group Chemical group 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 3
- 239000010452 phosphate Substances 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 229920000915 polyvinyl chloride Polymers 0.000 description 3
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- 238000000197 pyrolysis Methods 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 229920001944 Plastisol Polymers 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 239000007983 Tris buffer Substances 0.000 description 2
- 229920006266 Vinyl film Polymers 0.000 description 2
- 229910052787 antimony Inorganic materials 0.000 description 2
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 2
- 235000019504 cigarettes Nutrition 0.000 description 2
- WHHGLZMJPXIBIX-UHFFFAOYSA-N decabromodiphenyl ether Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1OC1=C(Br)C(Br)=C(Br)C(Br)=C1Br WHHGLZMJPXIBIX-UHFFFAOYSA-N 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 238000007756 gravure coating Methods 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 2
- 239000004999 plastisol Substances 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 2
- 150000003673 urethanes Chemical class 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- AQPHBYQUCKHJLT-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-(2,3,4,5,6-pentabromophenyl)benzene Chemical group BrC1=C(Br)C(Br)=C(Br)C(Br)=C1C1=C(Br)C(Br)=C(Br)C(Br)=C1Br AQPHBYQUCKHJLT-UHFFFAOYSA-N 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- 229920002126 Acrylic acid copolymer Polymers 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 239000004908 Emulsion polymer Substances 0.000 description 1
- 235000009967 Erodium cicutarium Nutrition 0.000 description 1
- 240000003759 Erodium cicutarium Species 0.000 description 1
- PXGOKWXKJXAPGV-UHFFFAOYSA-N Fluorine Chemical compound FF PXGOKWXKJXAPGV-UHFFFAOYSA-N 0.000 description 1
- 241000287828 Gallus gallus Species 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- 229920000459 Nitrile rubber Polymers 0.000 description 1
- 229920002125 Sokalan® Polymers 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 229940088990 ammonium stearate Drugs 0.000 description 1
- 230000000844 anti-bacterial effect Effects 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- JPNZKPRONVOMLL-UHFFFAOYSA-N azane;octadecanoic acid Chemical compound [NH4+].CCCCCCCCCCCCCCCCCC([O-])=O JPNZKPRONVOMLL-UHFFFAOYSA-N 0.000 description 1
- 239000003899 bactericide agent Substances 0.000 description 1
- NTXGQCSETZTARF-UHFFFAOYSA-N buta-1,3-diene;prop-2-enenitrile Chemical compound C=CC=C.C=CC#N NTXGQCSETZTARF-UHFFFAOYSA-N 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 239000013530 defoamer Substances 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- UJSSNDKVUQJEGE-UHFFFAOYSA-N dichloro propyl phosphate Chemical compound CCCOP(=O)(OCl)OCl UJSSNDKVUQJEGE-UHFFFAOYSA-N 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000003670 easy-to-clean Effects 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 230000009970 fire resistant effect Effects 0.000 description 1
- 229910052731 fluorine Inorganic materials 0.000 description 1
- 239000011737 fluorine Substances 0.000 description 1
- XUCNUKMRBVNAPB-UHFFFAOYSA-N fluoroethene Chemical compound FC=C XUCNUKMRBVNAPB-UHFFFAOYSA-N 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000000855 fungicidal effect Effects 0.000 description 1
- 239000000417 fungicide Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 239000002650 laminated plastic Substances 0.000 description 1
- 239000012939 laminating adhesive Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000025 natural resin Substances 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 150000002896 organic halogen compounds Chemical class 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 150000001282 organosilanes Chemical class 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 150000003014 phosphoric acid esters Chemical class 0.000 description 1
- 150000003017 phosphorus Chemical class 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 239000004584 polyacrylic acid Substances 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920006264 polyurethane film Polymers 0.000 description 1
- 229920002620 polyvinyl fluoride Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 238000007763 reverse roll coating Methods 0.000 description 1
- 230000000391 smoking effect Effects 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- DFQHFXCKNSCDFW-UHFFFAOYSA-N tris(4-chlorophenyl) phosphate Chemical compound C1=CC(Cl)=CC=C1OP(=O)(OC=1C=CC(Cl)=CC=1)OC1=CC=C(Cl)C=C1 DFQHFXCKNSCDFW-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
- A47C31/001—Fireproof means
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
- A62B17/00—Protective clothing affording protection against heat or harmful chemical agents or for use at high altitudes
-
- 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
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- 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
- B32B2255/00—Coating on the layer surface
- B32B2255/02—Coating on the layer surface on 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
- 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
- B32B2262/0223—Vinyl resin 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
- B32B2262/0223—Vinyl resin fibres
- B32B2262/0238—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
- B32B2262/0292—Polyurethane 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
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass 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
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S297/00—Chairs and seats
- Y10S297/05—Fireproof
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/92—Fire or heat protection feature
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3472—Woven fabric including an additional woven fabric layer
- Y10T442/3504—Woven fabric layers comprise chemically different strand material
Abstract
ABSTRACT OF THE DISCLOSURE
A flame resistant fire barrier fabric comprising a preformed self-extinguishing thermoplastic face fabric laminated to an underlying glass fabric wherein the glass fibers are coated with a thin adherent encapsulating coating, and wherein the encapsulating coating substantially minimizes fiber to fiber self abrasion.
A flame resistant fire barrier fabric comprising a preformed self-extinguishing thermoplastic face fabric laminated to an underlying glass fabric wherein the glass fibers are coated with a thin adherent encapsulating coating, and wherein the encapsulating coating substantially minimizes fiber to fiber self abrasion.
Description
6~
BAC;RG~Ol:~NI) OF T~E IN~IENTIO~
1. FIE:LD OF TE~E I~ENTI0~7 The present invention relates to an improved fire barrier abric and i~s method of preparation.
BAC;RG~Ol:~NI) OF T~E IN~IENTIO~
1. FIE:LD OF TE~E I~ENTI0~7 The present invention relates to an improved fire barrier abric and i~s method of preparation.
2. DESCRIPTION OF T~E PRIOR ART
In the United States in 1983, over 37,000 people were seriously injured in residential and institutional 5 fires. Property damage due to the same ~ires amounted to six billion dollars. Another source of serious and fa~al burn injuries are accidents involving vehicles. In addition, many serious burn injuries occur in vehicles which are caused by careless smoking or children playing 10 with matches. Since many vehicular fires are enclosed within the metal shell of the car body, they reach very high temperatures in a short period of time.
Extensive research has been conducted by both government and industry to develop materials for home furnishings that are either non-Elammable or retard flame propagation. Other important considerations are that the materials be functional, aesthetic and economical.
Standards such as DOT 302 have been promulgated for materials used in vehicles. DOT Standard 302 limits the rate of flame propagation Eor fabrics used in vehicles. However, it has been repeatedly demonstrated that the burning characteristics of a multi-component structure can not be predicted from the burning characteristics of the individual components.
The federal government has developed the "cigarette burn test" to rate upholstery fabrics.
However, certain fabrics that will not ignite from a smoldering cigarette (class 1 fabrics), can burn in contact with an open flame and allow the underlying batting in a cushion or upholstered furnishing to ignite.
Fire retardant ~oam coatings for drapery liners and backcoatings for upholstery ~abrics are commercially available. There are chemical treatments for apparel fabrics. However, at best, these materials are self-s extinguishing when the flame source is removed. If theflame source is not removed, these materials will char, lose their integrity and allow the flame to reach materials under the fabric coating.
Plasticized polyvinyl chloride (vinyl) and polyurethanes are extensively used for upholstery fabrics especially in transportation vehicles, kitchen furniture, furnishings in restaurants, theaters, night clubs and public buildings. These fabrics are inexpensive, long wearing, easy to clean and can be produced in a wide variety of textures, colors and weights.
Such fabrics usually consist of a cctton, polyester or polyester/cotton scrim to which is bonded a layer of vinyl or urethane. The scrim fabric can be woven, knit or non-woven and is usually a lightweight open fabric designed to provide dimensional stability, tensile strength and tear resistance to the composite fabric. The vinyl (where term "vinyl" is used, polyurethane would be equally applicable~ can be extrusion coated onto the scrim or can be cast as a separate film and subsequently bonded to the scrim by stitch bonding, adhesive bonding, or heat bonding.
A typical vinyl upholstered chair consists of a metal, wood or plastic frame. The seat consists of a plywood base, a two to three inch thick slab o polyurethane foam and vinyl fabric enclosing the foam and stapled to the bottom of the wood base. SeatS in vehicles such as school buses and subway cars are of similar construction. In automobiles, metal springs replace the plywood.
By proper selection of plasticizer and ~ire retardant fillers such as antimony oxide, self-extinguishing vinyl fabric can be produced. However, in ~7~
the presence of a flame, the vinyl can shrink and expOSe the underlying material, usually urethane foam or polyester fiberfill. When these materials ignite, the entire chair or seat will be quickly engulfed in flames.
