Flame-retardant fire-retardant layer film

Abstract

The utility model relates to the technical field of new materials, and discloses a flame-retardant fire-retardant laminated film, which structurally comprises a first layer, a second layer, a third layer and a fourth layer, the second layer is made of silicon dioxide cloth; the third layer is a second coating; the component of the fourth layer is an adhesive containing an inorganic filler; wherein the first coating layer and the second coating layer are formed by coating silicon dioxide cloth with a polyaromatic powder coating and sintering. A first layer of film and a second layer of film are replaced by the polyaromatic powder coating to achieve a barrier effect, so that the use of an adhesive is reduced, and the flame burning-through resistant coating layer (flame-retardant composite film) function of a final product is reserved; and the performances include the weight per unit area, the tensile property, the water absorption rate, the flame burnthrough resistance (fire retardance), the 12S vertical combustion performance (flame retardance) and the like, the process is simplified, and the cost is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of new materials, in particular to a flame retardant and fireproof layer film. Background Art

[0002] Aircraft fuselages are commonly insulated with thermal and acoustic insulation materials to reduce noise entering the cabin from outside and maintain a comfortable cabin temperature. Thermal and acoustic insulation materials can (i) create a barrier to prevent or reduce heat / flame transfer, and (ii) weaken external noise to ensure cabin and cockpit comfort and conversation volume is moderate.

[0003] The Federal Aviation Administration (FAA) of the United States has issued regulations that thermal and acoustic insulation materials used in commercial aircraft must be able to prevent burn-through and flame propagation. Currently, thermal and acoustic insulation materials, including the film and the core, must be tested in accordance with Federal Aviation Regulations No. FAR25.856(a) and (b).

[0004] In the past, fiberglass wool encapsulated in a plastic moisture-proof film performed both functions. The film was composed of polyester (PET), polyvinyl fluoride (PVF) and a small amount of polyimide. Although these materials are necessary to meet the vertical Bunsen burner test, some materials can also propagate flames under certain conditions.

[0005] To this end, the applicant applied for a Chinese invention patent (publication number: CN105593016A, publication date: 2016-05-18) to disclose a typical example of a flame retardant and fire-retardant laminated film comprising a glass layer, a first film, a second film and an adhesive. The glass layer may include a high-purity silica cloth. The first film and the second film need to meet the flame retardant requirements. The adhesive may include at least one inorganic filler to obtain the best fire retardant performance. The glass layer, the first film and the second film can be connected together by adhesive and heat lamination. The outer surface of the first film or the second film can be coated with adhesive for heat sealing. However, the process of the flame retardant and fire-retardant laminated film of this structure is relatively complicated, and the cost is relatively high compared to the utility model. Summary of the invention

[0006] The utility model aims at the deficiencies of the prior art and provides a flame retardant and fireproof layer film. The barrier effect is achieved by replacing the first and second layers of film with a polyaromatic powder coating, which reduces the use of adhesives, simplifies the process, and reduces costs. The flame retardant and fireproof laminated film of the utility model can be used in the thermal insulation and sound insulation system of commercial aircraft, or in other applications of flame retardancy and fireproofing required by current commercial aircraft. The flame retardant and fireproof laminated film can meet or even exceed the current Federal Aviation Administration's requirements and regulations on the flammability standards of thermal insulation / sound insulation materials for transport aircraft.

[0007] In order to achieve the above-mentioned purpose, the utility model adopts the following technical solutions:

[0008] A flame retardant and fire retardant film, the structure of which comprises:

[0009] The first layer, the composition is the first coating layer;

[0010] The second layer is composed of silica cloth;

[0011] The third layer, the composition is the second coating layer;

[0012] The fourth layer is composed of an adhesive containing an inorganic filler;

[0013] Wherein, the first coating layer and the second coating layer are formed by applying polyaromatic powder coating on silica cloth and sintering.

[0014] Preferably, the material of the first coating layer is selected from a series of materials: polyethersulfone; polyetheretherketone; polyaryletherketone; polysulfone; polyetherimide; polyetherketoneketone; polyphenylene sulfide; and polyarylsulfone.

