US20060234027A1 - Fire retardant laminate - Google Patents
Fire retardant laminate Download PDFInfo
- Publication number
- US20060234027A1 US20060234027A1 US11/370,607 US37060706A US2006234027A1 US 20060234027 A1 US20060234027 A1 US 20060234027A1 US 37060706 A US37060706 A US 37060706A US 2006234027 A1 US2006234027 A1 US 2006234027A1
- Authority
- US
- United States
- Prior art keywords
- laminate
- resin
- fiber reinforced
- layer
- fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000003063 flame retardant Substances 0.000 title claims abstract description 10
- 239000000835 fiber Substances 0.000 claims abstract description 67
- 229920005989 resin Polymers 0.000 claims abstract description 47
- 239000011347 resin Substances 0.000 claims abstract description 47
- 239000011094 fiberboard Substances 0.000 claims abstract description 33
- 230000004888 barrier function Effects 0.000 claims abstract description 23
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 36
- 239000011521 glass Substances 0.000 claims description 26
- 239000000203 mixture Substances 0.000 claims description 22
- 239000011230 binding agent Substances 0.000 claims description 18
- 238000009408 flooring Methods 0.000 claims description 17
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 17
- 229920000877 Melamine resin Polymers 0.000 claims description 16
- 239000000377 silicon dioxide Substances 0.000 claims description 15
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 12
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- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 claims description 12
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- 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
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- XPPKVPWEQAFLFU-UHFFFAOYSA-J diphosphate(4-) Chemical compound [O-]P([O-])(=O)OP([O-])([O-])=O XPPKVPWEQAFLFU-UHFFFAOYSA-J 0.000 description 1
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Images
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- 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
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Definitions
- This invention relates generally to fire retardant laminates such as utilized for flooring.
- Laminated flooring formed from boards having a wood basis such as chipboard or fiberboard are known in the aft.
- the present invention relates to a novel laminate characterized by improved fire and impact resistance.
- the fire retardant laminate of the present invention comprises a resin impregnated decorative layer, a fire barrier formed from a fiber reinforced veil and a layer of fiberboard.
- the fiber reinforced veil includes fibers selected from a group consisting of glass fibers, basalt fibers, metal fibers, inorganic fibers, silica fibers, carbide fibers, nitride fibers, carbon fibers and mixtures thereof.
- Glass fibers utilized for the fiber reinforced veil may be selected from a group of materials consisting of boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and mixtures thereof.
- the fiber reinforced veil also includes a binder comprising a B-stageable resin.
- Suitable binders include but are not limited to self-crosslinkable polyacrylates, polyamide-amine epichlorohydrin resin (PAE), polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin and mixtures thereof.
- the fiber reinforced veil also includes a filler selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, general intumescent
- the fiber reinforced veil is nonwoven. Following resin impregnation, the fiber reinforced veil includes between about 5 to about 95 weight percent reinforcement fibers, about 5 to about 75 weight percent binder and about 0 to about 80 weight percent filler. Following impregnation and prior to pressing, the fiber reinforced veil has a weight per unit area of between about 20 and about 500 g/m 2 .
- the layer of fiberboard in the laminate may be generally described as a wood-based panel.
- the fiberboard may be constructed from a material selected from the group consisting of high density fiberboard, medium density fiberboard, oriented strand board, chipboard and mixtures thereof.
- the laminate may include a layer of resin impregnated overlay paper overlying the resin impregnated decorative paper and/or a resin impregnated backing layer underlying the layer of fiberboard. Both the resin impregnated decorative layer and the resin impregnated backing layer may be made from a decorative paper of a type known in the art.
- a method for making a fire retardant laminate comprises pressing a resin impregnated overlay layer, a resin impregnated decorative layer, a fire barrier formed from a fiber reinforced veil, a layer of fiberboard and a resin impregnated backing layer together at a pressure of between about 1050 N/m 2 and about 5250 N/m 2 while simultaneously heating to a temperature of between about 150 to about 225 degrees C. for a time period of between about 10 to about 50 seconds.
