FIRE-RESISTANT STRUCTURAL MATERIAL AND COATED FABRICS MANUFACTURED WITH SUCH CROSS-REFERENCE MATERIAL RELATED REQUESTS This application is a continuation of part of US application Serial No. 09 / 663,255 filed on September 15, 2000 which claims priority in accordance with 35 USC §119 (e) on provisional application number 60 / 168,057, filed on November 30, 1999; and this request is also a continuation in. part of the pending North American application serial number 09 / 955,395 filed on September 18, 2001; and that request also claims priority in accordance with 35 U.S.C. §119 (e) on provisional applications number 60 / 352,691, 60 / 352,692, and 60 / 352,693, which were all filed on January 29, 2002. FIELD OF THE INVENTION This invention relates to structural materials resistant to fire and fire-resistant fabric materials made from them and more particularly to materials that can be adhered on decorative fabrics to provide fire-resistant decorative fabrics especially suitable for use in mattresses, upholstery, furniture upholstery, and the like. Accordingly, the invention also relates to fabric materials comprising a reusable substrate, which comprises the structural material of the present invention. The fabric materials are fire resistant. BACKGROUND OF THE RELEASE Various attempts were made to produce fire-resistant fabrics having characteristics that make such fabrics suitable for use in mattresses and other applications, for example, upholstery and upholstery. U.S. Patent No. 5,540,980 focuses on a fire resistant fabric useful for wrapping a mattress. The fabric is formed of a core spun yarn comprising a core of continuous filament glass fiber resistant to high temperatures and a fiber wrap resistant to low temperatures. The fiberglass core forms approximately 20 to 40% of the total weight of the core spun yarn while the envelope forms approximately 80% to approximately 60% of the total weight of the spun core yarn. The core spun yarn can be woven- or needle-knitted fabric to form a fabric with fire-resistant characteristics. When exposed to a flame, the envelope is burned and the fiberglass core serves as a fire barrier. In a preferred embodiment, the wrap is made of cotton. U.S. Patent No. 5,091,243 discloses a fire barrier fabric comprising a substrate formed of nylon spun yarns and a r¾ve¾-rtden-o-e ^ t-a ^ e - ??? - u¾a-surface of the substrate. Other fire resistant fabrics include Phoenix (registered trademark) (Milliken, LaGrange, GA) and fabrics made by Freudenberg (Lo ell, MA), Ventex Inc. (Great Falls, VA), BASF, Basofil Fiber Division (Enka, NC) , Carpenter Co. (Richmond, VA), Legget and Platt (Nashville, TN), Chiquala Industries Products Group (Kingspoint, TN), and Sandel (Amsterdam, NY). DuPont also manufactures a fabric made from Kevlar yarns (registered trademark). In addition, the mattress industry has tried to manufacture mattresses by using Kevlar yarn (registered trademark) glass thread, fire retardant polyurethane foams, flame retardant casings, flame retardant cotton padding as well as fire retardant tape. However, the UoO of these materials can increase the cost of mattresses and can result in an excessively expensive product. In addition, some fire resistant yarns such as glass threads are difficult to work with and can break which increases the time required to manufacture the mattresses and also results in increased costs. Flame retardant tapes are also difficult to work with and increase production time. In addition, flame retardant ribbons are available only in a limited number of colors and sizes. Flame retardant polyurethanes can release gasses T: OXICO ~ 5 -errando-airden-o - when. Are consumed. further, the flame retardant wrapping process frequently affects the desired characteristics of the wrapping (for example, it may lose its characteristics of softness, flexibility, folding capacity, etc.). For many years substrates such as glass fiber have been coated with various compositions to produce useful materials, among other applications, in the construction industry. U.S. Patent No. 5,001,005 refers to structural laminates made with facing sheets. The laminates described in this patent include plastic thermosetting foam having flat facing sheets consisting of 60% to 90% by weight of glass fibers (exclusively of micro glass fibers), 10% to 40% by weight of material of non-glass filling and from 1% to 30% of non-asphalt binder material. The filling materials are indicated as clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony trioxide, cellulose fibers, plastic polymer fibers or a combination of two or more of these substances. The patent further indicates that the filler materials are bonded to the glass fibers using binders such as urea-, phenol- or melamine-formaldehyde resins (UF, PF, and MF resins) or a resin of ~ pdT is eT ~ The following are used in accordance with the disclosures are styrene-butadiene-rubber (SBR), ethylene-chloride, and the like. vinyl (EVCi), poivivinylidene chloride (PvdC), modified polyvinyl chloride (PVC), polyvinyl alcohol (PVOH), and 5 polyvinyl acetate (PVA). The glass fibers, the non-glass filler material and the non-asphalt binder are mixed together to form the coating sheets. U.S. Patent No. 4,745,032 discloses an acrylic coating comprising an underlying resin
10 acrylic that includes fly ash and an acrylic coating resin that differs from the underlying resin. U.S. Patent No. 4,229,329 discloses a flame retardant coating composition comprising fly ash and a vinylacrylic polymer emulsion. The
15 fly ash forms 24 50% of the composition. The composition may also preferably contain one or more of the following: a dispersing agent, a foam remover, a plasticizer, a thickener, a drying agent, a preservative, a fungicide and a
20 ingredient to control the pH of the composition and therefore inhibit corrosion of a metal surface on which the composition is applied. U.S. Patent No. 4,784,897 discloses a coating layer material based on a mat or cloth ~ 2 ~ 5 that is "s ^ s s ^ s t ^ ^ - ^? - ía ~ ^^ áü < ^ emp ~ ee -t ^^^ G ^ s - ^ - yQso ~ ^ -hard polyurethane foam boards.The cover layer material has a coating on one side consisting of 70% to 94% inorganic powder, as per example, calcium carbonate, and from 6% to 30% binder In addition, thickening agents and cross-linking agents are added and a high-density mat is used, U.S. Patent No. 4, 495, 238 discloses a composite structure. heat-resistant, fire-resistant comprising a mixture of approximately 50% to 94% by weight of inorganic microfibers, especially glass, and from about 50% to 6% by weight of a heat-resistant binder agent US Pat. No. 5,965,257, issued to the present beneficiary, whose entire disclosure is incorporated here by reference The invention discloses a structural article having a coating that includes only two major constituents, while eliminating the need for viscosity modifiers, stabilizers or blowing. The structural article of U.S. Patent No. 5,965,257 is made by coating a substrate having an ionic charge with a coating having essentially the same ionic charge - the coating consisting essentially of a filler material and a binder material. The beneficiary, Elk