CA2156630C - Flame-retardant, waterproof and breathable laminate - Google Patents
Flame-retardant, waterproof and breathable laminate Download PDFInfo
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- CA2156630C CA2156630C CA002156630A CA2156630A CA2156630C CA 2156630 C CA2156630 C CA 2156630C CA 002156630 A CA002156630 A CA 002156630A CA 2156630 A CA2156630 A CA 2156630A CA 2156630 C CA2156630 C CA 2156630C
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- Prior art keywords
- laminate
- flame
- adhesive
- retardant
- layer
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
- A41D31/08—Heat resistant; Fire retardant
- A41D31/085—Heat resistant; Fire retardant using layered materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
- C08G18/12—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step using two or more compounds having active hydrogen in the first polymerisation step
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/48—Polyethers
- C08G18/50—Polyethers having heteroatoms other than oxygen
- C08G18/5075—Polyethers having heteroatoms other than oxygen having phosphorus
- C08G18/5081—Polyethers having heteroatoms other than oxygen having phosphorus having phosphorus bound to oxygen only
- C08G18/5084—Phosphate compounds
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J175/00—Adhesives based on polyureas or polyurethanes; Adhesives based on derivatives of such polymers
- C09J175/04—Polyurethanes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/92—Fire or heat protection feature
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249955—Void-containing component partially impregnated with adjacent component
- Y10T428/249958—Void-containing component is synthetic resin or natural rubbers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249982—With component specified as adhesive or bonding agent
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
- Y10T428/31544—Addition polymer is perhalogenated
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Fireproofing Substances (AREA)
Abstract
A water and breathable flame-retardant laminate of two layers (1, 3) of porous expanded polytetrafluoroethylene laminated together by a flame-retardant adhesive layer (2) of poly(urea-urethane) polymer containing phosphorus ester groups built into the chains of the polymer. The flame-retardant components do not wash out of the adhesive and laminate under repeated laundering or dry cleaning.
Description
TITLE OF THE INVENTION
FLAME-RETARDANT, WATERPROOF AND BREATHABLE LAMINATE
i FIELD OF THE INVENTION
The invention relates to the field of flame-retardant materials, particularly to fabrics and laminates utilized in protective garments to provide durable flame-retardance along with other useful properties.
BACKGROUND OF THE INVENTION
Flame-retardant compositions are generally applied to the surfaces of materials, such as fabrics and laminates. The flame-retardant materials may be liquids or may be applied as solutions in a solvent or emulsified in a liquid. The liquids are usually sprayed on the substrate to be rendered flame-resistant or padded on from rolls. The flame-retardant may also be forced into pores and interstices of the substrate under pressure so that the flame-retardant occupies pores and cracks within the substance of the substrate, such as disclosed in U.S. Patent No. 4,223,066.
In the presence of heat or flame, the flame-retardants usually undergo chemical reaction or physical change to render the substrate flame-resistant. Polymers or resins are also often used to aid in adhering the flame-resistant material to the substrate.
The principal problem which often causes surface coating of substrates to be deficient in rendering the substrates flame-retardant is the tendency of most surface coatings to washing off of the substrates under conditions of cleaning or laundering.
After a few cleanings, a surface coated flame retardant most often washes away to leave a fabric or laminate thus coated unprotected against flame or heat. Use of resinous materials, adhesives, and other such ingredients usually only delays wash removal of the flame-retardant material or causes it to break away from the substrate when under heat.
WO 94/21453 PCT/US93/03$77 21~G~Q
FLAME-RETARDANT, WATERPROOF AND BREATHABLE LAMINATE
i FIELD OF THE INVENTION
The invention relates to the field of flame-retardant materials, particularly to fabrics and laminates utilized in protective garments to provide durable flame-retardance along with other useful properties.