- That method may be further described as including a step of providing a binder in the fiber reinforced veil selected from a group consisting of polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin, polyamide-amine epichlorohydrin resin and mixtures thereof.
- a binder in the fiber reinforced veil selected from a group consisting of polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin, polyamide-amine epichlorohydrin resin and mixtures thereof.
- the method may include the step of providing a filler in the fiber reinforced veil selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide conden
- the laminate may be used in a laminate flooring application wherein the laminate is formed from boards having a wood basis such as chipboard, fiberboard including high and medium density fiberboard, and oriented strand board. Additional applications for the laminate include, but are not limited to, wall linings, ceilings, interior shop fittings, and decoration panels such as those found in ships, trains, and buildings.
- FIG. 1 is a side elevational view of one possible embodiment of the present invention.
- the laminate 10 includes a resin impregnated overlay paper 12 overlying a resin impregnated decorative layer 14 .
- the decorative layer 14 overlies a first fire barrier formed from a fiber reinforced veil 16 .
- the veil 16 overlies a layer of fiberboard 18 .
- a backing layer 20 underlies the fiberboard 18 .
- the laminate 10 may also include a second fire barrier, formed from a fiber reinforced veil 22 , between the fiberboard 18 and the backing layer 20 . This second veil 22 further enhances the fire retardant properties of the laminate 10 and insures that heat is transferred at about the same rate from the top or the bottom.
- the fiber reinforced veil 16 may include fibers selected from a group consisting of glass fibers, basalt fibers, metal fibers, inorganic fibers, silica fibers, carbide fibers, nitride fibers, carbon fibers and mixtures thereof.
- glass fibers may, for example, be selected from a group of fibers including boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and mixtures thereof.
- Advantex® glass fibers commercially available from Owens Corning (Toledo, Ohio), may be used.
- the fiber reinforced veils 16 and 22 following resin impregnation includes between about 5 to about 95 weight percent reinforcement fibers, about 5 to about 75 weight percent resin/binder and 0 to about 80 weight percent filler.
- the binder utilized may be a B-stageable resin which may be reactivated during the pressing step to reach its final properties.
- the binder may be selected from a group of resins consisting of polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin, polyamide-amine epichlorohydrin resin and mixtures thereof.
- the filler utilized in the fiber reinforced veil 16 may be selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, general int
- the fiber reinforced veils 16 and 22 are typically constructed from nonwoven glass fibers or mixed fibers.
- the veils 16 , 22 may include directionally oriented fibers if desired. Both continuous and chopped fibers may be utilized.
- the continuous fibers typically have a diameter of between about 3 and about 30.
- the chopped fibers typically have a length of between about 2 and about 100 mm and a diameter of between about 3 and about 30 ⁇ m.
- the fiber reinforced veil 16 following impregnation and prior to pressing typically has a weight per unit area of between about 20 and about 500 g/m 2 .
- the fiberboard 18 utilized in the present laminate is a wood based panel.
- the fiberboard 18 may, for example, be made from materials including high density fiberboard, medium density fiberboard, oriented strand board, chipboard and mixtures thereof.
- the decorative layer 14 and backing layer 20 may be made from decorative paper as is known in the art.
- the overlay paper 12 may be made from cellulose as is also known in the art.
- the overlay paper 12 , the decorative layer 14 and the backing layer 20 may all be impregnated with the same resin/binder as the fiber reinforced veil 16 .
- the laminate 10 is made by pressing the resin impregnated overlay layer 12 , the resin impregnated decorative layer 14 , the first fire barrier formed from the resin impregnated, fiber reinforced veil 16 , the layer of fiberboard 18 , the second fire barrier formed from the resin impregnated fiber reinforced veil 22 (if present) and the resin impregnated backing layer 20 together at a pressure of between about 1050 N/M 2 while simultaneously heating to a temperature of between about 225 degrees C. for a time period of between about 10 to about 50 seconds.