[0015] Preferably, the material of the second coating layer is selected from a series of materials: polyethersulfone; polyetheretherketone; polyaryletherketone; polysulfone; polyetherimide; polyetherketoneketone; polyphenylene sulfide; and polyarylsulfone.

[0016] Preferably, the silica cloth is made by weaving high-purity silica roving according to the original structure of woven fabric, the density of warp and weft yarns is 15-30 strands / cm, and the silica roving is made of silica fibers bundled into many strands, and the linear mass density of each strand is between 10-25tex.

[0017] Preferably, the warp yarn and weft yarn are spaced 4-10 mm apart in the radial and weft directions and are replaced by reinforcing yarns instead of high-purity silica rovings; the reinforcing yarns are made of one of nylon, polyester, aramid, carbon fiber, high-strength polyethylene fiber, polyphenylene sulfide fiber, polyimide fiber, high-strength glass fiber, and high-purity silica roving with a linear density greater than 2 times.

[0018] Preferably, the inorganic filler is selected from antimony trioxide, mica, vermiculite, ceramic fiber, titanium dioxide, fumed silica and ultrafine silica fiber; the mesh size of the inorganic filler is between 100-600 meshes.

[0019] Preferably, the thickness of the first coating layer is between 5-15 um.

[0020] Preferably, the thickness of the second coating layer is between 5-15 um.

[0021] Preferably, the silica cloth has an area weight of 45-260 g / m2.

[0022] Preferably, the area weight of the adhesive layer is between 5 and 20 g / m2.

[0023] The utility model adopts the above-mentioned technical scheme, adopts polyaromatic powder coating to replace the first layer and the second layer of film to achieve the barrier effect, reduces the use of adhesives, and retains the flame-resistant coating layer (flame-retardant and fire-resistant composite film) function of the final product, including unit area weight, tensile properties, water absorption rate, flame-resistant performance (fire retardant), 12S vertical combustion performance (flame retardant) and other properties, simplifies the process and reduces costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a cross-sectional detail diagram of the flame retardant and fire retardant layer film laminated according to the present invention.

[0025] Figure 2A This is a top view of a plain glass cloth in one embodiment of the present invention. Figure 2B The figure is a top view of a patterned glass cloth in one embodiment of the present invention.

[0026] Figure 3 It is a cross-sectional view of a flame retardant adhesive in one embodiment of the present invention.

[0027] Figure 4 The present invention is a flow chart of the preparation of a flame retardant and fireproof layer film in one embodiment of the present invention. DETAILED DESCRIPTION

[0028] The utility model will be further described in detail below in conjunction with the accompanying drawings: This embodiment is implemented on the premise of the technical solution of the utility model, and a detailed implementation method is given, but the protection scope of the utility model is not limited to the following embodiments.

[0029] Figure 1 Detailed cross-sectional view of the flame retardant and fireproof layer film 100. The flame retardant and fireproof layer film 100 can be used as a packaging film for sound insulation and heat insulation materials on various vehicles. For example, the flame retardant and fireproof layer film 100 can be used in various vehicles, including but not limited to airplanes, trains and ships. The flame retardant and fireproof layer film 100 includes a silica cloth layer 102, an adhesive 104, a first coating layer 106 and a second coating layer 108. In one example, the silica cloth layer 102 can be a high-temperature resistant high-purity SiO2 glass fiber cloth, and the glass fiber cloth is a multi-strand woven silica (SiO2) roving 110, such as Figure 2A , Figure 2B shown.

[0030] Generally speaking, multiple strands of high-purity silica filaments of a pre-selected diameter can be bundled into a single silica roving 110. In one example, the diameter of each filament in each silica roving 110 can be 6-20 µm. The number and diameter of the filaments ultimately determine the linear mass density (unit: tex (g / 1000m)) of the silica roving 110. The silica roving 110 is a 92-99.98% pure silica filament.

[0031] The silica cloth layer 102 can be formed by a weaving process, and in one embodiment, a flat weave is implemented. The flat weave can be called a plain weave, a linen weave or a plain fabric. In the flat weave, the warp yarn and the weft yarn can form a simple cross shape.

[0032] There are two ways to achieve the purity of silica roving. The first way is to use high-purity quartz sand for drawing.

