High intensity flame resistant composites

• US 20070004307A1
• Filed: 06/30/2005
• Published: 01/04/2007
• Est. Priority Date: 06/30/2005
• Status: Abandoned Application

• Current Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Wyss, Kurt, Pfister, Friedrich, Jeanrenaud, Yves
• Application Number:
  US11/172,156
• Publication Number:
  US 20070004307A1
• Time in Patent Office: Days
• US Class Current: 442/415
• CPC Class Codes: C09K 21/14 Macromolecular materials
• CPC Class Codes: D04H 1/413 containing granules other than absorbent substances
• CPC Class Codes: D04H 1/4218 Glass fibres
• CPC Class Codes: D04H 1/4334 Polyamides
• CPC Class Codes: D04H 1/435 Polyesters
• CPC Class Codes: D04H 1/4374 using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/43835 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 3/11 by fluid jet
• CPC Class Codes: D04H 5/02 strengthened or consolidated by mechanical methods, e.g. needling needling machines D04H18/00
• CPC Class Codes: D21H 13/24 Polyesters
• CPC Class Codes: D21H 17/68 siliceous, e.g. clays
• CPC Class Codes: D21H 21/34 Ignifugeants
• CPC Class Codes: D21H 27/20 Flexible structures being applied by the user, e.g. wallpaper printed wallpapers B41M3/18; paperhanging B44C7/00; pregummed wallpaper C09J7/21
• CPC Class Codes: E04B 1/942 slab-shaped
• CPC Class Codes: Y10T 442/3976 Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/684 Containing at least two chemically different strand or fiber materials
• CPC Class Codes: Y10T 442/689 Hydroentangled nonwoven fabric
• CPC Class Codes: Y10T 442/695 Including a wood containing layer
• CPC Class Codes: Y10T 442/696 Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/697 : Containing at least two chemically different strand or fiber materials
• CPC Class Codes: Y10T 442/698 : Containing polymeric and natural strand or fiber materials
• CPC Class Codes: Y10T 442/699 : Including particulate material other than strand or fiber material

Abstract

Heat and flame resistant composites are provided, suitable for use as construction and furnishing panels and as covers for construction and furnishing panels.

Claims

1. A heat- and flame-resistant composite comprising:

non-melting fibres;

melting fibres; and

at least one silicate.

2. The composite of claim 1, wherein the non-melting fibres are selected from cellulose, wool, silk, aramids, polybenzimidazoles, polyimides, polyarenes, rayon, and mixtures of these.

3. The composite of claim 1, wherein the melting fibres are selected from polyester, mixed polyetheresters, polyamide, polyolefins, polyphenylene sulfide (PPS), polyethertherketone (PEEK), poly(ether ketone ketone) (PEKK), PFA (copolymer of tetrafluoroethylene and perfluorovinylether), FEP (copolymer of tetrafluoroethylene and hexafluoropropylene), melt spun fluorofibres (homopolymer of tetrafluoroethylene), glass or basalt fibres, and mixtures of these.

4. The composite of claim 1, wherein the non-melting fibres are cellulose fibres and the melting fibres are polyester fibres.

5. The composite of claim 1, wherein the fibres are non-woven.

6. The composite of claim 1, wherein the fibres are spun-laced structures.

7. The composite of claim 1, wherein the silicate is potassium silicate, sodium silicate, or a mixture of these.

8. The composite of claim 1, additionally comprising particles of serpentine mineral.

9. The composite of claim 8, wherein the serpentine mineral is Northfil®

325, or a serpentine mineral having similar characteristics.

10. The composite of claim 1, wherein the silicate is present at or about 50 to at or about 98 wt %, based on the weight of the composite.

11. The composite of claim 1, wherein the non-melting fibres are present at or about 45 to at or about 90 wt %, based on the dry weight of the total fibre content.

12. The composite of claim 1, wherein the melting fibres are present at or about 10 to at or about 55 wt %, based on the dry weight of the total fibre content.

13. The composite of claim 1, which is a fireskin, in the form of a sheet having a thickness of not more than at or about 1 mm.

14. The composite of any claim 1, which is a laminate.

15. The composite of claim 1, which is a laminate in the form of two or more layers that have been subjected to pressure and optionally heat to form a laminate.

16. A heat- and flame-resistant panel comprising at least one layer which is a composite according to claim 1.

17. The panel of claim 16, wherein the composite forms an outer layer, on an inner core.

18. The panel of claim 16, comprising two outer layers which are composites according to claim 1, and an inner core.

19. The panel of claim 17, wherein the inner core comprises wood pulp and an organic binder resin.

20. The panel of claim 17, wherein the inner core comprises non-melting fibre and a silicate.

21. The panel of claim 20, wherein the core comprises non-melting fibre and at or about 50-98 wt % of a silicate, based on the weight of the inner core.

22. A construction panel comprising the composite of claim 1.

23. An item of furniture comprising the composite of claim 1.

24. A countertop comprising the composite of claim 1.

25. A wallpaper comprising the composite of claim 1.