Corporation of Dallas, plrc¾uceT-uñ-proocrc o-corrfrorml-dad-con-ta-i-nv-eneión-of the US patent number 5,965,257 that 1 is marketed under the name VersaShield®. In accordance with what is indicated by US Pat. No. 5,965,257, VersaShield® has many uses. However, it has been found that products made according to U.S. Patent No. 5,965,257 are unsatisfactory for certain uses since they do not have sufficient upholstery capacity. U.S. Patent Application Serial No. 09/955, 395 filed September 18, 2001, the entire disclosure of which is incorporated herein by reference, focuses on resolving these inadequate features with a fire-resistant fabric material comprising a substrate having a ionic charge rc / estida with a coating that has essentially the same ionic charge where the coating comprises a filler component that includes a clay and a binder component. A fire resistant fabric material produced in this way has a flexibility, crease capacity and satisfactory upholstery characteristics. However, while this material is suitable as a fire resistant fabric material, it is desirable to provide a fire resistant material that also has acoustic or "bounce" characteristics. COMPU ^ I ^^^^^^^^^^^^^^^^^^^
The present invention relates to a structural material comprising a surfactant component, microceeds generated by surfactant, a gel catalyst component, and a binder component. The structural material can also comprise a filler component, the structural material is fire resistant and are useful,. inter alia, for manufacturing fire resistant fabric materials comprising a substrate coated with a coating comprising the structural materials of the present invention. The substrate may be planar and may have one or both sides coated with the structural materials. In addition, the fabric material may further include a water repellent material, an antifungal material, an antibacterial material, a surface friction agent, a flame retardant material and / or an algicide. In addition, the fabric material can be dyed with dye. The present invention also relates to a mattress fabric comprising a decorative fabric and a fabric material, comprising a substrate coated with the structural materials of the present invention. In addition, the present invention relates to a mattress comprising a decorative fabric and a fabric material comprising a substrate coated with the structural materials of the present invention. In a particular mode-p ^ ef¾ ~ ri ~ dar -e ± -r¾v¾std-trriren-t © -not run through the substrate during the process of making the material. The substrate can be any suitable reinforcing material capable of withstanding the processing temperatures and preferably it is glass fiber. The structural material of the present invention can be used as a stand-alone product, for example, "as fire-resistant foam material, or" it can be used in combination with a decorative fabric (for example as a decorative fabric lining) which can itself be fire-resistant The present invention also relates to an article of manufacture comprising the structural material of the present invention and / or the materials of fire-resistant fabrics of the present invention and includes, inter alia, mattress fabrics covered for mattresses, mattresses, articles upholstery, building materials, bedroom items, (including items for children's bedrooms), upholstery, carpets, tents, awnings, fire sheds, sleeping bags, ironing board covers, grill covers, gloves Fire resistant, aircraft seats, engine liners, fire resistant clothing for race car pilots, warplanes pilots, fire fighters, and the like. The use of fire-resistant materials and fire-resistant fabric materials of pre-design 1 or
invention for the manufacture of fabrics for use in articles such as mattresses, cots, upholstery, and upholstered fabrics, may allow the article to exceed the current flammability standards for these types of articles. BRIEF DESCRIPTION OF THE FIGURES The present invention will be understood, better with reference to the attached figures in which: Figure 1 is a photograph showing the microcells generated by surfactant of an example embodiment of a fire resistant fabric material manufactured in accordance with with the present invention that does not include a filler component; Figure 2 is a photograph showing the microcells generated by surfactants of another example embodiment manufactured in accordance with the present invention further comprising a filler component; and Figure 3 is an illustration of an exemplary embodiment of a mattress made in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION The structural material of the present invention comprises a component of surfactant, microcells generated by surfactant, a gel catalyst component and a binder component. The structural material may further comprise a filler component. As used here ~; Tastes "generated mTcToce'lttas - t: surfactant are essentially hollow c wells are hollow spheres that are formed through the presence of a surfactant during the process of manufacturing the fire resistant material.The surfactant component of the present invention can form such microcells Microcells generated by surfactant provide several characteristics to the fabric materials of the present invention including, inter alia, improved fire resistance, improved flexibility, folding ability, upholstery and "bounce." The gei catalyst can also increase all or some of these characteristics In accordance with the present invention, a fabric material is manufactured by coating a substrate with a coating comprising the structural material mentioned above. the coating does not run through the substrate during the manufacturing process of the mat The structural material of the present invention is prepared by using a binder component, for example a high performance heat reactive acrylic latex polymer and / or a non-thermally reactive styrene-butadiene latex to bond the materials of filling together. When the structural material is used to coat a substrate, the binder component also acts for the non-limiting filling of the filler component including Rhoplex -s- fe © ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾. 