[0033] The second method is acid washing. After the silica cloth layer 102 is woven, the silica cloth layer 102 can be immersed in an acid solution. The silica cloth layer 102 can be immersed in the acid solution until the silica filaments have reached a purity of at least 92%. The acid solution can include, but is not limited to: H2SO4 solution, hydrochloric acid solution, hydrogen bromide solution, nitric acid solution, and phosphoric acid solution.

[0034] Figure 2A This is a top view detail of a plain woven silica cloth layer 102 in one embodiment of the present invention. The detail view shows a plurality of silica rovings 110 on a flat weave. Here, the vertical silica rovings 110 are called weft yarns, and the horizontal silica rovings 110 are called warp yarns.

[0035] In one embodiment, multiple weft yarns are interwoven with multiple warp yarns. For example, a weft yarn passes over one warp yarn and then under another, and so on. Another weft yarn passes under the warp yarn that the previous weft yarn passed over, and vice versa. In some embodiments, a balanced equal-weight flat weave is used, where the number of warp and weft yarns per inch is equal in weight. In addition, the number of warp yarns may not necessarily match the number of weft yarns. For example, the former may be more than the latter, or vice versa. In one embodiment, the ratio of the number of warp yarns to the number of weft yarns is determined by fire resistance properties.

[0036] In one example, the silica cloth layer 102 can be woven when the number of warp yarns (the number of yarns per inch) and the number of weft yarns (the number of yarns per inch) are determined in advance. Generally, the density and area weight of the silica cloth layer 102 can be determined by the number of warp yarns and the number of weft yarns per inch. A higher number of warp yarns and weft yarns can produce a higher density and a larger area weight at the same roving linear density. For example, for a specified density, if a lower area weight is desired, the linear density tex of the roving should be lower. Usually, in situations where higher performance requirements are required, it is required to have a lower area weight while maintaining density. However, as the linear density tex decreases, weaving yarn breakage and other problems may occur during processing.

[0037] Some examples of the present invention adopt a mesh weaving method, such as Figure 2B As shown. In this type, the silica rovings 110 can be bundled and then woven into the warp and / or weft yarns. In general, at least two or more silica rovings 110 can be combined and then woven into a flat woven fabric. As shown, the bundled warp yarns 116 can be interwoven with the bundled weft yarns 118. Please note that Figure 2A and Figure 2B This is just for illustration purposes, not to limit you to this style.

[0038] like Figure 2A As shown, in one example, the silica cloth 102 is made by weaving silica roving 110 according to the original structure of woven fabric, the density of warp and weft is 15-30 yarns / cm, and the warp and weft are spaced 4-10mm apart in radial and weft directions. The reinforcing rib yarn 111 replaces the silica roving 110. The reinforcing rib yarn 111 is made of nylon, polyester, aramid, carbon fiber, high-strength polyethylene fiber, polyphenylene sulfide fiber, polyimide fiber, high-strength glass fiber, and the silica roving 110 with a linear density greater than 2 times.

[0039] Figure 3 Detailed cross-sectional view of a flame retardant adhesive 104 in one embodiment of the present invention. Adhesive 104 may include filler 120. In one example, adhesive 104 may be selected from a series of materials, including but not limited to polymers, copolymers and / or trimers. Any polymer selected has inherent flame retardancy, or may be modified with a flame retardant to have flame retardancy. Polymers may include but are not limited to polyvinyl chloride, polyethylene monochloroethylene, polyacrylates, polyurethanes, polyacrylamides, etc. Flame retardants may include but are not limited to tripolycyanamide, tripolycyanamide derivatives, tripolycyanamide / formalin-based resins, phosphorus compounds, phosphates, borate esters, and halogen compounds.

[0040] In one example, the adhesive 104 can be a chemically non-reactive adhesive. For example, the adhesive 104 can be, but is not limited to, an adhesive emulsion. In one example, the adhesive 104 can be a polymer suspension adhesive, in which the polymer (polymer) is suspended in a solvent (e.g., water). For example, the adhesive 104 can be soluble in water or in a solvent. In general, as the solvent evaporates, the adhesive will harden.

