Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
2000-07-13
2003-02-18
Szekely, Peter (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C523S205000, C523S206000, C523S207000, C523S210000, C524S100000, C524S720000, C524S802000, C162S012000, C162S072000, C162S159000, C162S168100, C442S147000, C442S154000, C442S281000, C428S921000, C525S329900
Reexamination Certificate
active
06521682
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a flame-resistant agent for the treatment of non-woven fabrics, a procedure for its preparation and the non-woven fabrics made fireproof as a result of treatment with the flame-resistant agent.
2. Description of Prior Art
Microfiber non-woven fabrics are known in the art, for instance, the type produced by ALCANTARA S.p.A. Products of this type are also described in Italian patents 823,055; 839,921; 858,373; 873,699; 905,222; 921,871 and in U.S. Pat. Nos. 3,531,368 and 3,899,623.
For numerous final applications, for instance furnishing, and in some markets for almost all uses, the microfiber fabrics must conform to precise flame resistance requirements.
There are essentially three procedures known for endowing microfiber fabrics with the required flame-resistant characteristics. According to a first procedure, known as padding, the fabric is subjected to impregnation in a bath containing flame-resistant additives and subsequently dried. This process has the disadvantage of giving a “buffed suede” finish that has worse hand and softness characteristics than the original non-flame-resistant product. Furthermore, this treatment is not permanent.
A second method known as “back side” coating provides for the application of a paste containing flame-retarding compounds (such as halogens, antimony and phosphorus) to the “back” side of the synthetic non-woven fabric. This method does not have the disadvantage of padding in as much as the “front” side of the fabric is not affected by the treatment, but given the large quantity of flame-retarding compounds required to confer the desired effect, the treated product presents a “harder” hand and is therefore less drapable than the non-treated product.
A third method is to form a non-woven fabric compound of intrinsically flame-retardant microfiber polymer (e.g. PET) and a polyurethane solution, which alone or with antimony oxide and deca-bromo-diphenyl oxide additives, impregnates the substrate. Although guaranteeing flame resistance, the combined use of intrinsically fireproof microfiber polymers and additives (in varying proportion to the polyurethane) reflects negatively on the visual appearance (short nap, specking), the drapery (hard hand), and the dyeing characteristics (tone), even though the physical-mechanical performance remains within the required range.
Accordingly, there is a need for a flame-resistant additive for microfiber non-woven fabrics of the synthetic leather type that effectively makes such materials fireproof, without negatively affecting either the physical-mechanical characteristics or the aesthetic, hand or dyeing properties of the treated product.
In Italian Patent Application M197A001228, a microfiber non-woven fabric having a flame-retardant additive is described comprising a plurality of microfibers of a polymer material impregnated with a polyurethane matrix, containing trioxide of antimony and deca-bromo-diphenyl oxide, that achieves its fireproof activity by means of application on the “back” side of the fabric in such quantity and in such form as not to negatively influence the visual and hand characteristics of the treated material. This reference discloses a flame-resistant agent comprising antimony trioxide and deca-bromo-diphenyl oxide in a highly dispersed form and supported on a clay or other adsorbent material such as diatomaceous earth, zeolite, inorganic oxides such as alumina, silica, magnesium oxide or compounds of inorganic oxides. These additives and the products treated with said additives have entered commercial use and satisfy all the specific fireproof properties while maintaining the mechanical and aesthetic properties.
However, there is a tendency towards ever stricter regulations that could lead in the future to the imposition of severe limitations on the use of halogen compounds as components of fireproofing agents. The use of antimony derivatives could also be legally restricted in the future, with negative consequences for its wide use as a component of flame-resistant agents.
A possible alternative to the use of compounds containing bromine and antimony could be the use of phosphorus derivatives for the purpose of identifying compounds able to provide fireproof properties to materials impregnated with said compounds.
However, despite some phosphorus derivatives being known which show fireproof activity, compounds that simultaneously answer all the requirements established above, when applied to products of the artificial-leather type based substantially on microfiber non-woven fabrics are still not known.
Trials carried out on a large number of compounds containing phosphorus derivatives to determine their suitability as fireproofing agents for materials of the artificial-leather type constituted substantially of microfiber non-woven fabrics have shown that such additive products, while having good fireproofing characteristics, have evident aesthetic deficiencies. Another problem posed by the use of phosphorus derivatives as flame-resistant agents is that of identifying a binder that, on one hand, allows homogeneous distribution of the additive and yet prevents its separation from the treated product. The separation of the additive from the material treated is commonly called “powdering.” As far as properties related to the visual appearance of the product are concerned, it has been found that the application of these flame-resistant compounds imparted a damp or even wet appearance to the product.
Italian Patent Application M198A00192 discloses the use of a flame-resistant additive for non-woven fabrics consisting of a water-soluble compound of cyclical organic phosphonate complexes having a phosphorus content between 15% and 20%, and a water-soluble organic polymer. Such additive, while conferring excellent fireproofing characteristics on the products treated that remain even after repeated dry cleaning, showed the formation of stains on the fabric when the fabric was brought into contact with water.
Therefore the problem of making textile materials, in particular microfiber non-woven fabrics, fireproof in an effective and stable way without influencing the characteristics of the product substantially or negatively, has still not been completely resolved.
SUMMARY OF THE INVENTION
Therefore, it is one object of this invention to provide a flame-resistant additive for microfiber non-woven fabrics of the artificial-leather type that do not contain halogen compounds or other potentially harmful products and that impart good fireproof properties to the non-woven fabric without negatively affecting mechanical characteristics or softness to the touch and without modifying the external appearance even following repeated washings.
It is another object of this invention to provide a procedure for making microfiber non-woven fabric of the artificial-leather type fireproof using such a flame-resistant additive.
It is yet another object of this invention to provide a procedure for preparation of said flame-resistant agent.
It is yet another object of this invention to provide microfiber non-woven fabrics made fireproof by the aforementioned treatment.
These and other objects of this invention are addressed by a fireproofing additive for textile products and particularly for microfiber non-woven fabrics of the artificial-leather type comprising:
a) a fireproofing component comprising a finely divided compound of melamine and melamine cyanurate and a clay or other adsorbent material such as diatomaceous earth, zeolite, inorganic oxides such as alumina, silica, magnesium oxide or compounds of inorganic oxides and
b) a binder comprising an aqueous dispersion of an acrylic or maleic polymer or copolymer and a multi-functional cross-linker of the acrylic or maleic polymer or copolymer.
DESCRIPTION OF PREFERRED EMBODIMENTS
It is known that melamine and its derivatives constitute a class of materials which impart flame-resistant characteristics to polymer materials. However, these fireproof characteristics are generally co
Baroni Elisabetta
Bartolini Mario
Bartolini Paolo
Castagnoli Massimiliano
Cocci Mario
Alcantara S.p.A.
Pauley Petersen Kinne & Erickson
Szekely Peter
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