3349 (available from Rohm and Haas, Philadelphia, PA), Revene 4402 (Mailard Creek Poiymers, Inc., Akron, OH), Hycar (registered trademark) 26469, Hycar (registered trademark) 26472, Hycar (registered trademark) 26484, Hycar (registered trademark) 26497, Hycar (registered trademark) 264552, Hycar (registered trademark) 264512, Hycar (registered trademark) 264582, Hycar (registered trademark) 26083 (formaldehyde low), Hycar (registered trademark) 9201 (formaldehyde low), Hycar (registered trademark) 1552 (nitrile), Hycar (registered trademark) 1571 (nitrile, Vycar (registered trademark) 552, Hycar (registered trademark) 2679 acrylic latex polymer (all products Hycar (registered trademark) and Vycar (registered trademark) are supplied by BF Goodrich Company of Cleveland, Oh io) The binder components can also include Cymel (registered trademark) 373 (available from American Cyanamid), RHOPLEX (registered trademark) TR 407 and R &H GL-618 latex available from Rohm & Haas, and Borden resin FG-413F UF (available from Borden). It is believed, however, that any linear polymer, linear copoiimer, or branched polymer can be useful for preparing the coating such as those available from BASF and Goodyear. Additional possible binder materials include butyl rubber latex, SBR latex, neoprene latex, polyvinyl alcohol emulsion, SB ~ lathe, enursToirec and water-based polyurethane foam, vinyl chloride copolymers, nitrile rubbers, as well as polyvinyl acetate copolymers. In one preferred embodiment an SBR is used. An SBR latex adds good smoothness characteristics but is not a flame retardant agent. To improve fire resistance, an acrylic latex can be added or replaced. The greater the amount of acrylic latex, the better the resistance of the material to fire. However, the softness decreases as a SBR latex is replaced. In a particularly preferred embodiment, the binder component comprises Rhoplex 3349 and Rovene 4402. The surfactant component of the present invention can be any surfactant capable of forming microcells during the manufacturing process of the structural material. In a preferred embodiment, the surfactant component capable of forming microcells during the material processing process comprises a fast soap, such as, for example, ammonium lauryl sulfate (ALS), (e.g., Stepanol AM; Stepan Chemicals, Northfield, IL) and sodium lauryl sulfate (SLS). In general, a "fast soap" is a soap that can efficiently modify the surface tension of a solvent, such as water, but other surfactants can also be used, which are not characterized as fast soaps but are capable of To form microcells, fast soaps as for example b__AXS f "CTmaTi ~ mtrrocel: da-s-qtare are resilient and generally stable in the heat of processing. Microcells generated by surfactant are generally not stable at temperatures above 17 ° C (350 ° F). Additional components can be added to additionally stabilize the microcells as further discussed below. However, if desired, a surfactant that forms "weak" microcells can be used. LiSS micro "smart" cells can scan during processing to produce a less flexible fire resistant material. The gel catalyst component of the present invention can be any component known in the art which can catalyze gel formation. In a preferred embodiment, the gel catalyst is SSF-GEL available from Parachem (Dalton, GA). In addition, other catalysts can be added to prorover the vulcanization to provide permanent crosslinking and to heat-harden the material which can increase the strength of the microcell structure generated by surfactant. In a preferred embodiment of the present invention, ??? - 750 (a sulfur catalyst available in Tiarco, Dalton, GA) is used as a catalyst. In addition, On ocure®-590, Octocure®-456 and Octocure®-462 (available in Tiarco, Dalton, GA) can also be used for this purpose. ET "appointment zadór ~ de ^ gel- uede- cai_Hlrza-r- ta- training- degenerate very fast.In order to control the catalyst-gel formation, very small amounts of catalyst-gel can It can be added, for example, by diluting the gel catalyst and adding a small volume of dilute gel catalyst, since gel formation can occur very quickly when the gel catalyst is added, the binder component and the surfactant component can be mixed. together first and then the microcells generated by surfactants can be introduced to this mixture through any method known in the art such as by using a foam former, then the gel catalyst can be added in order to ensure that The formation of gel does not occur before the formation of microcells generated by surfactants.As observed, microcells generated by surfactants can be created per any technique known in the art such as, for example, not limited to this example, by blowing air into the mixture, stirring or through a foam former. Microcells generated by surfactant can also be introduced using chemical blowing agents such as, for example, azo compounds
In one embodiment of the invention, binder / surfactant is sornetide-a "foam-forming", The former acts to inject air into the mixture in such a manner that the surfactant forms microcells within the mixture. The foamer may comprise a tube-like component having several bolts that can rotate in opposite directions (for example, some bolts move in a clockwise direction and others move in the opposite direction). The mixture of binder and surfactant is added to the foam former through a port on one side and, as it passes through the foam former, the pins rotate causing the introduction of air and the creation of microcells generated by surfactant. The additional air can also be introduced into the foam former in another port to further increase the formation of microcells generated by surfactant. After the generation of microcells by surfactant, the gel catalyst can be added through a port of the foam former. The mixture can then be sprayed onto a substrate, eg a fiberglass mat. Alternatively, if no substrate is desired, the mixture can be spread on receiving platform, such as a steel tray to form a separate sheet. To be applied on a substrate or on a receiving platform, the material is then subjected to heat in an oven. The temperatures of ~~-eRfer-e-about 138 ° C (28 ° F) and about IH "(350 ° F) The heat of the processing further increases the formation of gei causing the reaction to occur at a faster rate In a preferred embodiment, the microcells generated by surfactant exhibit stability to the processing heat.As observed, microcells per surfactant are generally not stable at temperatures greater than 177 ° C \ vc F.} Fig. 1 shows microcells generated by surfactant for one embodiment of the invention In this embodiment, no filler component is added Figure 2 shows the formation of microcells generated by surfactant in another example embodiment of the present invention wherein a component has been included The filler is added to the mixture together with the surfactant and the binder and before the addition of the gel catalyst, as shown in Figures 1 and 3. Icel cells generated by surfactant are relatively small and have uniform sizes. In another embodiment, the structural material also includes a surfactant capable of regulating the formation of microcells generated by surfactant which is added before the addition of the gel catalyst. A surfactant of this type is Stanfex 3? N (Parac. Em, Dalton, GA) The surfactant capable of regulating the formation of microcells generated by surfactant can assure that the microcells ermari¾ ^ caTir- ^ efttr-o-de-uiv range of preferred sizes (for example, do not grow too much) and are formed in a relatively monodispersed state ie they are of the same general size). In a preferred embodiment, the microcells generated by surfactant are approximately 5.