Fire-resistant fiber sheet, moldings thereof, and flame-retardant acoustical absorbents for automobiles

• US 20070190876A1
• Filed: 02/08/2005
• Published: 08/16/2007
• Est. Priority Date: 02/26/2004
• Status: Abandoned Application

• Current Assignee: Nagoya Oilchemical Co., Ltd.
• Original Assignee: Nagoya Oilchemical Co., Ltd.
• Inventors: Watanabe, Tsuyoshi, Hirano, Morimichi, Ogawa, Masanori
• Application Number:
  US10/590,835
• Publication Number:
  US 20070190876A1
• Time in Patent Office: Days
• US Class Current: 442/136
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: B60R 13/0876 for mounting around heat sources, e.g. exhaust pipes
• CPC Class Codes: D06M 11/74 with carbon or graphite; with carbides; with graphitic acids or their salts
• CPC Class Codes: D06M 2200/30 Flame or heat resistance, fire retardancy properties
• CPC Class Codes: D06M 23/12 Processes in which the treating agent is incorporated in microcapsules making microcapsules B01J13/02
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24455 Paper
• CPC Class Codes: Y10T 442/2631 Coating or impregnation provides heat or fire protection

Abstract

The object of the present invention is to provide a fiber sheet having good fire resistant property, an expanded synthetic resin sheet having good fire resistant property and a molded article thereof, and a fire resistant acoustic material for cars, which uses the molded article. To attain the object, in the present invention, fire retardant capsules are adhered to the fiber sheet or the expanded synthetic resin sheet to provide a porous fire resistant sheet. When the fire retardant capsules are exposed to a high temperature, the synthetic film covering the fire retardant may break, exposing fire retardant, and giving fiber sheet or expanded synthetic resin sheet self extinguishing property. A molded article of the porous fire resistant sheet also has a good fire resistant property, and does not inhibit the ventilation property of the fiber sheet and the synthetic resin sheet, making said molded article useful as a fire resistant acoustic material for cars or buildings.

Claims

1. A fire resistant fiber sheet characterized by fire retardant capsules covered with a synthetic resin film, to adhere said capsules to said fiber sheet, wherein a sulfomethylated and/or sulfimethylated phenolic resin is added to said fiber sheet in an amount of between 5 and 200% by mass.

2. A fire resistant fiber sheet in accordance with claim 1, wherein said fire retardant capsules are added to said fiber sheet in an amount of between 5% and 80% by mass.

3. A fire resistant fiber sheet in accordance with claim 1, wherein said flame retardant is water soluble and said synthetic resin film is water insoluble.

5. A fire resistant fiber sheet in accordance with any of claims 1 to 3, wherein said fibers are all hollowed, or a mixture of solid and hollowed fibers.

6. A fire resistant fiber sheet in accordance with any of claims 1 to 5, wherein an additional fiber having a low melting point of below 180°

C., is mixed in with said fiber.

16. A molded article wherein said fire resistant fiber sheet in accordance with any of claims 1 to 6, is molded into a prescribed shape.

17. A molded article in accordance with claim 16, wherein a ventilation resistance of said molded article is in the range of between 0.1 and 100 kPa·

s/m.

18. A laminated material wherein other porous sheet(s) is (are) laminated onto one side or both sides of said fire resistant fiber sheet in accordance with any of claims 1 to 5.

19. A laminated material in accordance with claim 18, wherein other porous sheet(s) is (are) laminated onto one or both sides of said fire resistant fiber sheet through thermoplastic resin film(s) having a thickness of between 10 and 200 μ

m.

20. A laminated material in accordance with claim 19, wherein a hot melt adhesive powder is scattered onto one or both sides of said fire resistant fiber sheet in an amount of between 1 and 100 g/m² and said other porous material sheet(s) is (are) laminated onto said fiber sheet through said scattered layer of hot melt adhesive powder.

21. A molded article wherein a laminated material in accordance with claims 18, 19 is molded into a prescribed shape.

22. A molded article in accordance with claim 21, wherein a ventilation resistance of said molded article is in the range of between 0.1 and 100 kPa·

s/m.

23. A fire resistant acoustic material for cars made of a molded article in accordance with any of claims 16, 17, 21 and 22.

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