Stainproof, flame-resistant composite sheet material

• US 4,714,650 A
• Filed: 10/02/1986
• Issued: 12/22/1987
• Est. Priority Date: 01/29/1985
• Status: Expired due to Term

• Current Assignee: Hiraoka & Co. Ltd.
• Original Assignee: Hiraoka & Co. Ltd.
• Inventors: Ino, Kazuhide, Obayashi, Tsutomu, Hiraoka, Yoshiji, Baba, Saburo
• Primary Examiner(s): Ives, P. C.
• Application Number:
  US06/914,374
• Time in Patent Office: 446 Days
• Field of Search: 428/920, 428/921, 428/902, 428/451
• US Class Current: 442/93
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2310/14 Corona, ionisation, electrical discharge, plasma treatment
• CPC Class Codes: B32B 2319/00 Synthetic rubber natural rubber B32B2317/22
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2327/12 containing fluorine
• CPC Class Codes: B32B 2333/00 Polymers of unsaturated acids or derivatives thereof
• CPC Class Codes: B32B 25/08 of synthetic resin
• CPC Class Codes: B32B 25/20 comprising silicone rubber
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10S 428/902 High modulus filament or fiber
• CPC Class Codes: Y10S 428/92 Fire or heat protection feature
• CPC Class Codes: Y10S 428/921 Fire or flameproofing
• CPC Class Codes: Y10S 428/922 Static electricity metal bleed-off metallic stock
• CPC Class Codes: Y10T 428/2915 : including textile, cloth or fabric
• CPC Class Codes: Y10T 428/2918 : including free carbon or carbide or therewith [not as steel]
• CPC Class Codes: Y10T 428/294 : including metal or compound thereof [excluding glass, ceramic and asbestos]
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31515 : As intermediate layer
• CPC Class Codes: Y10T 428/3154 : Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31544 : Addition polymer is perhalogenated
• CPC Class Codes: Y10T 428/31576 : Ester monomer type [polyvinylacetate, etc.]
• CPC Class Codes: Y10T 428/31652 : Of asbestos
• CPC Class Codes: Y10T 428/31663 : As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/3175 : Next to addition polymer from unsaturated monomer[s]
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/3192 : Next to vinyl or vinylidene chloride polymer
• CPC Class Codes: Y10T 428/31942 : Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 442/2213 : Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant
• CPC Class Codes: Y10T 442/2279 : Coating or impregnation improves soil repellency, soil release, or anti- soil redeposition qualities of fabric
• CPC Class Codes: Y10T 442/2287 : Fluorocarbon containing
• CPC Class Codes: Y10T 442/2631 : Coating or impregnation provides heat or fire protection

Abstract

A stainproof, flame-resistant composite sheet material including at least one silicone polymer layer containing a silicon resin or rubber and optionally a flame-resistant inorganic filler and at least one stainproof surface layer containing at least one synthetic thermoplastic stain-resistant, weathering-resistant polymeric material, the silicone polymer layer and the stainproof surface layer being bonded optionally through an adhesive material, a cold plasma or corona discharge-modified surface portion of the silicone polymer layer or a cold plasma or corona discharge-modified and graft polymerization-modified surface portion of the silicone polymer layer.

Claims

1. An improved composite sheet material comprising:

(a) at least one stainproof surface layer containing at least one synthetic thermoplastic polymeric material having a high stain-resistance and weathering resistance selected from the group consisting of polyacrylic polymer resin materials and fluorine-containing polymer resin materials; and

(b) at least one silicone polymer layer containing at least one member selected from the group consisting of silicone resins and silicone rubber, and having a surface portion thereof modified by means of a corona discharge treatment, through which resultant corona discharge-treated surface portion, the silicone polymer layer is bonded to the stainproof surface layer.

2. The composite sheet material as claimed in claim 1, wherein the silicone resins are selected from the group consisting of organopolysiloxane resins, polyacryloxyalkylalkoxy silane resins, polyvinylsilane resins, and derivatives of the above-mentioned resins.

3. The composite sheet material as claimed in claim 1, wherein the silicone polymer layer consists of at least one member alone selected from the group consisting of silicone resins and silicone rubbers.

4. The composite sheet material as claimed in claim 1, wherein the silicone polymer layer comprises a silicone matrix consisting of at least one member selected from the group consisting of silicone resins and silicone rubbers and at least one flame-retardant inorganic filler in an amount of 30% to 300% based on the weight of the silicone matrix.

5. The composite sheet material as claimed in claim 1, wherein the stainproof surface layer comprises a laminate consisting of a polyvinylidene fluoride resin layer and a polyacrylic resin layer.

6. The composite sheet material as claimed in claim 1, wherein the stainproof surface layer comprises a laminate consisting of a polyvinylidene fluoride resin layer, a polyacrylic resin layer and a polyvinyl chloride resin layer.

7. The composite sheet material as claimed in claim 1, wherein the silicone polymer layer is formed on a substrate consisting of a fibrous fabric selected from woven fabrics, knitted fabrics and nonwoven fabrics.

8. The composite sheet material as claimed in claim 7, wherein the fabric substrate consists of a mixture of inorganic fibers and organic fibers.

9. The composite sheet material as claimed in claim 8, wherein the inorganic fibers and organic fibers are in a weight ratio of 10:

90 to 90;

10.

10. The composite sheet material as claimed in claim 8, wherein the organic fibers contains at least 25% by weight of flame-resistant organic fibers having a melting point or heat decomposition point of 300°

C. or more.

11. The composite sheet material as claimed in claim 7, wherein the fibrous fabric contains flame-resistant fibers.

12. The composite sheet material as claimed in claim 11, wherein the flame-resistant fibers are inorganic fibers selected from the group consisting of asbestos fibers, ceramic fibers, silica fibers, glass fibers, carbon fibers, and metal fibers.

13. The composite sheet material as claimed in claim 11, wherein the flame-resistant fibers are organic fibers having a melting point or heat decomposition point of 300°

C. or more.

14. The composite sheet material as claimed in claim 1, wherein the corona discharge-modified portion of the silicone polymer layer is adhered to the stainproof surface layer with an adhesive material.

15. The composite sheet material as claimed in claim 14, wherein the adhesive material is selected from the group consisting of polyacrylic adhesive polymer materials, epoxy adhesive materials, polyethyleneimine adhesive materials, polyisocyanate adhesive materials, and polyurethane adhesive materials.

16. An improved composite sheet material comprising:

(a) at least one stainproof surface layer containing at least one synthetic thermoplastic polymeric material having a high stain-resistance and weathering resistance selected from the group consisting of polyacrylic polymer resin materials and fluorine-containing polymer resin materials;

(b) at least one silicone polymer layer containing at least one member selected from the group consisting of silicone resins and silicone rubber, and having a surface portion thereof modified by means of a corona discharge treatment, through which resultant corona discharge-treated surface portion, the silicone polymer layer is bonded to the stainproof surface layer; and

(c) a substrate consisting of a fibrous fabric selected from woven fabrics, knitted fabrics and non-woven fabrics and bonded to the silicone polymer layer.