μμ to approximately 20μμ in diameter. In addition, citric acid can be used to ensure that the microcells generated by surfactant spread uniformly. It may also be desirable for fire-resistant materials to include a dispersing agent that acts to maintain the mixture comprising the binder, surfactant and well-dispersed gel catalyst during the material-making process. Examples of such dispersing agents include, inter alia, TSPP, Accum 9300, Achura 9400 and Accum 9000 (all available from Rohm &Haas). The fire resistant fabric materials of the. present invention are flexible, pliable and have good characteristics for upholstery. In addition, they are durable and preferably do not crack when bent. The durability of the fire resistant material can be increased by adding components capable of stabilizing the microcells generated by surfactants. Such components include surfactants such as ammonium stearate (Parachem, Dalton, GA), octosol A18 (Tiarco Chemicals, Dalton, GA), - T ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^; i-ieo--T-iar-eo Chemicals), 449 (potassium oleate, Tiarco Chemicals), - and Stanfex 320. The microcell generated by surfactant can be stabilized by making the wall of the microcell become thicker. A surfactant comprising a long waxy chain may be particularly useful for stabilizing microcells. The structural material may further include a crosslinking component, such as, for example, meiamine (Borden Chemicals, Morganton, NC), and / or ammonium chloride. The crosslinking component is useful for improving the durability and structural strength of the microcells generated by surfactant. In order to control the amount and rate of crosslinking, it may be desirable to control the pH of the mixed components. For example, under acid conditions (pH ~ 4.0), the crosslinking will occur very quickly and the mixture will have a short pot life. At a higher pH (~10.0), the crosslinking will be slower and can be thermally controlled. The crosslinking component can increase the rate at which gel formation occurs and allow gel formation to occur at a lower temperature. In addition, the crosslinking component can improve the strength of the material. The structural material of the present invention may also comprise a resin that can provide a polymer shell for the joints of the resin-DP-38, available in Daiton's Parachem. , GA. The structural materials of the present invention have "reb characteristics due to gel formation In one embodiment, the "bounce" characteristics can be further increased through the use of additional components. Here, the term "rebound" refers to the ability of material to return to its original shape after being distorted, such as stretched or compressed, additional components can be applied on the inside of the microcell in such a way that the microcell returns to its original shape after being distorted Preferred components useful for achieving rebound characteristics include CT101 (silicon oil; Kelmar Industries, Duncan, SC), Freepel 1225 (BF Goodrich, Cleveland, OH), Sequapel 409 (Omnovasolutions, Chester, SC), Michem 41740 emulsion (available from Michelman Inc., of Cincinnati, OH), Svloff-1171A (available from Dow Corning Co rp., from Midland, MI), Syloff-62 (Dow Corning), Syloff-7910 (Dow Corning) and Aurapel 391 (available from Sybron / Tanatex, Norwich Connecticut). These components also ensure that the microcells do not aggregate or form microcell clots. As noted, the structural materials of the present invention comprising a binder component, a gel may further comprise a filling component !. The filler component of the present invention preferably includes clay. The clay is preferably Chinese clay that is very soft and light. In addition, the clay can be Paragon (registered trademark); which is a soft clay (that is, soft to the touch), Suprex (registered trademark), which is a hard clay (that is, hard to the touch), Suprex (registered trademark) clay treated with amino cilane that is used for crosslinking put which binds chemically with binder, and for high load, Ballclay (registered trademark), which has elastic properties (i.e., has a rubber-like appearance), Texwhite 185 (available from Huber, Dry Branch, GA), and ECC 1201 (available in Huber). All clay products mentioned above, unless otherwise indicated, are available, for example, from the Kentucky-Tennese Clay Company of Langley, SC. In one embodiment, clay is Ball caly (registered trademark) 3380, especially economical compared to other clays. In a preferred embodiment, the clay is Kaolin clay which is a lower grade Chinese clay. In particularly preferred embodiments, the clay is Texwhite 185 and / or ECC 1201. In the present invention, clay is a preferred filler because of its elongation properties. { it has a low modulus), its resistance is-1a¾T: "as ^ ÓTT, su-reeis er.eia-a-la ptur V 5 IGSi t uCi 3 3. t USi.Cem e S, the Cilla is a good barrier against the heat; does not disintegrate when an open flame is directly applied (temperature = 815 ° C (= 1500 ° F)) directly onto a coating of the present invention that includes clay. In addition, the clay offers a glassy, elastic, smooth surface that exhibits good flexibility, furthermore, as indicated, the clay is economical and can therefore provide an inexterial cloth at a low cost. The filler material may alternatively or additionally comprise a filler selected from the group consisting of decabromodiphenyl oxide, antimony trioxide, calcium carbonate, charged calcium carbonate, titanium dioxide, flying clay (as for example Alsil 04TR (registered trademark). ) class F, flying clay produced by JTM industries, Inc. of Martin Lake and Jewett, Texas that has a tai particle size that less than 0.03% remains in a stirred mesh of 0.254 centimeters x 0.254 centimeters (0.1 inch X 0.1 inch) , mica 3-X mineralite (available from Engelhard, Inc. of Louisville, KY) and glass or ceramic microspheres (glass microspheres are 2.5 times lighter than ceramic microspheres and also provide fire resistance), or any mixture of these filler materials to meet the criteria ~ d "eséactos ~ de C? ^ ?? _ y- HS? -.-- íi; r|oes · -¾ - ^ aß - de-vi4 & ^ - ^ de ceramics are fa manufactured by eeian Industries of 3M Center Bldg., 220-8E-04, St.Paul, MN 55144-1000. Calcium salt can be obtained from Franklin Industrial Minerals at 612 Tenth Avenue North, Nashville, TN 37203. Calcium carbonate, talc and filler of flying clay increase the weight of the product but the use of glass microspheres and / or ceramic allows the manufacture of a product with reduced weight and increased properties of fire resistance. Clay can provide the product with the following non-limiting characteristics :( 1) less heat buildup., (2) heat reflection properties, (3) flame barrier properties, (4) no weight loss when exposed to heat and to an open flame, and (5) reduced disintegration when exposed to heat and open flame. Decabromodiphenyl oxide and antimony trioxide provide the following non-limiting characteristics: (1) flame retardant properties, (2) ability to form a combustion, (3) ability to stop the diffusion of flames. It is believed that the gas produced from the heating of the decabromodiphenyl oxide can also act as a flame retardant agent since the gas consumes oxygen or depletes the oxygen in the next layer of the fabric and consequently suppresses or stops the further advancement of the oxygen. fire. Glass microspheres ~ Y ~ ^ e ~ < ^ rs ^^^ Tied ^ n-r ^ s ± sti.T- < ^ a ^ ^ &s-superior to 1093"C (2Ü0Ü" F). Likewise, glass and ceramic microspheres increase the resistance to compression, do not absorb latex and / or water and consequently allow a faster drying of the product. Micro glass and ceramic spheres also provide the product with greater flexibility. In addition, the glass and ceramic microspheres help increase the life of the coating canister. Heavier particles in the fillers, even though they may comprise only a small percentage of the particles in the filler, tend to settle near the bottom of a storage container. When glass and / or ceramic microspheres are mixed together with another filler, a dispersion is produced having an increased can life or increased shelf life. Unwanted has been limited to any particular theory, it is believed that as the rip fillers fall naturally into the vessel and the glass and ceramic microspheres rise, the smaller size filler particles are supported by the glass microspheres and / or ceramics, thus allowing the microspheres to remain in solution avoiding crue the particles of ll n do ^ "aj hss ^ ~ ° ^ - 'fnniin of the rec ip i ng .