[0041] As mentioned above, the adhesive 104 can be mixed with an inorganic filler. The inorganic filler 120 can account for 5-15% of the solid weight of the adhesive 104. In one example, the filler 120 accounts for 8-11% of the solid weight of the adhesive 104. The selection of the inorganic filler can be determined based on whether the fire resistance can be strengthened, and the ability of the flame retardant and fire-blocking layer film 100 to block flame penetration is further enhanced. The inorganic filler 120 can be, but is not limited to, a sheet silicate mineral (e.g., phyllosilicate). For example, antimony trioxide, mica, or vermiculite can be used.

[0042] The particle size of the filler 120 is between 100-600 meshes. Within this range, the filler 120 has good filling capacity. In some cases, high temperature resistant microfibers (including but not limited to ceramic fibers or silica rovings) can be used as the filler 120 in the adhesive 104.

[0043] In one example, the adhesive 104 can be a water-based polyethylene monochloroethylene emulsion. Such an emulsion can use antimony trioxide as a filler 120. In another example, the emulsion uses mica as a filler 120.

[0044] The first coating layer 106 and the second coating layer 108 may be a type of polyaromatic powder coating material, which is selected from a series of materials including polyethersulfone (PES), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polysulfone (PSF), polyetherimide (PEI), polyetherketoneketone (PEKK), polyphenylene sulfide (PPSD) and polyarylethersulfone (PAS).

[0045] In some examples, the first coating layer 106 and the second coating layer 108 may be polyetheretherketone (PEEK). Generally, the thickness of the first coating layer 106 and the second coating layer 108 are 5-15 microns, respectively. It is worth noting that the thickness of the first coating layer 106 and the second coating layer 108 may be increased or decreased without exceeding the scope of the present invention.

[0046] Generally speaking, if Figure 1As shown, the silica cloth layer 102 may be sandwiched between a first coating layer 106 and a second coating layer 108. In one example, the first coating layer 106 and the second coating layer 108 may be applied to the surface of the silica cloth layer 102 by electrostatic spraying of polyaromatic powder coating.

[0047] Example 1

[0048] In this embodiment, the silica cloth 102 may include plain woven silica rovings, which are greater than 97% pure silica fibers. The silica cloth 102 may have a unit area weight of 59 g / m. The adhesive 104 contains a solid adhesive solution of 30% VINNOL 4500 (polyethylene-vinyl chloride), and VINNOL 4500 contains 1% Z6040 silane coupling agent, 0.5% dispersant, and 10% 300 type flake mica filler.

[0049] The first coating layer 106 and the second coating layer 108 may be composed of a polyetheretherketone (PEEK) powder coating having a thickness of 10 microns. The coated silica cloth 102 may be dried by passing the silica cloth 102 through an oven. The silica cloth 102 may have a controlled coating weight per unit area of ​​about 64 grams per square meter. Generally, the first coating layer 106 may be air-dried in hot air after the adhesive 104 is applied.

[0050] Example 2

[0051] In this embodiment 2, polyetherketoneketone (PEKK) is used to replace the polyetheretherketone (PEEK) in embodiment 1, and other technical features are the same as those in embodiment 1.

[0052] Comparative Example 1

[0053] This comparative example is Example 1 in the Chinese invention patent applied by the applicant (publication number: CN105593016A, publication date: 2016-05-18).

[0054] The following is a comparison of the performance of the products of Examples 1 and 2 of the present utility model and Comparative Example 1:

[0055]

[0056] However, it should be understood that the previously disclosed embodiments are for illustrative purposes only and are not intended to be limiting. Each flame retardant and fireproof layer film can be manufactured in a manner similar to the method disclosed in Example 1, the above disclosed embodiments, and the preparation method of the flame retardant and fireproof layer film disclosed below.

[0057] Method for preparing flame retardant and fireproof layer film containing flame retardant hot melt adhesive film

[0058] Figure 4 The present invention is a flow chart for preparing a flame retardant and fireproof layer film in one embodiment of the present invention. A manufacturing method or process 200 is described. The method 200 can achieve the lamination of a flame retardant and fireproof film. The flame retardant and fireproof film of the present invention includes a layer of silica cloth, a single adhesive layer, a first coating layer and a second coating layer.