- Such processing may be completed in-line utilizing equipment that is presently available in the commercial marketplace.
- Table 1 shows fifteen samples of glass veil, prior to impregnation with additional binder and a flame retarder. All samples contain a poly(vinyl alcohol) (PVA) binder.
- the glass fibers in the veil include Advantex® glass fibers manufactured by Owens Corning, Toledo, Ohio, USA.
- Table 2 shows samples 1-15 after they have been impregnated with additional binder and flame retardant.
- the “Add on” column shows the amount of fire retarder/filler per m2 impregnated into each sample.
- PVA type retarder (g/M2) (g/M2) 1 PVA melamine 26 73 phosphate 2 PVA Melamine 25 71 pyrophosphate 3 PVA Melamine 26 73 cyanurate 4 PVA Ammonium 25 72 polyphosphate 5 chlorine- Aluminum 25 71 acrylate trihydrate 6 chlorine- ATH + APP 24 70 acrylate 7 PVA none 0 47 8 none none 0 33 9 none none 0 54 10 none none 0 76 11 PVA APP 23 71 12 PVA Melamine 24 71 polyphosphate 13 none none 0 81 14 PVA ATH 7 42 15 PVA intumescent 7 42 formulation
- Table 3 shows the fire properties of samples 1-15 when each of the samples were exposed to flame. Samples 1-15 were lit above a Bunsen burner where the flame temperature reached about 950° C. Distance to the flame was fixed, about 20 mm, for all the samples to ensure that the samples were exposed to the same temperature. Samples were observed for smoke development then the samples were removed from the flame and observed for self-extinguishing behavior. TABLE 3 FIRE PROPERTIES Smoke Self- Burn-through Sample No.
- the samples were then placed at a fixed distance, about 10 mm, above a Bunsen burner (Flame temperature at about 950° C.) and the time (in seconds) was recorded when the flame burned through the veil samples.
- Bunsen burner Flume temperature at about 950° C.
- Specimens 7 and 14 were evaluated as an effective fire barrier in a laminate flooring panel.
- An unmodified flooring laminate was taken as a reference.
- the laminate flooring panels were evaluated on impact resistance and fire resistance.
- Specimens 7 and 14 were impregnated with melamine resin to ensure a good bonding with the decorative paper and with the fiber board. Specimens 7 and 14 were impregnated to final weights of approximately 150 g/m2.
- the melamine-impregnated specimens 7 and 14 were pressed (function as a fire barrier between the decorative paper and the fiber board) onto the 8 mm high density fiber board (pressing conditions: 180° C.; 40 kg/cm2; 20 s) to produce the laminate flooring panel.
- the final laminate flooring panel was subjected to two critical tests; impact resistance and fire resistance and tested with a reference laminate flooring panel, see Table 4.
- Code C Code A: Code B: Specimen 14 Unmodified Specimen 7 fire barrier standard fire barrier laminate laminate laminate flooring Norm flooring panel flooring panel panel Small ball EN 438 ⁇ 15 16.82 18.84 impact (N) Large ball EN 438 ⁇ 1600 >1600 >1600 impact (mm) Fire NF P 92- M3 M2 M2 resistance 501 Impact class IC1 or IC 2 IC 3 IC 3 (see FIG. 2 )
- laminate flooring panels A, B and C were tested using the small and large ball impact tests described below.
- the small ball impact test the panels with their decorative surfaces were subjected to the impact of a 5 mm steel ball mounted at one end of a spring-loaded bolt.
- the minimum spring force (N) needed to cause visible damage was used to measure resistance to impact.
- the large ball impact test the laminate flooring panels A, B and C were covered with a sheet of carbon paper and subjected to the impact of a large steel ball (324 g; diameter of 42.8 mm) which was allowed to fall from a known height.
- the height is increased in 50 mm intervals until the ball creates an impact imprint larger than 10 mm. This height determines the large ball impact resistance in mm.