- nn ~ ln mpn sh ^ sta ri prt "n niinro. The substrate of the present invention can be any suitable reinforcing material capable of resisting processing temperatures., for example glass fibers, polyester fibers, cellulose fibers, asbestos, steel fibers, alumina fibers, ceramic pounds, nylon fibers, graphite fibers, wool fibers, boron fibers, carbon fibers, fibers of jute, polyolefin fibers, polystyrene fibers, acrylic fibers, phenol formaldehyde resin fibers Of aromatic polyamide fibers and a11 i 1ica3, fibers e ?? lacriiaitiide, polyacrylimide pounds, or mixtures thereof which may include two-component fibers. Examples of substrates in accordance with the present invention include, inter alia, glass, fiberglass, ceramics, graphite (carbon), PBI (polybenzimidazole), PTFE, polyaramides, for example KE7LAR (registered trademark) and NOMEX (registered trademark), metals including metallic wire or metal mesh, polyolefins, for example TYVEK (registered trademark), polyesters eg DACRON (registered trademark) or REEMAY (registered trademark), polyamides, polides, thermoplastics such as KYNAR (registered trademark) and TEFZEL (registered trademark), poiiéter suifonas, polyether imide, polyether ketones, novoloid phenolic fibers, for example KYNOL (registered trademark), KoSa polyester fibers (registered trademark), JM-Í37 M glass fibers, Owens-Corning M glass, fibers of Owens-Corning K glass, Owens-Corning H glass fibers, microfiber from "-" Nidrio Evan te 4i3Mr iuit_. of glass fibers EvaiiiLe 719, cellulose fibers, cotton, asbestos and other natural fibers as well as synthetic fibers. The suture may comprise hile, ril me monofi lamento or other fiber material either as such or assembled in the form of a textile, or any woven, nonwoven, knitted, mat, felt, etc. material. The polyolefin can be polyvinyl alcohol, polyphenylene, polyethylene, cyclohex. Olivinyl, polyurethane, etc., alone or in combination with each other. The acrylics can be DYNEL, ACRILAN and / or ORLON. RHOPLEX AC-22 and RHOPLEX AC-507 are acrylic resins sold by Rohm and Haas that can also be used. The cellulose fibers can be natural cellulose such as wood pulp, newsprint, Kraft pulp and cotton and / or chemically processed cellulose such as rayon and / or lyocell. Non-limiting examples of non-woven materials which may be useful within the scope of the present invention include glass fiber webs, continuous, non-woven, for example Firmat registered trademark 100, trademark registered Pearlveil 110, trademark registered Pearlveii 210, trademark Curveii 120, Curveil trademark 220, Flexiveil trademark 130, Flexiveil trademark 230 and Pultrudable veil (all available from Schmeizer Industries, Inc., Somerset, OH). The
ITiñ tT? ? ? ? tc j icioS p L! T Cl T G1 G? JT .A.1? 13. i d G? 3. JT C 3. J7 G CJ l S t L ~ ci a t Spunbond ñaTrca ~ registered-trademark (available from BFG Industries, Inc. of Greensboro, NC). Non-limiting examples of filament materials include D, E, B, C, DE, G, H, K filaments of various grades, including electrical grade, chemical grade and high strength grade (all available BFG Industries, Inc. of Greensboro, NC). In a preferred embodiment, the substrate is a woven glass fiber mat. As used herein, a fiberglass mat includes non-woven and woven fiberglass mats. In a particularly preferred embodiment, the substrate of the present invention is a woven glass fiber mat such as style 1625, style 1091 and style 1614 from BFG Industries (Greensboro, NC). The use of the structural materials of the present invention for the manufacture of fabrics for use in articles such as mattresses, cots, upholstery and upholstered furniture, may allow the article to exceed the current standards of flame resistance for these types of articles. . While the flame resistance standards for mattresses do not. have been specifically established by federal or state governments, some government agencies have provided recommended guidelines. For example, the North American Department of Commerce, Gaithersburg, Maryland has published a document related to a methodology to evaluate the flammability of mattresses. See T.J. Ohlemiller et al., Flammability Assessment Methodology for Mattresses, NISTIR 6497, June 2000. While no clear standard is given, it is recommended that a mattress can withstand the described testing procedures. NIST has observed that beds pose a major fire hazard problem. It offers a series of tests to determine the flammability of mattresses. In addition, the Consumer Affairs Department of the State of California, Office of Home Furnishings and Thermal Insulation ("the Office") issued a Technical Bulletin in October 1992 that offers a flammability test procedure for mattresses. See State of California Department of Consumer Affairs Bureau of Home Furnishings and Thermal Insulation Technical Builetin 129, October 1992, Flammability Test Procedure for Mattresses for use in Public Buildings (California TB129). The technical bulletin offers standard methods for testing mattresses in terms of fire resistance. The methods produce data that describe the combustion behavior from the ignition of a mattress to the suspension of its combustion, or after a period of 1 hour. The cd'ur release regime is measured through a "Tc" oxygen consumption technique. The Office indicates that mattresses that comply with the test method will be safer and expects manufacturers to try to manufacture mattresses that will pass the recommended tests. The Office indicates that "a mattress does not meet the requirements of the test if any of the following criteria is exceeded:" (1) a maximum heat release rate of lOOk or more, (2) a total heat release of 25 MJ or more in the first 10 minutes, (3) a weight loss of 1362 grams (3 pounds) or more within the first 10 minutes due to combustion. A mattress made of a fire resistant fabric material of the present invention meets or exceeds the test standards recommended by both NIST and California TB129. In accordance with the foregoing, the fire-resistant fabric material of the present invention is useful in the manufacture of mattresses. In this embodiment of the invention, the fire-resistant fabric material can be used to line a mattress fabric for decoration purposes in order to produce a fire-resistant mattress fabric. Non-limiting examples of mattress fabrics include