U.S. Patent 4,526,830 to Fergizer relates to coated glass fiber fabrics suitable for use as mattress tickings, The fabrics comprise a woven or non-woven glass fiber fabric to which a layer of polymeric coating composition has been applied. The polymeric carrier can also include a fungicide, bactericide, flame retardant and filler.
U.S. Patent 2,956,917 to Fasano discloses the impregnation of a loosely woven glass fabric in a solution of a polyalkyl methacrylate and a vinyl resin polymer comprising predominantly vinyl chloride, to set or adhere the glass yarns to each other and prevent distortion of the weave pattern, and laminating a preformed vinyl resin film onto the treated fabric by means of pressure.
U.S. Patent 2,215,061 to Alt discloses a Eabric prepared by coating a woven glass fabric with a coating composition derived either from cellulose, a synthetic resin, a natural resin, or a protein.
U.S. Patent 2,686,737 to Caroselli et al discloses coated glass fiber fabrics wherein the coating is a butadiene-acrylonitrile copolymer.
U.S. Patent 3,~90,985 to Marzocchi et al discloses decorated woven glass fabric produced by taking two different types of interwoven strands and applying a mixture of thermoplastic resin, foaming agent and plasticizer over areas of the Eabric which include the two different types of strands. The foaming agent reacts to Eoam the mixture in situ about the adjacent portion of both types of strands to provide flexible raised areas of foamed resin. The foamed resin is poorly bonded to one type o strand but strongly coupled to the other.
~;2'7~
U.S. Patent 2,830,925 to Fennebresque discloses a plastic laminate for decorative purposes produced by incorporating into the laminate a pigmented fibrous material which can be made of glass fiber.
S~MMARY OF T~E INVE~TI~
The present invention relates to a coa~ed glass fiber fabric which is laminated to the back of a self-extinguishing thermoplastic face fabric to provide a flame resistant barrier when exposed to fire, and prevents the underlying material from igniting.
DESCRIPTION OF T~E PREF~RRED EMBODIMENTS
In accordance with the present invention, a flame resistant fire barrier fabric is composed of a prefinished self-extinguishing thermoplastic face fabric.
The thermoplastic face fabric, generally a plasticized polyvinyl chloride or polyurethane is laminated to an underlying glass fiber fabric. The glass fiber Eabric is inherently non-flammable and maintains its integrity when exposed to high heat and flames to act as a barrier in preventing underlying materials covere~ by the glass fiber fabric laminate from igniting.
Glass fibers are self-abrasive. Thus, glass Eibers rubbing against each other will self-destruct.
Since the glass fabric/vinyl laminate will flex in normal use, it is necessary to coat the glass fiber fabric ~ith a suitable protective material which will coat and encapsulate the fibers and minimi~e the tendency of the glass fibers to self-destruct.
The glass fiber fabric protective coatings should not reduce the non~flammable characteristics of the glass fiber nor should the pyrolysis products of the coating be a source of heavy smoke upon ignition. The coatings generally consist of a polymeric binder and suitable fillers. The synergistic action of antimony oxide and halogen containing compounds is well-known. Thus, a typical coating may consis~ of a halogenated polymer such as polyvinyl chloride, polyvinylidine chloride or 5 polyvinylfluoride or copolymers containing vinyl fluoride and finely dispersed antimony oxide. Halogenated plasticizers are used to alter the hand of the coating as well as to provide halogen. Phosphorus derivatives are also often incorporated to contribute smolder resistance.
10 Aluminum trihydrate can also be used as an additive. At elevated temperatures, the endothermic decomposition of aluminum trihydrate contributes water vapor to smother flames. Other systems can use highly brominated organic compounds such as decabromodiphenyl o~ide with antimony lS oxide.
The novel fire barrier fabrics of the present invention comprise a woven or non-woven glass fiber material which has been given a protective coating to encapsulate the glass fibers, and a vinyl face Eabric.
In the construction of a vehicle seat~ such as a school bus seat the cushioning material, usually polyurethane foam, can be first covered with the coated glass fiber fabric and then covered with the vinyl face fabric. A preferred approach is to prelaminate the glass fabric to the vinyl face fabric. The glass fabric can be adhesively bondedt stitch bonded or heat bonded to the vinyl face fabric.
It has been discovered from the results of simulated school bus ires, that the prelaminated Eabric is a superior fire barrier than the corresponding sequentially applied Eabrics. A se~uentially applied fabric is one wherein there is no bonding between the respective fabrics. Thus, a sequentially applied fabric for a bus seat would include a polyurethane foam base, 35 glass fiber fabric wrapped around the foam, followed by a layer of vinyl face fabric wrapped around the glass fiber fabric.
While it is not certain what the actual basis is for the superior perEormance of the prelaminated fabric over the sequentially applied ~abric in functioning as a fire barrier, it is believed that when the prelaminated fabric is exposed to flames, the vinyl does not shrink away from the underlying glass fiber fabric to which it is laminated, but softens and flows into the interstices of the glass ~iber fabric to prevent passage of oxygen to the underlying cushioning materials and also to prevent outward passage of flammable gases generated by anaerobic pyrolysis of the cushioning materials.
Despite the superior performance of the prelaminated fabric, the sequentially applied glass fiber fabric and vinyl face fabric on a vehicle seat represent a significant advance over the state of the art for fire resistant vehicle seats.
In general, the vinyl face fabric is impermeable.
However, it is not necessary that the vinyl ~ace fabric be impermeable to the passage of air in order for the glass ~iber fabric/vinyl face fabric composite to function as a fire barrier. In general, the porosity of the composite should not exceed a critical porosity value of about 300 cubic feet per square foot per minute when measured at a pressure of one-hal~ inch of water. The critical porosity value is not an absolute value, but depends to some degree on the flammability of the underlying cushioning material. It generally ranges from about a value of 200 to 300.
Suitable woven glass fiber Eabrics include plain weave, basket weave7 leno weave, twill weave, crowEoot satin or long shaft satin. Suitable knit fabrics include warp knits and weft knits. Non-woven glass mats are also suitable. The construction of the fabric should be such that the composite whether or not prelaminated should not exceed the critical porosity value.
....
~2~
~uitable plain weave fabrics include those having warp counts (the number o~ yarns per inch) of from about 40 to 120 and filling counts of from 30 to 60. Fabric wei~hts from about 2.0 to 8 oz/yd2 are suitable.
Suitable coa~ing compositions consist of a polymeric binder, fillers, fire retardant additives, and optional pigments and/or plasticizers. The continuous medium can be water or an organic solvent. Water is preferred because oE environmental considerations.
lo Typical binders include emulsion polymers such as vinyl chloride polymers, ethylene/vinyl chloride copolymers, vinylidine chloride/alkyl methacrylate copolymers, vinyl chloride/vinyl acetate copolymers, Neoprene polymers, polyurethanes, vinyl acetate/alkyl acrylate copolymers or combinations thereof. It is preferable that at least a portion of the binder consist of a polymer containing chlorine or fluorine. Typical fillers include clay, calcium carbonate, talc or titanium dioxide. Fire retardant additives include antimony trioxide, antimony pentoxider aluminum trihydrate, and decabromodiphenyl oxide.
An effective fire retardant is a mixture of antimony trioxide and a organohalogen compound. The source of halogen can be from the polymeric binder, for example, polyvinyl chloride or copolymers containing vinyl chloride. Where the binder contains no halogen, suitable halogen donors such as decabromodiphenyl oxide can be added to the composition~
Depending on the selection of the polymeric binderr it may be necessary to incorporate plasticizers into the composition to avoid stiffening the fabric.
While a wide variety o~ organic plasticizers are suitable for softening the coating it is preferable to use phosphate ester plasticizers which can contribute flame retardancy to the coating. Most preferable are phosphate esters containing halogen such as tris(p-chlorophenyl) phosphate, tris(2,3,dichloropropyl phosphate) and the like.
When the coated glass fiber fabric is adhesively bonded or heat bonded to the vinyl face fabric, it is important that none of the components of the coating composition reduce or detract from the strength of the bond.
The coating can be applied to the glass fiber fabric as a liquid coating or a collapsible foam.
Suitable methods for applying a liquid coating include gravure coating, reverse roll coating, knife over roll, knife over table, floating knife or pad/nip coating. The method of coating is not critical to the invention provided complete encapsulation of the glass fibers is accomplished.
Where the coating is applied as a collapsible foam, it is necessary to incorporate a foaming agent into the coating composition, again with the provision that the foaming agent not interfere with the efficacy of the bonding of the encapsulated glass fiber fabric to the face fabric. Suitable methods for applying collapsible foams include horizontal pad, f]oating knife, knife over roll Eollowed by crush rolls, or gravure coating.