- Impact resistance is expressed as the maximum drop height (mm) which can be achieved without incurring visible surface cracking or producing an imprint greater than a 10 mm diameter.
- the Epiradiateur test (NF P 92-501) is the national fire test for France and is mandatory for many building and construction materials.
- the size of the specimens (7 and 14) tested was 300 mm ⁇ 400 mm ⁇ max 120 mm and the specimens were positioned at an incline of 45° on an 8 mm fixed, self-supporting frame.
- the specimens were ignited, from above and below, using an electrical radiator (inclined at 45°) at 500 W. Two butane pilot flames were used to ignite the fiber board panels above and below the specimen for 20 minutes.
- FIG. 2 shows the impact classification ratings using both the small ball impact test and the large ball impact test.
Abstract
Description
- This application is a continuation-in-part of U.S. Ser. No. 11/108,340 filed Apr. 18, 2005.
- This invention relates generally to fire retardant laminates such as utilized for flooring.
- Laminated flooring formed from boards having a wood basis such as chipboard or fiberboard are known in the aft. The present invention relates to a novel laminate characterized by improved fire and impact resistance.
- The fire retardant laminate of the present invention comprises a resin impregnated decorative layer, a fire barrier formed from a fiber reinforced veil and a layer of fiberboard. The fiber reinforced veil includes fibers selected from a group consisting of glass fibers, basalt fibers, metal fibers, inorganic fibers, silica fibers, carbide fibers, nitride fibers, carbon fibers and mixtures thereof. Glass fibers utilized for the fiber reinforced veil may be selected from a group of materials consisting of boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and mixtures thereof.
- The fiber reinforced veil also includes a binder comprising a B-stageable resin. Suitable binders include but are not limited to self-crosslinkable polyacrylates, polyamide-amine epichlorohydrin resin (PAE), polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin and mixtures thereof. The fiber reinforced veil also includes a filler selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, general intumescent systems (systems which foam during fire and therefore generate in situ an insulating layer) and mixtures thereof.
- In one possible embodiment the fiber reinforced veil is nonwoven. Following resin impregnation, the fiber reinforced veil includes between about 5 to about 95 weight percent reinforcement fibers, about 5 to about 75 weight percent binder and about 0 to about 80 weight percent filler. Following impregnation and prior to pressing, the fiber reinforced veil has a weight per unit area of between about 20 and about 500 g/m2.
- The layer of fiberboard in the laminate may be generally described as a wood-based panel. The fiberboard may be constructed from a material selected from the group consisting of high density fiberboard, medium density fiberboard, oriented strand board, chipboard and mixtures thereof. In addition the laminate may include a layer of resin impregnated overlay paper overlying the resin impregnated decorative paper and/or a resin impregnated backing layer underlying the layer of fiberboard. Both the resin impregnated decorative layer and the resin impregnated backing layer may be made from a decorative paper of a type known in the art.
- In accordance with an additional aspect of the present invention a method is provided for making a fire retardant laminate. The method comprises pressing a resin impregnated overlay layer, a resin impregnated decorative layer, a fire barrier formed from a fiber reinforced veil, a layer of fiberboard and a resin impregnated backing layer together at a pressure of between about 1050 N/m2 and about 5250 N/m2 while simultaneously heating to a temperature of between about 150 to about 225 degrees C. for a time period of between about 10 to about 50 seconds. That method may be further described as including a step of providing a binder in the fiber reinforced veil selected from a group consisting of polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin, polyamide-amine epichlorohydrin resin and mixtures thereof.
- Still further the method may include the step of providing a filler in the fiber reinforced veil selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, general intumescent systems and mixtures thereof.
- As mentioned, the laminate may be used in a laminate flooring application wherein the laminate is formed from boards having a wood basis such as chipboard, fiberboard including high and medium density fiberboard, and oriented strand board. Additional applications for the laminate include, but are not limited to, wall linings, ceilings, interior shop fittings, and decoration panels such as those found in ships, trains, and buildings.
