Fire Retardant Laminates

Patent metadata

Field	Value
Publication number	US-2016129668-A1
Application number	US-201414535904-A
Country	US
Kind code	A1
Filing date	Nov 7, 2014
Priority date	Nov 7, 2014
Publication date	May 12, 2016
Grant date	—

Abstract

Fire retardant laminates including a textile layer, a protective layer, and a fire retardant are provided. The protective layer includes a porous membrane and a coating layer. The porous membrane is positioned between the textile layer and the coating layer. The fire retardant includes one or more phosphonate esters of the general formula:

where n=0 or 1, R 1 and R 2 are C 1 -C 4 alkyl, R 3 is H or C 1 -C 4 alkyl, and R 4 is a linear or branched alkyl. At least a portion of the phosphonate ester in the fire retardant laminate resides in the coating layer. The fire retardant laminates are suitable for use in protective garments that provide full flammability and burn protection, even after exposure to flammable materials such as petroleum, oils, and lubricants. A method of rendering the fire retardant laminate fire retardant is also provided.

First claim

What is claimed is:

1 . A fire retardant laminate comprising:
a first textile layer; a protective layer including a first porous membrane and a coating layer, said porous membrane being positioned between said first textile layer and said coating layer; and a fire retardant comprising one or more phosphonate esters having the general formula:

wherein n=0 or 1, R 1 and R 2 are C 1 -C 4 alkyl, R 3 is H or C 1 -C 4 alkyl, and R 4 is a linear or branched alkyl, and
wherein said fire retardant at least partially penetrates said coating layer.

2 . The fire retardant laminate of claim 1 , wherein said first porous membrane is a porous fluoropolymer membrane or a polyurethane membrane.

3 . The fire retardant laminate of claim 1 , wherein said first porous membrane comprises polytetrafluoroethylene or expanded polytetrafluoroethylene.

4 . The fire retardant laminate of claim 1 , wherein said first textile layer comprises a woven fabric, a nonwoven fabric, or a knit fabric.

5 . The fire retardant laminate of claim 4 , wherein the first textile layer comprises a nonwoven fabric, said nonwoven fabric including a member selected from the group consisting of a thermoplastic fiber, a carbon fiber, an aramid fiber and combinations thereof.

6 . The fire retardant laminate of claim 1 , wherein the first textile layer comprises a natural fiber, a synthetic fiber, or a combination thereof.

7 . The fire retardant laminate of claim 1 , wherein the first textile layer has thereon a water-repellant substance.

8 . The fire retardant laminate of claim 1 , wherein said coating layer comprises polyurethane.

9 . The fire retardant laminate of claim 1 , wherein the protective layer further comprises a second porous membrane and an intermediate layer, and
wherein said intermediate layer is sandwiched between said first porous membrane and said second porous membrane.

10 . The fire retardant laminate of claim 9 , wherein said intermediate layer comprises a member selected from the group consisting of a porous layer of polyurethane and a non-porous layer of polyurethane.

11 . The fire retardant laminate of claim 9 , wherein said intermediate layer comprises a member selected from the group consisting of an elastomer, a polymer resin, an expandable graphite, an adhesive, an antistatic material and combinations thereof.

12 . The fire retardant laminate of claim 11 , wherein said intermediate layer comprises silicone.

13 . The fire retardant laminate of claim 1 , further comprising a second textile layer positioned on said protective layer opposing said first textile layer.

14 . The fire retardant laminate of claim 13 , wherein second textile layer comprises a woven fabric, a nonwoven fabric, or a knit fabric.

15 . The fire retardant laminate of claim 14 , wherein said second textile layer comprises an aramid fiber.

16 . The fire retardant laminate of claim 14 , wherein the fire retardant at least partially penetrates said second textile layer.

17 . The fire retardant laminate of claim 1 , wherein the fire retardant comprises an aqueous mixture of phosphonic acid, methyl-,bis((5-ethyl-2-methyl-2-oxido-1,3,2-dioxaphosphorinan-5-yl)methyl)ester and methyl(5-ethyl-2-methyl-2-oxido-1,3,2-dioxaphosphorinan-5-yl)methyl methylphosphonate.