The quantity of coating applied to the glass fiber fabric can range from about 5% to about 100%
preferably from 8 to 30~ based on the weight of the fabric. ~lowever, it is critical that sufficient coating be applied to completely encapsulate the glass yarns.
Too much coating can be detrimental since it can stiffen the hand of the composite Eabric.
~ n optional primer coating or treatment can be given to the glass fiber fabric to improve adhesion of the encapsulating coating. Suitable primers include coupling agents such as organosilanes or organotitanates.
These are often blended with emulsion acrylic polymers and applied from dilute aqueous dispersions to the fabric.
~7~
g It has been found that when a preformed vinyl face fabric is laminated or coated onto the glass fiber fabric, be~er overall properties occur than if the vinyl were coated onto the glass fiber fabric in an uncured or liquid state, and then cured. Thus, the vinyl fabric should be preformed, and is considered to be preformed when laminated to the glass fiber fabric by means of extrusion casting of the vinyl onto the glass fiber fabric.
The fire barrier fabric of the present invention meets or exceeds the Original Equipment Manufacturers tOEM) Standards for the Bus Industry. Table I, which ~ollows, tabulates certain test results in comparison with the corresponding OEM standard.
Table I
Invention Q~ Standar~
1. Total Weight 33 oz/54 in. 34 oz/54 in.
2. Grab Tensile 150 x 145 135 x 120 (ASTM D 751) 20 3. Tongue Tear 10 x 12 9 x 13 (Fed Std l91A-5134) 4. Adhesion, lb/inch could not 5.5 x 5 lbs (ASTM D 751) separate 5. Flex Test Pass PasS
25(CFFA-10) 6. Seam Breakage 101 x 99 120 x 90 (AMC Method~
6~
The efficacy of the fire barrier fabrics has been established by constructing full size vehicle seats which were tested under fire conditions~ While such testing is expensive, it is well-known that simple small scale tests such as DOT 302, of the composite fabric can only distinguish differences in flammability of the fabrics and can not predict the burning characteristics of a multicomponent structure in a real fire.
The test chamber was a standard fire test room, 8 feet by 12 feet by 8 feet high with an open 30 by 80 inch door centered in one 8 foot wall. Three school bus seats were arranged end on to the the room back wall. Spacing was 27.5 inches (bolt to bolt), which is conventional for school buses. Bus seat construction was similar to that presently used in the industry.
All materials used for the test control bus seats meet present federal and state standards for school bus construction. The seats were made of a metal frame with slab urethane foam cushioning and a vinyl face fabric.
The following examples serve to illustrate the present invention. All parts and percentages are by weight, unless otherwise indicated.
A heat cleaned plain weave glass fabric fiber having a count of 60 warp ends per inch and ~8 fill ends per inch, a weight oE 3.16 oz per square yard was given a primer finish by immersing the fabric in an aqueous bath consisting of 0.3% of gamma glycidoxypropyltrimethoxy-silane, ~.0% of a ~6~ solids polyacrylic ester copolymer emulsion, 1.0% of a 25% solids polytetrafluoroethylene emulsion, 2.0% of antimigrant and 0.1% of aqua ammonia (26 Be). The fabric was squeezed through pad rolls and -~7~
dried. The dry add-on of Einish was about 1.25% based on weight of the fabric.
An encapsulating coating was prepared by blending the following components~
42% water
In the United States in 1983, over 37,000 people were seriously injured in residential and institutional 5 fires. Property damage due to the same ~ires amounted to six billion dollars. Another source of serious and fa~al burn injuries are accidents involving vehicles. In addition, many serious burn injuries occur in vehicles which are caused by careless smoking or children playing 10 with matches. Since many vehicular fires are enclosed within the metal shell of the car body, they reach very high temperatures in a short period of time.
Extensive research has been conducted by both government and industry to develop materials for home furnishings that are either non-Elammable or retard flame propagation. Other important considerations are that the materials be functional, aesthetic and economical.
Standards such as DOT 302 have been promulgated for materials used in vehicles. DOT Standard 302 limits the rate of flame propagation Eor fabrics used in vehicles. However, it has been repeatedly demonstrated that the burning characteristics of a multi-component structure can not be predicted from the burning characteristics of the individual components.
The federal government has developed the "cigarette burn test" to rate upholstery fabrics.
However, certain fabrics that will not ignite from a smoldering cigarette (class 1 fabrics), can burn in contact with an open flame and allow the underlying batting in a cushion or upholstered furnishing to ignite.
Fire retardant ~oam coatings for drapery liners and backcoatings for upholstery ~abrics are commercially available. There are chemical treatments for apparel fabrics. However, at best, these materials are self-s extinguishing when the flame source is removed. If theflame source is not removed, these materials will char, lose their integrity and allow the flame to reach materials under the fabric coating.
Plasticized polyvinyl chloride (vinyl) and polyurethanes are extensively used for upholstery fabrics especially in transportation vehicles, kitchen furniture, furnishings in restaurants, theaters, night clubs and public buildings. These fabrics are inexpensive, long wearing, easy to clean and can be produced in a wide variety of textures, colors and weights.
Such fabrics usually consist of a cctton, polyester or polyester/cotton scrim to which is bonded a layer of vinyl or urethane. The scrim fabric can be woven, knit or non-woven and is usually a lightweight open fabric designed to provide dimensional stability, tensile strength and tear resistance to the composite fabric. The vinyl (where term "vinyl" is used, polyurethane would be equally applicable~ can be extrusion coated onto the scrim or can be cast as a separate film and subsequently bonded to the scrim by stitch bonding, adhesive bonding, or heat bonding.
A typical vinyl upholstered chair consists of a metal, wood or plastic frame. The seat consists of a plywood base, a two to three inch thick slab o polyurethane foam and vinyl fabric enclosing the foam and stapled to the bottom of the wood base. SeatS in vehicles such as school buses and subway cars are of similar construction. In automobiles, metal springs replace the plywood.
By proper selection of plasticizer and ~ire retardant fillers such as antimony oxide, self-extinguishing vinyl fabric can be produced. However, in ~7~
the presence of a flame, the vinyl can shrink and expOSe the underlying material, usually urethane foam or polyester fiberfill. When these materials ignite, the entire chair or seat will be quickly engulfed in flames.
U.S. Patent 4,526,830 to Fergizer relates to coated glass fiber fabrics suitable for use as mattress tickings, The fabrics comprise a woven or non-woven glass fiber fabric to which a layer of polymeric coating composition has been applied. The polymeric carrier can also include a fungicide, bactericide, flame retardant and filler.
U.S. Patent 2,956,917 to Fasano discloses the impregnation of a loosely woven glass fabric in a solution of a polyalkyl methacrylate and a vinyl resin polymer comprising predominantly vinyl chloride, to set or adhere the glass yarns to each other and prevent distortion of the weave pattern, and laminating a preformed vinyl resin film onto the treated fabric by means of pressure.
U.S. Patent 2,215,061 to Alt discloses a Eabric prepared by coating a woven glass fabric with a coating composition derived either from cellulose, a synthetic resin, a natural resin, or a protein.
U.S. Patent 2,686,737 to Caroselli et al discloses coated glass fiber fabrics wherein the coating is a butadiene-acrylonitrile copolymer.
U.S. Patent 3,~90,985 to Marzocchi et al discloses decorated woven glass fabric produced by taking two different types of interwoven strands and applying a mixture of thermoplastic resin, foaming agent and plasticizer over areas of the Eabric which include the two different types of strands. The foaming agent reacts to Eoam the mixture in situ about the adjacent portion of both types of strands to provide flexible raised areas of foamed resin. The foamed resin is poorly bonded to one type o strand but strongly coupled to the other.
~;2'7~
U.S. Patent 2,830,925 to Fennebresque discloses a plastic laminate for decorative purposes produced by incorporating into the laminate a pigmented fibrous material which can be made of glass fiber.
S~MMARY OF T~E INVE~TI~
The present invention relates to a coa~ed glass fiber fabric which is laminated to the back of a self-extinguishing thermoplastic face fabric to provide a flame resistant barrier when exposed to fire, and prevents the underlying material from igniting.
DESCRIPTION OF T~E PREF~RRED EMBODIMENTS
In accordance with the present invention, a flame resistant fire barrier fabric is composed of a prefinished self-extinguishing thermoplastic face fabric.
The thermoplastic face fabric, generally a plasticized polyvinyl chloride or polyurethane is laminated to an underlying glass fiber fabric. The glass fiber Eabric is inherently non-flammable and maintains its integrity when exposed to high heat and flames to act as a barrier in preventing underlying materials covere~ by the glass fiber fabric laminate from igniting.
Glass fibers are self-abrasive. Thus, glass Eibers rubbing against each other will self-destruct.