sheath (the technique is known as a tightly woven fabric, strong that includes cotton or linen and is especially used to form cushion or mattress covers), or group consisting of cotton, polyester, rayon, polypropylene, and combinations thereof. The liner can be achieved by methods known in the art. For example, the fire-resistant fabric material of the present invention can be simply placed under the mattress fabric. Alternatively, the fire-resistant mattress material can be bonded or bonded to the mattress fabric, for example, using a flexible and preferably non-flammable glue or fixed with stitches with fire-resistant yarn, similar to a liner. The fire-resistant mattress fabric of the present invention can then be used by the person skilled in the art to make a mattress having better flame resistance characteristics. The mattresses of the present invention comprising the fire-resistant fabric material may comprise several layers, including, but not limited to, these at least one first layer comprising a layer of fabric (for example the mattress fabrics discussed above) , at least one layer comprising the fire resistant fabric material of the present invention (which may for example be a second layer or a third layer) or at least one cushion layer, a layer of polyurethane foam, a The nonwoven sheet forming layer, and a layer comprising fire resistant of the present invention in accordance with that indicated above, comprises a substrate and a coating. In one embodiment, fire resistant Lela material is coated on one side and the side with the coating faces the first layer. However, as indicated above, the fire resistant fabric material can be coated on both sides. In a particular embodiment of the invention, the mattress comprises at least a first layer comprising a mattress fabric and at least a second layer adjacent to the first layer and comprising the fire resistant fabric material of the present invention. invention. The fabric of the first layer may be the mattress fabric discussed above as for example a cover, or a fabric comprising selected fibers within the group consisting essentially of cotton, polyester, rayon, polypropylene, and combinations thereof. The nonwoven sheet layer may be any suitable material known in the art. For example, the non-woven sheet layer can be made from any non-combustible fiber. In a preferred embodiment, the non-woven sheet layer is made of glass fibers. The mattress according to the present invention may further comprise at least a third layer adjacent to the second layer and wherein each of the third layer and the fourth layer is a cushion layer and at least one fifth layer adjacent to the fourth layer and comprising polyurethane foam. The cushion layer may be made of polyester fibers or any fiber known in the art as being suitable for making a layer that provides cushioning. The polyurethane foam can be of variable thickness. In addition, the mattress of the present invention can comprise at least a sixth layer adjacent to the fifth layer and comprises a fire-resistant fabric material. Figure 3 shows an exemplary mattress in accordance with the present invention. In one embodiment of the invention, the polyurethane foam can be the second layer of the mattress (i.e., under the sheath and instead of the polyester fiber). The polyurethane foam layer provides a superior cushioning effect. However, the total weight of the polyester foam layer together with the sheath must be less than 1362 grams (3 pounds) since the polyester foam and sheath are burned and the mattress will not be able to pass the combustion test if the They lose more than 1362 grams (3 pounds). In one embodiment of this type the preferred thickness for the foam is approximately 6. A millimeters (0.25 inch). The mattress according to the present invention may further comprise a fire resistant edge. In a first layer that includes a mattress fabric; and a second layer adjacent to the first layer and comprising the fire resistant fabric material of the present invention. In addition, the edge may comprise a third layer adjacent to the second layer and comprising a polyurethane foam. The edge may also comprise a fourth layer, adjacent to the third layer and comprising a non-woven sheet. Alternatively, the edge may comprise a fourth layer adjacent to the third layer, and comprising the fire resistant fabric material of the present invention and a fifth layer, adjacent to the fourth layer and comprising a nonwoven sheet. In another embodiment of the present invention, the mattress comprises at least a first layer comprising a mattress fabric, and at least a second layer, adjacent to the first layer, and comprising the fire-resistant fabric material of the mattress. present invention, at least a third layer adjacent to the second layer, and comprising a polyurethane foam, and at least a fourth layer adjacent to the third layer, and comprising a non-woven sheet, at least a fifth layer adjacent to the fourth layer and comprising another fibrous pillow. All the abovementioned modes of the mattress of the present invention passed all fire tests, ^ u laG cj.á.r C *. p ezen, ex. The invention comprises at least one first layer comprising a mattress fabric, at least a second layer adjacent to the first layer wherein the second layer is a cushion layer, and at least a third layer adjacent to the second layer and comprising the fire resistant fabric material of the present invention The mattress may further comprise at least a fourth layer adjacent to the third layer and wherein a fourth layer is a mattress layer, at least a fifth layer adjacent to the fourth layer, and comprising a polyurethane foam, and at least a sixth layer, adjacent to the fifth layer, and e comprises a non-woven sheet. The mattress layer can be made of any fiber known in the art suitable for manufacturing a mattress In a preferred embodiment, the mattress layer comprises polyester fiber In a particularly preferred embodiment, from a comfort perspective but not from a perspective of fire resistance, the second layer is a layer of polyester fiber of 56 grams (2 ounces). In accordance with that indicated above for certain embodiments of the mattresses of the present invention, the coating of the fire-resistant fabric material faces the first layer. As used herein, "copes with the first layer" means that the resistant cloth material was Li ent; a j- e t i¿ iui ei "uO ~? ~? p? TJ ~ ~ amb" the o ~ 3-; - S-i - &lining is on one side, this side faces the first layer, with the uncoated side facing away from the first layer. In addition, the numbers of the layers is an indication of the order of the layers. For example, if the mattress fabric is the first layer, this layer will be the upper part of the mattress, with the second layer 100 being adjacent to the first layer, the third layer being adjacent the second layer, etc. In addition to the layers described above, the mattresses of the present invention may comprise other layers that may comprise one or more fibrous pillow layers and / or a spring layer. The mattresses can also comprise a board such as the board described above. Such additional materials that may be incorporated in the mattress