- In the following description there is shown and described one possible embodiment of the invention simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
- The accompanying drawing incorporated in and forming a part of this specification, illustrates several aspects of the present invention, and together with the description serves to explain certain principles of the invention. In the drawing:
-
FIG. 1 is a side elevational view of one possible embodiment of the present invention. - Reference is now made to
FIG. 1 illustrating one possible embodiment of thelaminate 10 of the present invention. As illustrated thelaminate 10 includes a resin impregnatedoverlay paper 12 overlying a resin impregnateddecorative layer 14. Thedecorative layer 14 overlies a first fire barrier formed from a fiber reinforcedveil 16. Theveil 16 overlies a layer offiberboard 18. Finally, abacking layer 20 underlies thefiberboard 18. Thelaminate 10 may also include a second fire barrier, formed from a fiber reinforcedveil 22, between thefiberboard 18 and thebacking layer 20. Thissecond veil 22 further enhances the fire retardant properties of thelaminate 10 and insures that heat is transferred at about the same rate from the top or the bottom. - More specifically describing the invention, the fiber reinforced
veil 16 may include fibers selected from a group consisting of glass fibers, basalt fibers, metal fibers, inorganic fibers, silica fibers, carbide fibers, nitride fibers, carbon fibers and mixtures thereof. Where glass fibers are utilized in the fiber reinforced veil, they may, for example, be selected from a group of fibers including boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and mixtures thereof. Advantex® glass fibers, commercially available from Owens Corning (Toledo, Ohio), may be used. - The fiber reinforced
veils veil 16 may be selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, general intumescent systems (systems which foam during fire and therefore generate in situ an insulating layer) and mixtures thereof. Advantageously, the fire barrier formed from the fiber reinforcedveil 16 imparts improved fire retarding and impact characteristics to the laminate above and beyond those achieved with wood based laminates of the prior art not incorporating a fire barrier of fiber reinforced veil. - The fiber reinforced
veils veils veil 16 following impregnation and prior to pressing typically has a weight per unit area of between about 20 and about 500 g/m2. - The
fiberboard 18 utilized in the present laminate is a wood based panel. Thefiberboard 18 may, for example, be made from materials including high density fiberboard, medium density fiberboard, oriented strand board, chipboard and mixtures thereof. - The
decorative layer 14 andbacking layer 20 may be made from decorative paper as is known in the art. Theoverlay paper 12 may be made from cellulose as is also known in the art. Theoverlay paper 12, thedecorative layer 14 and thebacking layer 20 may all be impregnated with the same resin/binder as the fiber reinforcedveil 16. - The
laminate 10 is made by pressing the resin impregnatedoverlay layer 12, the resin impregnateddecorative layer 14, the first fire barrier formed from the resin impregnated, fiber reinforcedveil 16, the layer offiberboard 18, the second fire barrier formed from the resin impregnated fiber reinforced veil 22 (if present) and the resin impregnatedbacking layer 20 together at a pressure of between about 1050 N/M2 while simultaneously heating to a temperature of between about 225 degrees C. for a time period of between about 10 to about 50 seconds. Such processing may be completed in-line utilizing equipment that is presently available in the commercial marketplace. - Table 1 shows fifteen samples of glass veil, prior to impregnation with additional binder and a flame retarder. All samples contain a poly(vinyl alcohol) (PVA) binder. The glass fibers in the veil include Advantex® glass fibers manufactured by Owens Corning, Toledo, Ohio, USA.