Since the glass fabric/vinyl laminate will flex in normal use, it is necessary to coat the glass fiber fabric ~ith a suitable protective material which will coat and encapsulate the fibers and minimi~e the tendency of the glass fibers to self-destruct.
The glass fiber fabric protective coatings should not reduce the non~flammable characteristics of the glass fiber nor should the pyrolysis products of the coating be a source of heavy smoke upon ignition. The coatings generally consist of a polymeric binder and suitable fillers. The synergistic action of antimony oxide and halogen containing compounds is well-known. Thus, a typical coating may consis~ of a halogenated polymer such as polyvinyl chloride, polyvinylidine chloride or 5 polyvinylfluoride or copolymers containing vinyl fluoride and finely dispersed antimony oxide. Halogenated plasticizers are used to alter the hand of the coating as well as to provide halogen. Phosphorus derivatives are also often incorporated to contribute smolder resistance.
10 Aluminum trihydrate can also be used as an additive. At elevated temperatures, the endothermic decomposition of aluminum trihydrate contributes water vapor to smother flames. Other systems can use highly brominated organic compounds such as decabromodiphenyl o~ide with antimony lS oxide.
The novel fire barrier fabrics of the present invention comprise a woven or non-woven glass fiber material which has been given a protective coating to encapsulate the glass fibers, and a vinyl face Eabric.
In the construction of a vehicle seat~ such as a school bus seat the cushioning material, usually polyurethane foam, can be first covered with the coated glass fiber fabric and then covered with the vinyl face fabric. A preferred approach is to prelaminate the glass fabric to the vinyl face fabric. The glass fabric can be adhesively bondedt stitch bonded or heat bonded to the vinyl face fabric.
It has been discovered from the results of simulated school bus ires, that the prelaminated Eabric is a superior fire barrier than the corresponding sequentially applied Eabrics. A se~uentially applied fabric is one wherein there is no bonding between the respective fabrics. Thus, a sequentially applied fabric for a bus seat would include a polyurethane foam base, 35 glass fiber fabric wrapped around the foam, followed by a layer of vinyl face fabric wrapped around the glass fiber fabric.
While it is not certain what the actual basis is for the superior perEormance of the prelaminated fabric over the sequentially applied ~abric in functioning as a fire barrier, it is believed that when the prelaminated fabric is exposed to flames, the vinyl does not shrink away from the underlying glass fiber fabric to which it is laminated, but softens and flows into the interstices of the glass ~iber fabric to prevent passage of oxygen to the underlying cushioning materials and also to prevent outward passage of flammable gases generated by anaerobic pyrolysis of the cushioning materials.
Despite the superior performance of the prelaminated fabric, the sequentially applied glass fiber fabric and vinyl face fabric on a vehicle seat represent a significant advance over the state of the art for fire resistant vehicle seats.
In general, the vinyl face fabric is impermeable.
However, it is not necessary that the vinyl ~ace fabric be impermeable to the passage of air in order for the glass ~iber fabric/vinyl face fabric composite to function as a fire barrier. In general, the porosity of the composite should not exceed a critical porosity value of about 300 cubic feet per square foot per minute when measured at a pressure of one-hal~ inch of water. The critical porosity value is not an absolute value, but depends to some degree on the flammability of the underlying cushioning material. It generally ranges from about a value of 200 to 300.
Suitable woven glass fiber Eabrics include plain weave, basket weave7 leno weave, twill weave, crowEoot satin or long shaft satin. Suitable knit fabrics include warp knits and weft knits. Non-woven glass mats are also suitable. The construction of the fabric should be such that the composite whether or not prelaminated should not exceed the critical porosity value.
....
~2~
~uitable plain weave fabrics include those having warp counts (the number o~ yarns per inch) of from about 40 to 120 and filling counts of from 30 to 60. Fabric wei~hts from about 2.0 to 8 oz/yd2 are suitable.
Suitable coa~ing compositions consist of a polymeric binder, fillers, fire retardant additives, and optional pigments and/or plasticizers. The continuous medium can be water or an organic solvent. Water is preferred because oE environmental considerations.
lo Typical binders include emulsion polymers such as vinyl chloride polymers, ethylene/vinyl chloride copolymers, vinylidine chloride/alkyl methacrylate copolymers, vinyl chloride/vinyl acetate copolymers, Neoprene polymers, polyurethanes, vinyl acetate/alkyl acrylate copolymers or combinations thereof. It is preferable that at least a portion of the binder consist of a polymer containing chlorine or fluorine. Typical fillers include clay, calcium carbonate, talc or titanium dioxide. Fire retardant additives include antimony trioxide, antimony pentoxider aluminum trihydrate, and decabromodiphenyl oxide.
An effective fire retardant is a mixture of antimony trioxide and a organohalogen compound. The source of halogen can be from the polymeric binder, for example, polyvinyl chloride or copolymers containing vinyl chloride. Where the binder contains no halogen, suitable halogen donors such as decabromodiphenyl oxide can be added to the composition~
Depending on the selection of the polymeric binderr it may be necessary to incorporate plasticizers into the composition to avoid stiffening the fabric.
While a wide variety o~ organic plasticizers are suitable for softening the coating it is preferable to use phosphate ester plasticizers which can contribute flame retardancy to the coating. Most preferable are phosphate esters containing halogen such as tris(p-chlorophenyl) phosphate, tris(2,3,dichloropropyl phosphate) and the like.
When the coated glass fiber fabric is adhesively bonded or heat bonded to the vinyl face fabric, it is important that none of the components of the coating composition reduce or detract from the strength of the bond.
The coating can be applied to the glass fiber fabric as a liquid coating or a collapsible foam.
Suitable methods for applying a liquid coating include gravure coating, reverse roll coating, knife over roll, knife over table, floating knife or pad/nip coating. The method of coating is not critical to the invention provided complete encapsulation of the glass fibers is accomplished.
Where the coating is applied as a collapsible foam, it is necessary to incorporate a foaming agent into the coating composition, again with the provision that the foaming agent not interfere with the efficacy of the bonding of the encapsulated glass fiber fabric to the face fabric. Suitable methods for applying collapsible foams include horizontal pad, f]oating knife, knife over roll Eollowed by crush rolls, or gravure coating.
The quantity of coating applied to the glass fiber fabric can range from about 5% to about 100%
preferably from 8 to 30~ based on the weight of the fabric. ~lowever, it is critical that sufficient coating be applied to completely encapsulate the glass yarns.
Too much coating can be detrimental since it can stiffen the hand of the composite Eabric.
~ n optional primer coating or treatment can be given to the glass fiber fabric to improve adhesion of the encapsulating coating. Suitable primers include coupling agents such as organosilanes or organotitanates.
These are often blended with emulsion acrylic polymers and applied from dilute aqueous dispersions to the fabric.
~7~
g It has been found that when a preformed vinyl face fabric is laminated or coated onto the glass fiber fabric, be~er overall properties occur than if the vinyl were coated onto the glass fiber fabric in an uncured or liquid state, and then cured. Thus, the vinyl fabric should be preformed, and is considered to be preformed when laminated to the glass fiber fabric by means of extrusion casting of the vinyl onto the glass fiber fabric.
The fire barrier fabric of the present invention meets or exceeds the Original Equipment Manufacturers tOEM) Standards for the Bus Industry. Table I, which ~ollows, tabulates certain test results in comparison with the corresponding OEM standard.
Table I
Invention Q~ Standar~
1. Total Weight 33 oz/54 in. 34 oz/54 in.
2. Grab Tensile 150 x 145 135 x 120 (ASTM D 751) 20 3. Tongue Tear 10 x 12 9 x 13 (Fed Std l91A-5134) 4. Adhesion, lb/inch could not 5.5 x 5 lbs (ASTM D 751) separate 5. Flex Test Pass PasS
25(CFFA-10) 6. Seam Breakage 101 x 99 120 x 90 (AMC Method~
6~
The efficacy of the fire barrier fabrics has been established by constructing full size vehicle seats which were tested under fire conditions~ While such testing is expensive, it is well-known that simple small scale tests such as DOT 302, of the composite fabric can only distinguish differences in flammability of the fabrics and can not predict the burning characteristics of a multicomponent structure in a real fire.
The test chamber was a standard fire test room, 8 feet by 12 feet by 8 feet high with an open 30 by 80 inch door centered in one 8 foot wall. Three school bus seats were arranged end on to the the room back wall. Spacing was 27.5 inches (bolt to bolt), which is conventional for school buses. Bus seat construction was similar to that presently used in the industry.
All materials used for the test control bus seats meet present federal and state standards for school bus construction. The seats were made of a metal frame with slab urethane foam cushioning and a vinyl face fabric.
The following examples serve to illustrate the present invention. All parts and percentages are by weight, unless otherwise indicated.