of the present invention include building materials such as fire retardant or non-flame retardant yarn for cooking the mattress materials together (eg, glass yarn or Kevlar yarn) as well as fire retardant tape or not. fire retardant. Silicon can be used with Kevlar yarn in order to reduce the rupture and improve the production time. In a particularly preferred embodiment of the present invention, a conventional tape and / or a conventional wire can be used and the mattress still meets the test requirements TB129 The fire resistant materials of the present invention can be used to produce materials with similar characteristics to foam and cushion layers that are used in mattresses and can replace or be added to these layers. In such an embodiment, the foam and cushion layers made of the fire resistant materials of the present invention provide fire resistance to the mattress when used there. Table I below provides, in approximate percentages, the components of the coating that applicants have used in a preferred embodiment of structural material of the invention. Even though the table shows possible combinations of binder, filler and surfactant, it is believed that other combinations may be employed. TABLE I Components of 1 coating AGLOMERANTE Rovene 4402 36.25 26.73 18.71 18.71 Rhoplex 3349 36.25 26.73 18.71 18.71 SURFACTANT Stanfax 320 4.5 3.32 2.30 2.30 FILLER JT fly ash Calcium carbonate Z-light microspheres 30.0 GEL CATALYST SSL-GEL 13.0 13.0 11.7 11.7
MISCELLANEOUS TI02 FR-15 26.21 2b.21 2b.21
DPG-38 5.0 3.69 3.5 3.5 UP-70 5.0 3.69 3.5 3.5 TABLE I (Continued ...) onents of 5 6 7 8 Coating AGLOMERANTE Rovene 4402 18.71 18.71 36.25 36.25
Rhoplex 3349 18.71 18.71 36.25 36.25
SURFACTANT Stanfax 320 2.30 2.30 2.30 2.30
FILLER Clay JTM fly ash Calcium carbonate 30.0 Z-light microspheres 7.5 3.75
MISCELLANEOUS GEL CATALYST TI02 30.0 7.5
FR-15 26.27 26.27 26.27 26.27
DPG-38 3.5 3.5 3.5 3.5 TJP-70 3.5 3.5 3.5 3.5
The fire resistant fabric materials according to the aforementioned, includes a substrate and a coating rising the structural material of the present invention. The coating (structural material) rises about 34% by weight of the fire resistant fabric material. In the coating, from about 10% to about 55% by weight is binder, from about 2% to about 15% surfactant, from about 5% to about 20% gel catalyst, and from about 0% to about 55%. % by weight is filler. In a preferred embodiment, the coating rises about 42% binder, about 5% surfactant, and about 13% gel catalyst and about 30% filler. The filler is preferably about 30% clay. The substrate is preferably woven glass. The substrate can be, for example, a filament woven fabric DE, E, K or G available from BFG Industries. The substrate is approximately 64% by weight of the fire resistant fabric material. The binder that joins with the Cun las f Lü-cts > The above-mentioned 25% to about 55% Rhoplex 3349 and / or Rovene 4402, or any other suitable binder, non-limiting examples of suitable binders are provided above. by air spraying, dip coating, knife coating, roller coating or film application such as thermal lamination or pressing.The coating may be bonded to the substrate by chemical bonding, mechanical bonding and / or thermal bonding. Mechanical is achieved by the forced application of the coating on the substrate with a blade The structural materials and fire-resistant fabric materials made in accordance with this invention can have any shape Preferably, such articles are flat. used in any of several products, including but not limited to, mattress fabrics ón / cradle, mattress / crib covers, upholstered items, bedroom items, (including items for children's bedroom), upholstery, carpets, wall coverings (including wallpaper), tents, sheds, fire springs, awnings, sleeping bag, cover for ironing board, fire-resistant gloves, furniture, airplane seats, and rugs, clothing reSlSient "di i ueyu μa? ^ a COtt rix -Í: or C 3- -a¾ ÜÍ ^ SS d- 'and ~ already warplanes, firefighters, and the like, building materials such as for roofing, sheets of structural laminate type lining, air duct lining for buildings, roof felt, lower layer for roof coating materials organic, roofing material in rolls, products in modified rolls, filter media (including automotive filter), linings for vehicle chests, linings for the head, fire walls, vapor barriers, etc. The structural material can be used alone or it can be used as a lining for a decoration fabric, for in the case used in mattresses, upholstery, sleeping bags, tents, etc., which can also be fire resistant. In materials of fire resistant fabrics, the substrate can be coated on one side or on both sides according to the application contemplated. For example, if one side of the substrate is coated with the filler / binder coating, the other surface can be coated with another material. In the roofing industry, for example, the other material may be conventional asphalt for ceilings, modified asphalts and non-asphalt coatings, and the article may be coated with roofing granules. It is believed that said roof lining material will be more L «rrt -dl-t L. /" -ffy ^ Q «- >; , L ±. It will have fire and will have better performance characteristics, (for example flexibility in cold weather, dimensional stability and strength) than roofing materials of the prior art. The mixture comprising the binder, the surfactant and the filler may have a light foam consistency, such as shaving cream. It is believed that due to the low density of the mixture, the microceeds do not pass through the substrate when applied to it. If desired, however, the viscosity of the coating can be increased through mixing to ensure that it does not run through the substrate. Non-limiting examples of thickening agents include Acrysol ASE-95NP, Acrysol ASE-60, Acrysol ASE-1000, Rhoplex ASE-75, Rhoplex ASE-108NP, and Rhoplex E-1961, all available from Rohm & Haas. In addition, the fire resistant material can be coated with fire resistant material can be coated with a water repellent material or the water repellent material can be added in the coating, (ie, internal waterproofing). Two water-repellent materials of this type are Aurapei trademark 330R and Aurapei trademark 391 available from Sybron / Tanatex of Norwich, Connecticut. In addition, Omnova Sequapel registered trademark and Sequapel 417 (available from Omnovasolutions, Wacker de Adrián, MI); Syl-off trademark-7922, Syl-off trademark-i'171A, Syl-off trademark-7910 and Dow Corning 346 Emulsion (available from Dow Corning, Corporation of Midland, MI); Freepel Registered Trademark - 1225 (available 5 from BFG Industries of Charlotte, NC); and Michem trademark Emulsion-41740 and Michem trademark Emulsion-03230 (available from Michelman, Inc. of Cincinnati, OH) may also be employed. It is believed that wax emulsions, oil emulsions, silicone emulsions, polyolefin emulsions, and sulfonyls as well as other sigillary performance products can be suitable water repellent materials. As indicated above these materials are also useful in providing rebound characteristics to the fire resistant materials of the present invention. The water repellents can be particularly preferred, for example, in the manufacture of mattresses for cradles, for aircraft seats and in the case of the manufacture of furniture, especially for industrial use. A foam remover can also be added to the coating of the present invention to reduce and / or eliminate foam formation during production. A remevedo of foam of this type is Y-250 available from Drcws Industrial Division of Boston, NJ. Pyro-retardant materials can also be added to