TABLE 1 glass Ni weight binder SAMPLE FIBER TYPE g/m2 perc % 1 Advantex; 47 15 11 um-6 mm 2 Advantex; 46 15 11 um-6 mm 3 Advantex; 47 15 11 um-6 mm 4 Advantex; 47 15 11 um-6 mm 5 Advantex; 46 15 11 um-6 mm 6 Advantex; 46 15 11 um-6 mm 7 Advantex; 47 15 11 um-6 mm 8 Advantex/silica 33 10 (85:15) 9 Advantex/silica 54 10 (85:15) 10 Advantex/silica 76 10 (85:15) 11 Advantex/silica 48 10 (85:15) 12 Advantex/silica 47 10 (85:15) 13 silica 100% 81 12 14 Advantex; 35 15 11 um-6 mm 15 Advantex; 35 15 11 um-6 mm - Table 2 shows samples 1-15 after they have been impregnated with additional binder and flame retardant. The “Add on” column shows the amount of fire retarder/filler per m2 impregnated into each sample.
TABLE 2 GLASS VEIL IMPREGNATION End Sample Binder Flame Add on weight No. type retarder (g/M2) (g/M2) 1 PVA melamine 26 73 phosphate 2 PVA Melamine 25 71 pyrophosphate 3 PVA Melamine 26 73 cyanurate 4 PVA Ammonium 25 72 polyphosphate 5 chlorine- Aluminum 25 71 acrylate trihydrate 6 chlorine- ATH + APP 24 70 acrylate 7 PVA none 0 47 8 none none 0 33 9 none none 0 54 10 none none 0 76 11 PVA APP 23 71 12 PVA Melamine 24 71 polyphosphate 13 none none 0 81 14 PVA ATH 7 42 15 PVA intumescent 7 42 formulation - Table 3 shows the fire properties of samples 1-15 when each of the samples were exposed to flame. Samples 1-15 were lit above a Bunsen burner where the flame temperature reached about 950° C. Distance to the flame was fixed, about 20 mm, for all the samples to ensure that the samples were exposed to the same temperature. Samples were observed for smoke development then the samples were removed from the flame and observed for self-extinguishing behavior.
TABLE 3 FIRE PROPERTIES Smoke Self- Burn-through Sample No. Development* Extinguishing** times (s) 1 + +++ 40 2 + +++ 20 3 ++ +++ 3 4 + +++ 159 5 + ++ 3 6 + +++ 130 7 − + 1 8 −− +++ 600 9 −− +++ 170 10 −− +++ 300 11 + +++ 250 12 + +++ 26 13 −− +++ >600 14 + +++ 1 15 ++ +++ 250
*Smoke development:
−−: no smoke development
−: hardly any smoke development
+: moderate smoke development
++: significant smoke development
**Self-extinguishing behavior
+: poor self-extinguishing properties
++: moderate self-extinguishing properties
+++: significant self-extinguishing properties
- The samples were then placed at a fixed distance, about 10 mm, above a Bunsen burner (Flame temperature at about 950° C.) and the time (in seconds) was recorded when the flame burned through the veil samples.
- Flooring Laminate Examples
-
Specimens 7 and 14 were evaluated as an effective fire barrier in a laminate flooring panel. An unmodified flooring laminate was taken as a reference. The laminate flooring panels were evaluated on impact resistance and fire resistance. - Method of Making the Laminate Flooring Panel:
-
Specimens 7 and 14 were impregnated with melamine resin to ensure a good bonding with the decorative paper and with the fiber board.Specimens 7 and 14 were impregnated to final weights of approximately 150 g/m2. - The melamine-impregnated
specimens 7 and 14 were pressed (function as a fire barrier between the decorative paper and the fiber board) onto the 8 mm high density fiber board (pressing conditions: 180° C.; 40 kg/cm2; 20 s) to produce the laminate flooring panel. The final laminate flooring panel was subjected to two critical tests; impact resistance and fire resistance and tested with a reference laminate flooring panel, see Table 4.TABLE 4 Code C: Code A: Code B: Specimen 14Unmodified Specimen 7 fire barrier standard fire barrier laminate laminate laminate flooring Norm flooring panel flooring panel panel Small ball EN 438 <15 16.82 18.84 impact (N) Large ball EN 438 <1600 >1600 >1600 impact (mm) Fire NF P 92- M3 M2 M2 resistance 501 Impact class IC1 or IC 2 IC 3 IC 3 (see FIG. 2 ) - As shown in Table 4, laminate flooring panels A, B and C were tested using the small and large ball impact tests described below. In the small ball impact test, the panels with their decorative surfaces were subjected to the impact of a 5 mm steel ball mounted at one end of a spring-loaded bolt. The minimum spring force (N) needed to cause visible damage was used to measure resistance to impact. In the large ball impact test, the laminate flooring panels A, B and C were covered with a sheet of carbon paper and subjected to the impact of a large steel ball (324 g; diameter of 42.8 mm) which was allowed to fall from a known height. In the large ball test, the height is increased in 50 mm intervals until the ball creates an impact imprint larger than 10 mm. This height determines the large ball impact resistance in mm. Impact resistance is expressed as the maximum drop height (mm) which can be achieved without incurring visible surface cracking or producing an imprint greater than a 10 mm diameter.