A heat cleaned plain weave glass fabric fiber having a count of 60 warp ends per inch and ~8 fill ends per inch, a weight oE 3.16 oz per square yard was given a primer finish by immersing the fabric in an aqueous bath consisting of 0.3% of gamma glycidoxypropyltrimethoxy-silane, ~.0% of a ~6~ solids polyacrylic ester copolymer emulsion, 1.0% of a 25% solids polytetrafluoroethylene emulsion, 2.0% of antimigrant and 0.1% of aqua ammonia (26 Be). The fabric was squeezed through pad rolls and -~7~
dried. The dry add-on of Einish was about 1.25% based on weight of the fabric.
An encapsulating coating was prepared by blending the following components~
42% water
3.6% antimony trioxide 6.8~ chlorinated paraffin wax 6.8% aluminum trihydrate 26.0% ethyl acrylate/acrylonitrile copolymer latex 5.3% ethylene/vinyl chloride copolymer latex 1.0% triaryl phosphate plasticizer 2.3~ ethyl acrylate/acrylic acid copolymer latex 0.5% ethoxylated octylphenol 0.5~ aqua ammonia 5.2% 33% solution of ammonium stearate The coating was mechanically foamed to a blow ratio of 4 to l and applied to the glass fiber Eabric using a horizontal pad. The fabric was dried and cured.
The dry add-on of coating was 12% by weight of the fabric.
~5 ~ 2 - Standard School Bus Se~
The seat covering was selE-extinguishing vinyl abric weighing 22 oz. per square yard. The ignition source was the Boston bag test. A kraft grocery bag containing four sheets of loosely crumpled newspaper (weight 155 grams) was placed in the center of the middle seat with the wide side of the bag against the back cushion. The base of the paper bag was ignited with a 30 match and a timer started. Within one minute, there was an accelerating rate of combustion with evolution of large quantities of black smoke. At 1.5 minutes, smoke ~74~
completely obscured the upper three feet of the test chamber. At 2.5 minutes, the fire flashed over to the back of the front seat and smoke obscured the upper five feet of the chamber. At 3.0 minutes, the rear seat ignited and the chamber flashed over. The fire was then extinguished with water. The maximum ceiling temperature was 1850F.
EXA~P~E 3 - Bus Seats Coyered Sequentially With Glass Fiber Fabric And The Vinvl Face Fabric The seat covering consisted of a layer of the glass fiber fabric of Example 1 and a layer of the 22 oz.
per square yard vinyl described in Example 2. The ignition source was the Boston bag test with the bag placed on the middle seat. Flames Erom the burning paper bag diminished after five minutes. After six minutes there was only a tiny flame at the intersection of the seat and back cushions. This flame self extinguished after nine minutes. Maximum ceiling temperature was 279F. About 80% of the face fabric on the back cushion and 60~ of the face fabric on the seat cushion was charred but the glass fabric remained intact. Some of the urethane foam in the back cushion melted behind the glass fabric but there was no molten drip beneath the seat nor was there any evidence of any burning behind the barrier. Neither the Eront nor the rear seats were damaged. Other than the smoke from the burning newspaper, there was very little smoke generation and the smoke generated was white.
~13~
EXAMp~ 4 - Bus Seats ~over~d With A Coated G~ass The glass fiber fabric oE Example 1 was laminated to a vinyl fabric by extrusion casting the vinyl onto the glass fiber fabric. The vinyl used was identical in composition and weight to that used in Example 2. The ignition source was the Boston Bag test. Flaming was not as severe as in Example 3 and considerably diminished in 3~25 minu~es and self-extinguished in 4.25 minutes.
About 60% of the face of the back cushion and 50~ of the face of the seat cushion was charred. The glass fiber fabric remained intact and neither the front nor rear seats were damaged. Maximum ceiling temperature was 254F, It is evident that while the sequentially applied fabrics of Example 3 function as a self-extinugishing fire barrier, the laminated fabric of Example 4 was superior.
EXAMPLE 5 - CaliEornia I~nition Source Bus seats identical to those in Example ~ were used~ The more stringent California 113 ignition source was used. The California source consists of a small "stove" with 10 inch X 10 inch X 10 inch dimensions. The top and one side are made of sheet metal, the two adjacent sides are chicken wire and the fourth side and bottom are open. Five sheets of newspaper (90 + S gms) are crumpled and placed within the stove. The open side i5 placed against the back cushion and the open bottom rests on the seat cushion. The purpose of the "stove" is to confine and Eocus the ignition energy on the joint between the seat and back cushions. Flames diminished in 2.0 minutes and self-extinguished in 3.25 minutes.
., ~2~ 6~
Maximum ceiling temperature was 279F. About 50% of the seat cushion face and back cushion face was charred.
Neither the front nor rear seats were damaged.
EXAMP~E Ç - Vandalized ~us ~
In order to determine whether cuts and punctures in the fabric would significantly reduce the fire barrier properties, three bus seats of the Example 4 construction were placed in the test chamber. ~hree punctures were made in the back cushion as well as a 5 inch long slash located about 3 inches above the intersection of the seat and back cushions. A 9 inch slash was made in the center of the sea~ cushion at a diagonal angle. The fabric edges at the slashes curled back exposing the underlying urethane foam. The Boston Bag ignition source was used.
The paper bag was located at the top of the slash~ Two minutes after ignition, the paper was still burning although smoke generation had diminished. At 3.0 minutes, flames had diminished; at 3.75 minutes the back cushion had self-extinguished but there were still 3 to 4 inch high flames on the seat cushion probably at the slash. There were occasional flashes of Elame on the seat cushion probably due to ignition of gaseous pyrolysis products from urethane decomposition at the vicinity of the slash. The fire self-extinguished at 5.50 minutes. Thus, even where the fabric has been damaged leading to exposure o the urethane foam, the fire barrier functions.
EXAMPLE 7 - School Bus Burn~
A full scale fire test o school bus seating was performed and produced actual conditions of air flow, heat, smoke and flames that may occur in a school bus fire. Five types of seat cov~rings were tested, each being a form of vinyl upholstery covering the standard polyurethane seat pad/cushion. The first material was the standard vinyl/scrim laminate fabric presently used in school buses and meeting all applicable federal and state standards. The other four were various barrier fabrics. These tests were carried out by a major manufacturer of scbool buses and the composition of the fabrics, other than the vinyl/glass fabric of this invention, were proprietary. The other fabrics were identified as Vonar (Chris Craft), Polyvoltac (Polyvoltac Corp.) and Neoprene (Dupont Corp.). The vinyl/glass fiber fabric performed extremely well, self-extinguishing in 6 minutes and 15 seconds without permitting flame penetration into the polyurethane seat material. Each of the other three proprietary fabric seat coverings performed better than current standard fabric by delaying the flame penetration into the polyurethane. However, each of the other proprietary seat covering materials:
Vonar, Polyvoltac and Neoprene did experience a Elare up of flames after penetration into the polyurethane took place.
The bus was a 1967 standard conventional bus body with seats constructed o standard metal seat frames with 30 plywood back, standard rebonded polyurethane seat pad/cushion and standard vinyl cover. There were ten rows of seats spaced at 27.5 inches. The fire resistance test procedure for seats utilizes as an ignition source six sheets of standard size newspaper loosely crumpled and placed in a standard paper grocery bag. The total welght of ignition source was about 7.3 ounces. The bag 5 was placed with the open top of the bag at the centerline of the seat with the narrow side down on the cushion and the wider side against the back pad and the bottom of the bag toward the wall mount side of the seat.
Thermocouples were placed in the walkway adjacent to the sea~ being ignited. The thermocouples were located one inch below the ceiling, 36 inches above the floor and one inch above the floor. The rear door, front door and first right side window were open. The ignition source was lighted with a match. One minute, 53 seconds after ignition, flames were lapping over the top of the seat and the bus was filled with black smoke. At 2 minutes and 15 seconds flash-over occurred to the next forward seat back and at 3 minutes and 35 seconds flash-over occurred to the next rearward seat. A maximum temperature of over 1432F was reached within 3 minutes and 45 seconds. Within 7 minutes the bus was completely engulfed in flames and at 7 minutes and 23 seconds the fire was extinguished by the local fire department.
All conditions in the test were identical to Test A except that the fabric consisted of the glass fiber fabric of Example 1 laminated to vinyl fabric by extrusion casting the vinyl onto the glass fiber fabric.
Six minutes and 15 seconds after ignition, the fabric self-extinguished. The vinyl/glass upholstery prevented penetration of flames into the pad material. There was no damage to adjacent seats. The maximum temperature was 248FI 2 minutes and 15 seconds after ignition.
Test C
All conditions in this test were identical to Test A except that the fabric was ~onar (Chris-Craft Corp.). Flames became well established on ~he seat pad 5 vinyl and consumed hal of the surace area. The flames diminished until about 5 minutes and 40 seconds after ignition when the flames penetrated through the Vonar material and ignited the polyurethane and plywood backinq. The fire continued to increase in stren~th and 10 was extinguished by the fire department 7 minutes and 43 seconds ater ignition.
