Multilayer coating for flame retardant substrates

Patent metadata

Field	Value
Publication number	US-9540764-B2
Application number	US-201213562069-A
Country	US
Kind code	B2
Filing date	Jul 30, 2012
Priority date	Mar 4, 2009
Publication date	Jan 10, 2017
Grant date	Jan 10, 2017

Abstract

A method includes coating a substrate to provide a flame resistant substrate. In an embodiment, the method includes exposing the substrate to a cationic solution to produce a cationic layer deposited on the substrate. The cationic solution comprises cationic materials. The cationic materials comprise a polymer, a colloidal particle, a nanoparticle, a nitrogen-rich molecule, or any combinations thereof. The method further includes exposing the cationic layer to an anionic solution to produce an anionic layer deposited on the cationic layer to produce a layer comprising the anionic layer and the cationic layer. The anionic solution comprises a layerable material.

First claim

What is claimed is:

1. A method for coating a substrate to provide a flame resistant substrate, comprising:
(A) depositing a primer layer onto the substrate, wherein the primer layer comprises a surface, and wherein the surface of the primer layer proximate to the substrate is neutral or is charged with an attraction to the substrate;
(B) exposing the substrate to a cationic solution to produce a cationic layer deposited on the substrate, wherein the cationic solution comprises a cationic material, and wherein the cationic material comprises a polymer, a colloidal particle, a nanoparticle, a nitrogen-rich molecule, or any combinations thereof, wherein the cationic material does not comprise a clay, and wherein the substrate comprises foam, fabric, or any combinations thereof;
(C) exposing the cationic layer to an anionic solution to produce an anionic layer deposited on the cationic layer to produce the flame resistant substrate having a layer comprising the anionic layer and the cationic layer, wherein the anionic solution comprises a layerable material, and wherein the layerable material does not comprise a clay; and
further wherein the primer layer comprises a primer layer material which is different from any cationic material in any cationic layer and any layerable material in any anionic layer.

2. The method of claim 1 , wherein the layerable material comprises an anionic polymer, a colloidal particle, a phosphated molecule, a sulfated molecule, a boronic acid, a boron containing acid, or any combinations thereof.

3. The method of claim 1 , wherein the primer layer comprises branched polyethylenimine.

4. The method of claim 1 , further comprising exposing the anionic layer to a second cationic solution to produce a second cationic layer deposited on the anionic layer.

5. The method of claim 4 , further comprising exposing the second cationic layer to a second anionic solution to produce a second anionic layer on the second cationic layer.

6. The method of claim 1 , wherein the cationic polymer comprises branched polyethylenimine, cationic polyacrylamide, cationic poly diallyldimethylammonium chloride, poly (melamine-co-formaldehyde), polymelamine, copolymers of polymelamine, polyvinylpyridine, copolymers of polyvinylpyridine, or any combinations thereof.

7. The method of claim 1 , wherein the cationic polymer comprises polyethylene oxide, polyallylamine, or any combinations thereof.

8. The method of claim 1 , further comprising a crosslinker.

9. The method of claim 8 , wherein the crosslinker comprises a bromoalkane, an aldehyde, a carbodiimide, an amine active ester, or any combinations thereof.

10. The method of claim 1 , wherein the cationic material comprises branched polyethylenimine.

11. A method for coating a substrate to provide a flame resistant substrate, comprising:
(A) depositing a primer layer onto the substrate, wherein the primer layer comprises a surface, and wherein the surface of the primer layer proximate to the substrate is neutral or is charged with an attraction to the substrate;
(B) exposing the substrate to an anionic solution to produce an anionic layer deposited on the substrate, wherein the anionic solution comprises a layerable material, wherein the layerable material does not comprise a clay, and wherein the substrate comprises foam, fabric, or any combinations thereof;
(C) exposing the anionic layer to a cationic solution to produce a cationic layer deposited on the anionic layer to produce the flame resistant substrate having a layer comprising the anionic layer and the cationic layer, wherein the cationic solution comprises a cationic material, and wherein the cationic material comprises a polymer, a colloidal particle, a nanoparticle, a nitrogen-rich molecule, or any combinations thereof, and wherein the cationic material does not comprise a clay; and
further wherein the primer layer comprises a primer layer material which is different from any cationic material in any cationic layer and any layerable material in any anionic layer.

12. The method of claim 11 , wherein the layerable material comprises an anionic polymer, a colloidal particle, a phosphated molecule, a sulfated molecule, a boronic acid, a boron containing acid, or any combinations thereof.

13. The method of claim 11 , wherein the primer layer comprises branched polyethylenimine.

14. The method of claim 11 , further comprising exposing the cationic layer to a second anionic solution to produce a second anionic layer deposited on the cationic layer.

15. The method of claim 14 , further comprising exposing the second anionic layer to a second cationic solution to produce a second cationic layer on the second anionic layer.

16. The method of claim 11 , wherein the cationic polymer comprises branched polyethylenimine, cationic polyacrylamide, cationic poly diallyldimethylammonium chloride, poly (melamine-co-formaldehyde), polymelamine, copolymers of polymelamine, polyvinylpyridine, copolymers of polyvinylpyridine, or any combinations thereof.

17. The method of claim 11 , wherein the cationic polymer comprises polyethylene oxide, polyallylamine, or any combinations thereof.

18. The method of claim 11 , further comprising a crosslinker.

19. The method of claim 18 , wherein the crosslinker comprises a bromoalkane, an aldehyde, a carbodiimide, an amine active ester, or any combinations thereof.

20. The method of claim 11 , wherein the cationic material comprises branched polyethylenimine.

Assignees

• Grunlan Jaime C
• Texas A & M Univ Sys

Inventors

• Grunlan Jaime C

Classifications

• D06M23/08

  Processes in which the treating agent is applied in powder or granular form (adhesives for multi-layer textile fabrics D06M17/00) · CPC title

• D06M15/61

  Polyamines {polyimines} · CPC title

• D06M11/79

  with silicon dioxide, silicic acids or their salts · CPC title

• B05D1/36

  Successively applying liquids or other fluent materials, e.g. without intermediate treatment · CPC title

• D06M15/3562

  containing nitrogen · CPC title