¿.5 lO R e eriating P uca l i l i i i i i i i I i I i I i I i I i I i I I I I I lii t; x ± T¡ dL 5 further improve fire resistance characteristics. Non-limiting examples of pyro-retardant materials that can be used in accordance with the present invention include FRD-004 (decarbromodiphenyl oxide, Tiarco 5 Chemicals, Dalton, GA), FRD-01, FR-10, FR-11, FR-12 , FR-13, FR-14 (all available in Tiarco Chemicals), zinc oxide, and aluminum trihydrate (ATH). In addition, color pigments, including, but not limited to, T-113 (Abco, Inc.), Pigment Blue W-4123, Pigment 0 Orange W2090, Pigment Black W7717 and Pigment Green W6013, red pigments of iron oxide ( available in Engelhard of Louisville, KY) can also be added to the coating of the present invention to provide desired characteristics, for example, the desired color. 5 Additional coatings of, for example, water repellent material, anti-fungal material, antibacterial material, etc., may be applied on one side or on both sides of fire resistant materials and fire resistant fabric materials. For example, materials of fire-resistant fabrics comprising substrates coated on one side or on both sides with a filler / binder coating could be applied on one side to a water-repellent composition and on the other side with an antibacterial agent. Alternatively, the antibacterial material, etc., may be added to the coating prior to its use to coat the substrate. EXAMPLE Example 1: Fire resistant fabric material To produce the structural materials of the present invention, the applicant formulated the coating using only four major components, water, gel catalyst, surfactant and binder. In an additional mode, filler was also added (see Table I above). The components were mixed in a reaction pot or in a mixing pot for 30 minutes at a temperature of 18-35 ° C (65-95 ° F). The coating was used to coat a fiberglass mat on one side or on both sides. The mat was manufactured by BFG Industries, Inc. of Greensboro, North Carolina and was style number 1625 and presented a basis weight within a range of 0.817 kg / square (1.80 pounds / square) to 0.863 kg / square (1.90 pounds / square). The mat presented a porosity within a range of 182.91 to 198.15 m "7minute / irr (600 to 650 cfm / square foot) .The coated article was durable and flexible and did not show cracks when bending and presented" bounce "characteristics. Typical tensile strengths for coated material versus uncoated material were 21,338 kilograms / 7.6 - -. j / / \ TI n? -.__ · ·; / centimeters (171 pounds / 3"), respectively. Typical resistance measurements at the Elmendorff rupture were > 3400 grams without rupture of the sample. The fire resistant cloth material was checked to determine its combustion capacity. When exposed to the flame of a Bunsen burner at a distance of 51 millimeters (two inches), the woven cloth and the wet-applied fabric failed the fire test (ie, the fiberglass was melted or created a hole in the place in
1 0 where the flame came into contact with the fabric). However, when a pyro-resistant fabric material of the above invention was exposed to the flame of a Bunsen burner at a distance of 51 millimeters (two inches) for a period of five minutes or more, no holes were created and
1 5 the glass fibers did not melt. The coating protected the glass cloth with melting or disintegration and the integrity of the structure of the glass cloth was maintained. In addition, when cotton was placed on top of the fire resistant cloth material of such
In such a way that the fire-resistant cloth material was between the Bunsen burner and the cotton, the cotton was also protected against the flame of the Bunsen burner. Technical Bulletin 129 of the Department of Consumer Affairs of the State of California, Office of Furniture
~~? ~ and BúiuerS L i Cúá and Ai or J. aftri cli o - r- &irífri- € Ej -G ?? t ???? ? - - < = t; - 1-5-3-S-) i'id -acre "a cloth should maintain its integrity when exposed to an open flame for 20 minutes and this test was approved in the laboratory with the fire-resistant cloth material of this invention and the mattresses of the present invention comprising the fire resistant fabric material The invention offers a fire resistant fabric material which is flexible, foldable, and has a good upholstery characteristic and does not exhibit cracking, etc. The material Fire resistant fabric has a porosity of less than 5.49 mVminute / m (18 cfm) (uncoated has a porosity of 134.13 m3 / minute / m2 (440 cfm)) and can adhere very well to other materials, including decorative fabrics, foam of polyurethane, isocyanurate foam, asphalt compounds, and granules (composed of non-asphaltic tiles) The fire-resistant fabric material may have some needle punctures or may have numerous perforations needlework and still maintain a porosity of less than about 0.14 nVVminute to about 1.4 m3 / minute (about 5 to about 50 cfm) when coated with solvent-based adhesive such as, for example, Firestone Bonding Adhesive BA-2004 gue nc r "^ -r »-or through the coated product. The components listed in Table I, with the exception of
UdLdiiZdUUL t: y'e i /? '?? ? YES ~ Z "C" .L i AO j mi Lw o y l ~ a "me i i a f ~ ut;
added to a foam former. Subsequently, through a port in the foam former, the gel catalyst was then added. The entire mixture containing the gel catalyst was then spread on a substrate. 5 The application of the coating on the substrate was achieved through knife coating. In addition, the coating can also be effected by foaming and knife application, foaming and knife coating, foaming and knife coating, pressure, dip coating, roller application (tightening between two rolls having a space that determines the thickness of the coating), by means of a manual applicator that can be obtained in the Gardner Company, spraying, immersion and flow coating of aqueous dispersion or solvent, calendering, rolling and the like, followed by drying and baking, can be used for coating the substrate as is known in the art. After coating, the samples were placed in an oven at a temperature of about 325 ° F for about 2.0 minutes to achieve gel formation, drying and curing. In addition, the coating can be formed separately as a film in one or several layers for subsequent combination with the substrate. Even though the present invention has been described with the following modifications, alterations and substitutions will be apparent to the persons with know-how in the field without departing from the spirit and scope of the invention, as defined in the appended claims.For example, other sources of filler, as well as mixtures of acrylic latex and / or surfactants can be used in the formulation of materials In addition, the coating compositions can be applied to various types of substrates, in accordance with what is described above.