Test D
All conditions in this tesi were identical to Test A except that the fabric consisted of vinyl with an 15 underlying layer of Polyvoltac (Polyvoltac Corp.).
Flames became well established on the seat pad vinyl and consumed half of the surface area. The flames diminished until at 4 minutes and 45 seconds after ignition. At that time flames penetrated the Polyvoltac layer and ignited the polyurethane. After 6 minutes and 2a seconds, the fire had to be extinguished by the fire department.
All conditions in this test were identical to 25 Test A except that between the vinyl face fabric and the polyurethane foam was a 1/2 inch layer of Neoprene (Dupont) foam. Flames became well established on the seat pad vinyl and consumed hal o the surace area.
The flames penetrated the Neoprene layer. However, the 30 fire self-extinguished ater 6 minutes and ~0 seconds.
~7~6~
EXAMPLE ~
~ heat cleaned plain weave glass fiber fabric having a count of ~0 warp ends per inch and 60 fill ends per inch was given a primer finish by immersing the fabric in an aqueous bath consisting of 0.3% of gamma glycidoxypropyltrimethoxy-silane, 4.0% of a 46% solids polyacrylic ester copolymer emulsion. The ~abric was squeezed through pad rolls and dried. The dry add-on was about 1.25% based on the weight of the fabric. An encapsulating coating similar to that described in Example 1 was used except that the ethyl acrylate/acrylonitrile copolymer latex was replaced by a thermoplastic aromatic polyurethane latex. The coating was applied to the primed glass fiber fabric using a floating knife coater. After drying, the add--on was 14%.
The same encapsulating coating was applled to a greige plain weave glass fiber fabric weighing 3.2 oz. per square yard. Both fabrics were laminated to a 30 oz. per square yard vinyl film which had been given a leather-like emboss on the face side. The laminates wereprepared by heating a sandwich oE the glass fabric and vinyl film in a press heated to 350F for about 6 minutes. Cushions having dimensions of 24 X 36 X 4 inches were prepared by wrapping the vinyl/glass fabric around a slab oE standard polyurethane foam o comparable dimensions, Two cushions were arranged in an "L"
coniguration to simulate seat and back of a chair or bench, A grocery sack containing 155 grams of crumpled newspaper was placed in the center of the seat at the intersection of the vertical and horizontal cushions.
The sack was ignited. The vinyl melted and charred in the vicinity of the paper sack but self-extinguished when the paper fuel supply was exhausted, About 75% of the seat cushion and about 60% of the seat cushion were charred but the glass Eabric was intact. The fabric was removed and the urethane foam examined. About ~0% of the face of the urethane foam in the seat cushion was charred and in the area where the paper sack was burned, the urethane had melted away to a depth of about one inch.
There was little difference in flame barrier proper~ies between the two fabrics.
A heat cleaned crowfoot weave glass fiber fabric having a yarn count of 60 X 60 (warp X fill) and a weight of 3.2 oz per square yard was given an encapsulating coating. The coating consisted of a low molecular weight polyvinyl chloride resin dispersed in tris(2-ethylhexyl/phosphate). The plastisol was coated on the fabric and fused at 350F for 90 seconds. The dry add-on was 120% bàsed on the weight of the fabric. A 28 ounces per square yard blue plasticized vinyl fabric normally used for bus seat upholstery was heat laminated to the plastisol coated glass fabric at 400F for 6.5 minu.es.
The peel strength of the vinyl to glass fabric bond was 9.7 pounds per inch width. The Eire barrier properties of the vinyl/glass fabric were comparable to those of the fabric described in Example 8.
~8~
A greige plain weave glass ~iber fabric having a yarn count of 60 X 48 ends per inch (warp X fill) was heat cleaned. The resulting fabric weighed 3.16 ounces per square yard. The fabric was given a primer coating as described in Example 8. The fabric was then given an encapsulating coating of a solvent based heat activatable polyurethane (Royal S-5213, a product of Uniroyal Inc.).
The dry add-on of coating was 16~ based on the weight of fabric. Flame barrier properties were satisfac~ory.
~2~
A vinyl/ylass fiber fabric similar to that of Example 10 was prepared except that the laminating adhesive consis~ed of the following:
100 parts aromatic thermoplastic urethane latex 3.5 parts polyacrylic acid latex 0.2 parts defoamer 1.6 parts water The pH was raised to 9.5 - 9.8 with aqua ammonia.
lo The resultant coating had a viscosity of 100,000 cps.
The dry deposit of coating on the glass fabric was 0.5 ounces per square yard. The laminate was prepared by extruding a hot ~380F) pla.sticized vinyl coating onto the coated glass fabric and passing the sandwich through 15 hot nip rolls. The weight of the laminate was 22 ounces per square yard. The glass to vinyl bond strength of the laminate exceeded the tear strength of either component.
The fabric was an effective fire barrier Eor upholstered kitchen stools and bus seats.
~ æh~
A vinyl/glass fabric was prepared in a manner identical to that of Example 11 except that the polyurethane latex was a 50/50 blend of a thermoplastic aromatic polyurethane and a thermoplastic aliphatic 25 polyurethane. The strength of the glass to vinyl bond exceeded the tear strength of either component.
EXAMP~E 1~
A polyurethane/glass fiber fabric was prepared by heat laminating an 8 ounce per square yard cast polyurethane film (Estane, a product o~ B.F. Goodrich 5 Co.) to the urethane coated glass fabric of Example 11.
The bond strength was greater than 10 pounds per inch of width. The laminated upholstery fabric was needle punched to produce an air permeable fabric. The permeability was 150 cubic feet of air per square foot of ~abric per minute at a water pressure of one-half inchO
The fabric was used to prepare a cushion by covering a 16 X 16 X 3 inch foam polyurethane slab with the fire barrier fabric. The fabric prevented penetration of flames to the foam polyurethane when the ignition source 15 was the Boston bag test.
While the fabrics described in the preceding examples are especially suitable as upholstery fabrics, they can also have application as wallcoverings, room dividers, tenting, tarpaulins and protective fabrics for 20 military applications.
It would be apparent to those skilled in the art that polymeric films other than vinyls or urethanes could be used as face fabrics. However, the great majority of polymeric films used as upholstery face fabrics are based 25 on vinyls and urethanes.
The dry add-on of coating was 12% by weight of the fabric.
~5 ~ 2 - Standard School Bus Se~
The seat covering was selE-extinguishing vinyl abric weighing 22 oz. per square yard. The ignition source was the Boston bag test. A kraft grocery bag containing four sheets of loosely crumpled newspaper (weight 155 grams) was placed in the center of the middle seat with the wide side of the bag against the back cushion. The base of the paper bag was ignited with a 30 match and a timer started. Within one minute, there was an accelerating rate of combustion with evolution of large quantities of black smoke. At 1.5 minutes, smoke ~74~
completely obscured the upper three feet of the test chamber. At 2.5 minutes, the fire flashed over to the back of the front seat and smoke obscured the upper five feet of the chamber. At 3.0 minutes, the rear seat ignited and the chamber flashed over. The fire was then extinguished with water. The maximum ceiling temperature was 1850F.
EXA~P~E 3 - Bus Seats Coyered Sequentially With Glass Fiber Fabric And The Vinvl Face Fabric The seat covering consisted of a layer of the glass fiber fabric of Example 1 and a layer of the 22 oz.
per square yard vinyl described in Example 2. The ignition source was the Boston bag test with the bag placed on the middle seat. Flames Erom the burning paper bag diminished after five minutes. After six minutes there was only a tiny flame at the intersection of the seat and back cushions. This flame self extinguished after nine minutes. Maximum ceiling temperature was 279F. About 80% of the face fabric on the back cushion and 60~ of the face fabric on the seat cushion was charred but the glass fabric remained intact. Some of the urethane foam in the back cushion melted behind the glass fabric but there was no molten drip beneath the seat nor was there any evidence of any burning behind the barrier. Neither the Eront nor the rear seats were damaged. Other than the smoke from the burning newspaper, there was very little smoke generation and the smoke generated was white.
~13~
EXAMp~ 4 - Bus Seats ~over~d With A Coated G~ass The glass fiber fabric oE Example 1 was laminated to a vinyl fabric by extrusion casting the vinyl onto the glass fiber fabric. The vinyl used was identical in composition and weight to that used in Example 2. The ignition source was the Boston Bag test. Flaming was not as severe as in Example 3 and considerably diminished in 3~25 minu~es and self-extinguished in 4.25 minutes.
About 60% of the face of the back cushion and 50~ of the face of the seat cushion was charred. The glass fiber fabric remained intact and neither the front nor rear seats were damaged. Maximum ceiling temperature was 254F, It is evident that while the sequentially applied fabrics of Example 3 function as a self-extinugishing fire barrier, the laminated fabric of Example 4 was superior.