18 . The fire retardant laminate of claim 17 , wherein the fire retardant comprises an aqueous mixture of said phosphonic acid, methyl-,bis((5-ethyl-2-methyl-2-oxido-1,3,2-dioxaphosphorinan-5-yl)methyl)ester and said methyl(5-ethyl-2-methyl-2-oxido-1,3,2-dioxaphosphorinan-5-yl)methyl methylphosphonate in a weight ratio of about 0.3 to about 2.

19 . The fire retardant laminate of claim 1 , wherein at least 1 wt % of phosphorus present as said phosphonate ester in said fire retardant laminate resides in said protective layer.

20 . The fire retardant laminate of claim 1 , wherein the fire retardant laminate, when subjected to a vertical flame test according to ASTM D6413, demonstrates an afterflame of less than 2 seconds.

21 . The fire retardant laminate of claim 20 , wherein said fire retardant laminate has been subjected to petroleum, oil, a lubricant, or combinations thereof prior to being subjected to said vertical flame test.

22 . The fire retardant laminate of claim 1 , wherein the fire retardant laminate, when subjected to a vertical flame test according to ASTM D6413, demonstrates a char length of less than 10 cm.

23 . The fire retardant laminate of claim 22 , wherein said fire retardant laminate has been subjected to petroleum, oil, a lubricant, or combinations thereof prior to being subjected to said vertical flame test.

24 . The fire retardant of claim 1 , further comprising a polymer resin-expandable graphite mixture positioned on an inner surface of said first textile layer.

25 . A fire retardant laminate comprising:
a first textile layer; a protective layer including a first porous membrane, a second porous membrane, and a polyurethane layer positioned between said first and second porous membranes, wherein said first porous membrane is positioned adjacent said first textile layer; and a fire retardant comprising one or more phosphonate esters having the general formula:

wherein n=0 or 1, R 1 and R 2 are C 1 -C 4 alkyl, R 3 is H or C 1 -C 4 alkyl, and R 4 is a linear or branched alkyl, and
wherein said fire retardant at least partially penetrates said polyurethane layer.

26 . The fire retardant laminate of claim 25 , wherein said first and second porous membranes comprise a membrane selected from the group consisting of a porous fluoropolymer membrane and a polyurethane membrane.

27 . The fire retardant laminate of claim 26 , wherein at least one of said first porous membrane and said second porous membrane comprises polytetrafluoroethylene or expanded polytetrafluoroethylene.

28 . The fire retardant laminate of claim 25 , wherein said first textile layer comprises a woven fabric, a nonwoven fabric, or a knit fabric.

29 . The fire retardant laminate of claim 25 , wherein the first textile layer comprises a nonwoven fabric, said nonwoven fabric comprising a member selected from the group consisting of a thermoplastic fiber, a carbon fiber, an aramid fiber and combinations thereof.

30 . The fire retardant laminate of claim 25 , wherein said first textile layer comprises a natural fiber, a synthetic fiber, or a combination thereof.

31 . The fire retardant laminate of claim 25 , further comprising a second textile layer positioned on said protective layer opposing said first textile layer.

32 . The fire retardant laminate of claim 31 , wherein said second textile layer comprises a woven fabric, a nonwoven fabric, or a knit fabric.

33 . The fire retardant laminate of claim 31 , wherein said second textile layer comprises an aramid fiber.

34 . The fire retardant laminate of claim 31 , wherein said fire retardant at least partially penetrates said second textile layer.

35 . The fire retardant laminat

Assignees

• Gore & Ass

Inventors

• Kurian Joseph V

Classifications

• B32B5/245 Primary

  another layer next to it being a foam layer · CPC title

• B32B2260/04

  Impregnation, embedding, or binder material · CPC title

• B32B5/026

  Knitted fabric · CPC title

• B32B2262/0253

  Polyolefin fibres · CPC title

• B32B2255/28

  Multiple coating on one surface · CPC title