- Fire Resistance
- The Epiradiateur test (NF P 92-501) is the national fire test for France and is mandatory for many building and construction materials.
- The size of the specimens (7 and 14) tested was 300 mm×400 mm×max 120 mm and the specimens were positioned at an incline of 45° on an 8 mm fixed, self-supporting frame. The specimens were ignited, from above and below, using an electrical radiator (inclined at 45°) at 500 W. Two butane pilot flames were used to ignite the fiber board panels above and below the specimen for 20 minutes.
-
FIG. 2 shows the impact classification ratings using both the small ball impact test and the large ball impact test. - The foregoing description of a preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, the second fire barrier and the backing layer could be combined into a single layer if desired.
- The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims and their fair and broad interpretation in any way.
Claims (23)
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/370,607 US20060234027A1 (en) | 2005-04-18 | 2006-03-08 | Fire retardant laminate |
PCT/EP2006/061194 WO2006111458A1 (en) | 2005-04-18 | 2006-03-30 | Fire retardant laminate |
JP2008507043A JP2008536721A (en) | 2005-04-18 | 2006-03-30 | Flame retardant laminate |
EP06725442A EP1874533A1 (en) | 2005-04-18 | 2006-03-30 | Fire retardant laminate |
CA002605155A CA2605155A1 (en) | 2005-04-18 | 2006-03-30 | Fire retardent laminate |
KR1020077026767A KR20080027229A (en) | 2005-04-18 | 2006-03-30 | Fire retardant laminate |
MX2007012967A MX2007012967A (en) | 2005-04-18 | 2006-03-30 | Fire retardant laminate. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/108,340 US20060234026A1 (en) | 2005-04-18 | 2005-04-18 | Non-combustible high pressure laminate |
US11/370,607 US20060234027A1 (en) | 2005-04-18 | 2006-03-08 | Fire retardant laminate |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/108,340 Continuation-In-Part US20060234026A1 (en) | 2005-04-18 | 2005-04-18 | Non-combustible high pressure laminate |
Publications (1)
Publication Number | Publication Date |
---|---|
US20060234027A1 true US20060234027A1 (en) | 2006-10-19 |
Family
ID=38802418
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/370,607 Abandoned US20060234027A1 (en) | 2005-04-18 | 2006-03-08 | Fire retardant laminate |
Country Status (7)
Country | Link |
---|---|
US (1) | US20060234027A1 (en) |
EP (1) | EP1874533A1 (en) |
JP (1) | JP2008536721A (en) |
KR (1) | KR20080027229A (en) |
CA (1) | CA2605155A1 (en) |
MX (1) | MX2007012967A (en) |
WO (1) | WO2006111458A1 (en) |
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Also Published As
Publication number | Publication date |
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EP1874533A1 (en) | 2008-01-09 |
WO2006111458A1 (en) | 2006-10-26 |
MX2007012967A (en) | 2008-03-18 |
JP2008536721A (en) | 2008-09-11 |
CA2605155A1 (en) | 2006-10-26 |
KR20080027229A (en) | 2008-03-26 |
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