EXAMPLE 5 - CaliEornia I~nition Source Bus seats identical to those in Example ~ were used~ The more stringent California 113 ignition source was used. The California source consists of a small "stove" with 10 inch X 10 inch X 10 inch dimensions. The top and one side are made of sheet metal, the two adjacent sides are chicken wire and the fourth side and bottom are open. Five sheets of newspaper (90 + S gms) are crumpled and placed within the stove. The open side i5 placed against the back cushion and the open bottom rests on the seat cushion. The purpose of the "stove" is to confine and Eocus the ignition energy on the joint between the seat and back cushions. Flames diminished in 2.0 minutes and self-extinguished in 3.25 minutes.
., ~2~ 6~
Maximum ceiling temperature was 279F. About 50% of the seat cushion face and back cushion face was charred.
Neither the front nor rear seats were damaged.
EXAMP~E Ç - Vandalized ~us ~
In order to determine whether cuts and punctures in the fabric would significantly reduce the fire barrier properties, three bus seats of the Example 4 construction were placed in the test chamber. ~hree punctures were made in the back cushion as well as a 5 inch long slash located about 3 inches above the intersection of the seat and back cushions. A 9 inch slash was made in the center of the sea~ cushion at a diagonal angle. The fabric edges at the slashes curled back exposing the underlying urethane foam. The Boston Bag ignition source was used.
The paper bag was located at the top of the slash~ Two minutes after ignition, the paper was still burning although smoke generation had diminished. At 3.0 minutes, flames had diminished; at 3.75 minutes the back cushion had self-extinguished but there were still 3 to 4 inch high flames on the seat cushion probably at the slash. There were occasional flashes of Elame on the seat cushion probably due to ignition of gaseous pyrolysis products from urethane decomposition at the vicinity of the slash. The fire self-extinguished at 5.50 minutes. Thus, even where the fabric has been damaged leading to exposure o the urethane foam, the fire barrier functions.
EXAMPLE 7 - School Bus Burn~
A full scale fire test o school bus seating was performed and produced actual conditions of air flow, heat, smoke and flames that may occur in a school bus fire. Five types of seat cov~rings were tested, each being a form of vinyl upholstery covering the standard polyurethane seat pad/cushion. The first material was the standard vinyl/scrim laminate fabric presently used in school buses and meeting all applicable federal and state standards. The other four were various barrier fabrics. These tests were carried out by a major manufacturer of scbool buses and the composition of the fabrics, other than the vinyl/glass fabric of this invention, were proprietary. The other fabrics were identified as Vonar (Chris Craft), Polyvoltac (Polyvoltac Corp.) and Neoprene (Dupont Corp.). The vinyl/glass fiber fabric performed extremely well, self-extinguishing in 6 minutes and 15 seconds without permitting flame penetration into the polyurethane seat material. Each of the other three proprietary fabric seat coverings performed better than current standard fabric by delaying the flame penetration into the polyurethane. However, each of the other proprietary seat covering materials:
Vonar, Polyvoltac and Neoprene did experience a Elare up of flames after penetration into the polyurethane took place.
The bus was a 1967 standard conventional bus body with seats constructed o standard metal seat frames with 30 plywood back, standard rebonded polyurethane seat pad/cushion and standard vinyl cover. There were ten rows of seats spaced at 27.5 inches. The fire resistance test procedure for seats utilizes as an ignition source six sheets of standard size newspaper loosely crumpled and placed in a standard paper grocery bag. The total welght of ignition source was about 7.3 ounces. The bag 5 was placed with the open top of the bag at the centerline of the seat with the narrow side down on the cushion and the wider side against the back pad and the bottom of the bag toward the wall mount side of the seat.
Thermocouples were placed in the walkway adjacent to the sea~ being ignited. The thermocouples were located one inch below the ceiling, 36 inches above the floor and one inch above the floor. The rear door, front door and first right side window were open. The ignition source was lighted with a match. One minute, 53 seconds after ignition, flames were lapping over the top of the seat and the bus was filled with black smoke. At 2 minutes and 15 seconds flash-over occurred to the next forward seat back and at 3 minutes and 35 seconds flash-over occurred to the next rearward seat. A maximum temperature of over 1432F was reached within 3 minutes and 45 seconds. Within 7 minutes the bus was completely engulfed in flames and at 7 minutes and 23 seconds the fire was extinguished by the local fire department.
All conditions in the test were identical to Test A except that the fabric consisted of the glass fiber fabric of Example 1 laminated to vinyl fabric by extrusion casting the vinyl onto the glass fiber fabric.
Six minutes and 15 seconds after ignition, the fabric self-extinguished. The vinyl/glass upholstery prevented penetration of flames into the pad material. There was no damage to adjacent seats. The maximum temperature was 248FI 2 minutes and 15 seconds after ignition.
Test C
All conditions in this test were identical to Test A except that the fabric was ~onar (Chris-Craft Corp.). Flames became well established on ~he seat pad 5 vinyl and consumed hal of the surace area. The flames diminished until about 5 minutes and 40 seconds after ignition when the flames penetrated through the Vonar material and ignited the polyurethane and plywood backinq. The fire continued to increase in stren~th and 10 was extinguished by the fire department 7 minutes and 43 seconds ater ignition.
Test D
All conditions in this tesi were identical to Test A except that the fabric consisted of vinyl with an 15 underlying layer of Polyvoltac (Polyvoltac Corp.).
Flames became well established on the seat pad vinyl and consumed half of the surface area. The flames diminished until at 4 minutes and 45 seconds after ignition. At that time flames penetrated the Polyvoltac layer and ignited the polyurethane. After 6 minutes and 2a seconds, the fire had to be extinguished by the fire department.
All conditions in this test were identical to 25 Test A except that between the vinyl face fabric and the polyurethane foam was a 1/2 inch layer of Neoprene (Dupont) foam. Flames became well established on the seat pad vinyl and consumed hal o the surace area.
The flames penetrated the Neoprene layer. However, the 30 fire self-extinguished ater 6 minutes and ~0 seconds.
~7~6~
EXAMPLE ~
~ heat cleaned plain weave glass fiber fabric having a count of ~0 warp ends per inch and 60 fill ends per inch was given a primer finish by immersing the fabric in an aqueous bath consisting of 0.3% of gamma glycidoxypropyltrimethoxy-silane, 4.0% of a 46% solids polyacrylic ester copolymer emulsion. The ~abric was squeezed through pad rolls and dried. The dry add-on was about 1.25% based on the weight of the fabric. An encapsulating coating similar to that described in Example 1 was used except that the ethyl acrylate/acrylonitrile copolymer latex was replaced by a thermoplastic aromatic polyurethane latex. The coating was applied to the primed glass fiber fabric using a floating knife coater. After drying, the add--on was 14%.
The same encapsulating coating was applled to a greige plain weave glass fiber fabric weighing 3.2 oz. per square yard. Both fabrics were laminated to a 30 oz. per square yard vinyl film which had been given a leather-like emboss on the face side. The laminates wereprepared by heating a sandwich oE the glass fabric and vinyl film in a press heated to 350F for about 6 minutes. Cushions having dimensions of 24 X 36 X 4 inches were prepared by wrapping the vinyl/glass fabric around a slab oE standard polyurethane foam o comparable dimensions, Two cushions were arranged in an "L"
coniguration to simulate seat and back of a chair or bench, A grocery sack containing 155 grams of crumpled newspaper was placed in the center of the seat at the intersection of the vertical and horizontal cushions.
The sack was ignited. The vinyl melted and charred in the vicinity of the paper sack but self-extinguished when the paper fuel supply was exhausted, About 75% of the seat cushion and about 60% of the seat cushion were charred but the glass Eabric was intact. The fabric was removed and the urethane foam examined. About ~0% of the face of the urethane foam in the seat cushion was charred and in the area where the paper sack was burned, the urethane had melted away to a depth of about one inch.
There was little difference in flame barrier proper~ies between the two fabrics.
A heat cleaned crowfoot weave glass fiber fabric having a yarn count of 60 X 60 (warp X fill) and a weight of 3.2 oz per square yard was given an encapsulating coating. The coating consisted of a low molecular weight polyvinyl chloride resin dispersed in tris(2-ethylhexyl/phosphate). The plastisol was coated on the fabric and fused at 350F for 90 seconds. The dry add-on was 120% bàsed on the weight of the fabric. A 28 ounces per square yard blue plasticized vinyl fabric normally used for bus seat upholstery was heat laminated to the plastisol coated glass fabric at 400F for 6.5 minu.es.
The peel strength of the vinyl to glass fabric bond was 9.7 pounds per inch width. The Eire barrier properties of the vinyl/glass fabric were comparable to those of the fabric described in Example 8.