[0059] In process 202, polyaromatic powder coating is applied to the surface of high temperature resistant silica cloth. For example, the polyaromatic powder coating can be applied to the surface of silica cloth layer 102 by electrostatic spraying.

[0060] In process 204, the coated silica cloth layer 102 is sintered at 50-100°C above the melting point of the polyaromatic powder coating so that the powder coating forms a dense and continuous coating film. In some embodiments, the silica cloth layer 102 can be sintered at high temperature by passing through an oven.

[0061] In process 206, the adhesive may be applied to the first coating layer using one or more rollers. In one embodiment, the adhesive may be a non-reactive adhesive. For example, the adhesive may only need to be dried to obtain adhesion. For example, the adhesive may be a polymer suspension in which the polymer is dissolved in a solvent (e.g., water). Generally, the inorganic filler may account for 5-15% of the weight of the adhesive solids.

[0062] In process 208, the first coating layer can be exposed to a heat source to dry the adhesive thereon. Generally, during the adhesive drying process, water or other solvents can be removed from the adhesive.

[0063] The above is a description of the embodiments of the utility model. Through the above description of the disclosed embodiments, professionals and technicians in the field can implement or use the utility model. Various modifications to these embodiments will be obvious to professionals and technicians in the field. The general principles defined in this article can be implemented in other embodiments without departing from the spirit or scope of the utility model. Therefore, the utility model will not be limited to these embodiments shown in this article, but will conform to the widest range consistent with the principles and novelties disclosed in this article.

Claims

1. A flame retardant fireproof layer film, characterized in that: The structure of the flame retardant fireproof layer film includes: A first layer, comprising a first coating layer (106); The second layer is composed of silica cloth (102); A third layer, comprising the same composition as the second coating layer (108); The fourth layer comprises an adhesive (104) containing an inorganic filler; The first coating layer (106) and the second coating layer (108) are formed by applying polyaromatic powder coating onto the silica cloth (102) and sintering the coating.

2. The flame retardant and fireproof layer film according to claim 1, characterized in that: The material of the first coating layer (106) is selected from a series of materials: polyethersulfone; polyetheretherketone; polyaryletherketone; polysulfone; polyetherimide; polyetherketoneketone; polyphenylene sulfide; polyarylsulfone.

3. The flame retardant and fireproof layer film according to claim 1, characterized in that: The material of the second coating layer (108) is selected from a series of materials: polyethersulfone; polyetheretherketone; polyaryletherketone; polysulfone; polyetherimide; polyetherketoneketone; polyphenylene sulfide; polyarylsulfone.

4. The flame retardant and fireproof layer film according to claim 1, characterized in that: The silica cloth (102) is made by weaving high-purity silica roving (110) according to the original structure of woven fabric, and the density of warp yarn and weft yarn is 15-30 yarns / cm. The silica roving (110) is made by bundling silica fibers into a plurality of strands, and the linear mass density of each strand is between 10-25 tex.

5. The flame retardant and fireproof layer film according to claim 4, characterized in that: In the radial and weft directions, warp yarns and weft yarns are spaced 4-10 mm apart and are replaced by reinforcing rib yarns (111) to replace high-purity silica rovings (110); the reinforcing rib yarns (111) are made of one of nylon, polyester, aramid, carbon fiber, high-strength polyethylene fiber, polyphenylene sulfide fiber, polyimide fiber, high-strength glass fiber, and high-purity silica rovings (110) having a linear density greater than 2 times.

6. The flame retardant and fireproof layer film according to claim 1, characterized in that: The inorganic filler is selected from antimony trioxide, mica, vermiculite, ceramic fiber, titanium dioxide, fumed silica and ultrafine silica fiber; the mesh size of the inorganic filler is between 100-600 meshes.

7. The flame retardant and fireproof layer film according to claim 1, characterized in that: The thickness of the first coating layer (106) is between 5 and 15 um; the thickness of the second coating layer (108) is between 5 and 15 um.

8. The flame retardant and fireproof layer film according to claim 1, characterized in that: The silica cloth (102) has an area weight of 45-260 g / m2.

9. The flame retardant and fireproof layer film according to claim 1, characterized in that: The area weight of the adhesive (104) layer is between 5 and 20 g / m2.

Images