~8~
A greige plain weave glass ~iber fabric having a yarn count of 60 X 48 ends per inch (warp X fill) was heat cleaned. The resulting fabric weighed 3.16 ounces per square yard. The fabric was given a primer coating as described in Example 8. The fabric was then given an encapsulating coating of a solvent based heat activatable polyurethane (Royal S-5213, a product of Uniroyal Inc.).
The dry add-on of coating was 16~ based on the weight of fabric. Flame barrier properties were satisfac~ory.
~2~
A vinyl/ylass fiber fabric similar to that of Example 10 was prepared except that the laminating adhesive consis~ed of the following:
100 parts aromatic thermoplastic urethane latex 3.5 parts polyacrylic acid latex 0.2 parts defoamer 1.6 parts water The pH was raised to 9.5 - 9.8 with aqua ammonia.
lo The resultant coating had a viscosity of 100,000 cps.
The dry deposit of coating on the glass fabric was 0.5 ounces per square yard. The laminate was prepared by extruding a hot ~380F) pla.sticized vinyl coating onto the coated glass fabric and passing the sandwich through 15 hot nip rolls. The weight of the laminate was 22 ounces per square yard. The glass to vinyl bond strength of the laminate exceeded the tear strength of either component.
The fabric was an effective fire barrier Eor upholstered kitchen stools and bus seats.
~ æh~
A vinyl/glass fabric was prepared in a manner identical to that of Example 11 except that the polyurethane latex was a 50/50 blend of a thermoplastic aromatic polyurethane and a thermoplastic aliphatic 25 polyurethane. The strength of the glass to vinyl bond exceeded the tear strength of either component.
EXAMP~E 1~
A polyurethane/glass fiber fabric was prepared by heat laminating an 8 ounce per square yard cast polyurethane film (Estane, a product o~ B.F. Goodrich 5 Co.) to the urethane coated glass fabric of Example 11.
The bond strength was greater than 10 pounds per inch of width. The laminated upholstery fabric was needle punched to produce an air permeable fabric. The permeability was 150 cubic feet of air per square foot of ~abric per minute at a water pressure of one-half inchO
The fabric was used to prepare a cushion by covering a 16 X 16 X 3 inch foam polyurethane slab with the fire barrier fabric. The fabric prevented penetration of flames to the foam polyurethane when the ignition source 15 was the Boston bag test.
While the fabrics described in the preceding examples are especially suitable as upholstery fabrics, they can also have application as wallcoverings, room dividers, tenting, tarpaulins and protective fabrics for 20 military applications.
It would be apparent to those skilled in the art that polymeric films other than vinyls or urethanes could be used as face fabrics. However, the great majority of polymeric films used as upholstery face fabrics are based 25 on vinyls and urethanes.
Claims (10)
1. A flame resistant fire barrier fabric comprising a preformed self extinguishing thermoplastic face fabric laminated to an underlying glass fabric comprising glass fibers coated with a thin adherent encapsulating coating that substantially minimizes fiber to fiber self abrasion, and wherein the porosity of the fire barrier fabric does not exceed about 300 cubic feet per square foot per minute when measured at a pressure of one half inch of water.
2. The fire barrier fabric of Claim 1, wherein the face fabric is plasticized polyvinyl chloride.
3. The fire barrier fabric of Claim 1, wherein the face fabric is a polyurethane.
4. The fire barrier fabric of Claim 1, wherein the encapsulating coating comprises a polymeric binder selected from the group consisting of: vinyl. chloride polymers, ethylene/vinyl chloride copolymers, vinylidine chloride/alkyl methacrylate copolymers, vinyl chloride/vinyl acetate copolymers, polyurethanes, vinyl acetate/alkyl acrylate copolymers, or combinations thereof.
5. The fire barrier fabric of Claim 4, wherein the polymeric binder is an ethylene/vinyl chloride copolymer.
6. The fire barrier fabric of Claim 1, wherein the encapsulating coating comprises a primer finish containing a silane coupling agent, acrylic ester copolymer and an encapsulating coating including a halogen containing polymer, antimony oxide and aluminum trihydrate.
7. The fire barrier fabric of Claim 1, wherein the glass fiber fabric is woven.
8. A method for imparting flame resistance to a laminated fire barrier fabric material comprising:
(a) coating a glass fiber fabric with a thin adherent protective coating to encapsulate the glass fibers and minimize fiber to fiber self abrasion; and (b) laminating a preformed thermoplastic face fabric to the coated glass fiber fabric to produce the laminated fire barrier fabric material wherein the porosity does not exceed about 300 cubic feet per square foot per minute when measured at a pressure of one half inch of water.
(a) coating a glass fiber fabric with a thin adherent protective coating to encapsulate the glass fibers and minimize fiber to fiber self abrasion; and (b) laminating a preformed thermoplastic face fabric to the coated glass fiber fabric to produce the laminated fire barrier fabric material wherein the porosity does not exceed about 300 cubic feet per square foot per minute when measured at a pressure of one half inch of water.
9. The method of claim 8, wherein said face fabric is a vinyl material.
10. The method of claim 8, wherein the encapsulating coating comprises a polymeric binder selected from the group consisting of: vinyl chloride polymers, ethylene/vinyl chloride copolymers, vinylidine chloride/alkyl methacrylate copolymers, vinyl chloride/vinyl acetate copolymers, polyurethanes, vinyl acetate/alkyl acrylate copolymers, or combinations thereof.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US912,264 | 1986-09-26 | ||
US06/912,264 US4746565A (en) | 1986-09-26 | 1986-09-26 | Fire barrier fabrics |
Publications (1)
Publication Number | Publication Date |
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CA1274161A true CA1274161A (en) | 1990-09-18 |
Family
ID=25431609
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA000547652A Expired - Fee Related CA1274161A (en) | 1986-09-26 | 1987-09-23 | Fire barrier fabrics |
Country Status (9)
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US (1) | US4746565A (en) |
EP (1) | EP0261841A3 (en) |
JP (1) | JPS6391237A (en) |
KR (1) | KR930009285B1 (en) |
AU (1) | AU591342B2 (en) |
CA (1) | CA1274161A (en) |
IE (1) | IE872551L (en) |
NO (1) | NO874029L (en) |
NZ (1) | NZ221929A (en) |
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US5284700A (en) * | 1987-11-09 | 1994-02-08 | Owens-Corning Fiberglas Corporation | Fire-resistant mineral fibers, structures employing such mineral fibers and processes for forming same |
JP2639820B2 (en) * | 1988-05-20 | 1997-08-13 | 日本カーバイド工業株式会社 | Flame retardant fiber cloth |
US4987026A (en) * | 1988-08-31 | 1991-01-22 | Uniroyal Plastics Co., Inc. | Flame retardant fabric structure |
US4946739A (en) * | 1988-12-13 | 1990-08-07 | Borden, Inc. | Enamel receptive banner fabric |
US4921756A (en) * | 1989-03-03 | 1990-05-01 | Springs Industries, Inc. | Fire resistant balanced fine corespun yarn and fabric formed thereof |
US5113527A (en) * | 1989-05-23 | 1992-05-19 | Noel Robertson-Mckenzie | Fire and smoke protective hood |
KR100191983B1 (en) * | 1989-05-30 | 1999-06-15 | 레그랜드 지.윌리엄 | Heat barrier laminate and manufacturing method thereof |
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-
1986
- 1986-09-26 US US06/912,264 patent/US4746565A/en not_active Expired - Lifetime
-
1987
- 1987-09-10 EP EP19870308021 patent/EP0261841A3/en not_active Ceased
- 1987-09-21 JP JP62237072A patent/JPS6391237A/en active Pending
- 1987-09-22 IE IE872551A patent/IE872551L/en unknown
- 1987-09-23 CA CA000547652A patent/CA1274161A/en not_active Expired - Fee Related
- 1987-09-24 NZ NZ22192987A patent/NZ221929A/en unknown
- 1987-09-24 AU AU78987/87A patent/AU591342B2/en not_active Ceased
- 1987-09-25 KR KR1019870010734A patent/KR930009285B1/en active IP Right Grant
- 1987-09-25 NO NO874029A patent/NO874029L/en unknown
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AU591342B2 (en) | 1989-11-30 |
US4746565A (en) | 1988-05-24 |
JPS6391237A (en) | 1988-04-21 |
KR880003844A (en) | 1988-05-30 |
AU7898787A (en) | 1988-03-31 |
NZ221929A (en) | 1989-11-28 |
KR930009285B1 (en) | 1993-09-25 |
EP0261841A3 (en) | 1989-02-01 |
NO874029D0 (en) | 1987-09-25 |
NO874029L (en) | 1988-03-28 |
EP0261841A2 (en) | 1988-03-30 |
IE872551L (en) | 1988-03-26 |
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