BACKGROUND OF THE INVENTION
Flame-retardant compositions are generally applied to the surfaces of materials, such as fabrics and laminates. The flame-retardant materials may be liquids or may be applied as solutions in a solvent or emulsified in a liquid. The liquids are usually sprayed on the substrate to be rendered flame-resistant or padded on from rolls. The flame-retardant may also be forced into pores and interstices of the substrate under pressure so that the flame-retardant occupies pores and cracks within the substance of the substrate, such as disclosed in U.S. Patent No. 4,223,066.
In the presence of heat or flame, the flame-retardants usually undergo chemical reaction or physical change to render the substrate flame-resistant. Polymers or resins are also often used to aid in adhering the flame-resistant material to the substrate.
The principal problem which often causes surface coating of substrates to be deficient in rendering the substrates flame-retardant is the tendency of most surface coatings to washing off of the substrates under conditions of cleaning or laundering.
After a few cleanings, a surface coated flame retardant most often washes away to leave a fabric or laminate thus coated unprotected against flame or heat. Use of resinous materials, adhesives, and other such ingredients usually only delays wash removal of the flame-retardant material or causes it to break away from the substrate when under heat.
WO 94/21453 PCT/US93/03$77 21~G~Q
The present invention provides a permanently incorporated flame-retardant material into the structure of a laminate so that cleaning and applied heat or flame have no effect on its permanence in the substrate.
i SUMMARY OF THE INVENTION
The invention comprises a flame-retardant, waterproof and breathable laminate of a first layer of porous expanded polytetrafluoroethylene (ePTFE) membrane adhered to a second layer of ePTFE by a phosphorus-containing poly(urea-urethane) adhesive.
One layer of ePTFE may vary from the other considerably in thickness. The adhesive comprises a reaction product of at least one long chain polyglycol, at least one short chain glycol, at least one phosphorus ester containing polyglycol, and excess polyisocyanate. This adhesive is preferably moisture cured to become a solid piece of poly(urea-urethane) sheet adhered to the ePTFE sheets. Mixtures of several long chain polyglycols, several short chain glycols, several phosphorus ester containing polyglycols may be used as well as mixtures of several polyisocyanates. The long chain polyglycol is preferably selected from various polyether and polyester polyglycols of varying molecular weight and degrees of polymerization. The short chain glycol is preferably selected from straight, branched, and ring containing aliphatic C1_10 diols. The polyisocyanate is preferably a diiocyanate but may contain some isocyanate having more than two isocyanate groups. A preferred isocyanate is MDI (polymethylene polyphenylene diisocyate).
The phosporus-containing polyglycols useful in the invention to provide flame retardancy to the adhesive and to the laminate as a whole comprise one or more of:
HO(C3H50)x-P(0)(OR)-OC3H60-P(O)(OR1)-0(C3H60)yH, where x + y = 2-10, R=C1_6 alkyl, R1=C1_6 alkyl, and HOCH2CH2 [OP(0)(OR)OCH2CH2]m [OP(0)(R1)OCH2CH2]n OH, where: R=C1_6 alkyl, R1=C1_6 alkyl, n »m, and n + m = 2-20.
~O 94/21453 3 PCT/US93/03877 BRIEF DESCRIPTION OF THE DRAWING
The figure shows a cross-sectional view of a laminate of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The figure describes a laminate of the invention in which a first relatively thick layer 1 of ePTFE membrane is adhered to a relatively thin layer 3 of ePTFE membrane by a layer of poly(urea-urethane) adhesive 2_ which contains phosphorus ester groups as an integral part of the polymer chain of the adhesive 2_.
The ePTFE membranes used to form a laminate of the invention are those disclosed and described in detail in U.S. Patents 3,953,566, 3,962,153, 4,096,227, 4,187,390, 4,902,423, and 4,478,665, assigned to W. L. Gore & Associates, Inc. The porous membranes of ePTFE have a microstructure characterized by nodes interconnected by fibrils and are highly porous and of high strength. The ePTFE membranes are waterproof and breathable owing to the high resistance to wetting of ePTFE by water and to their high porosity. When coated with a hydrophilic layer, particularly of hydrophilic polyurethane, they remain waterproof and oil resistant, retaining their waterproofness as the hydrophilic layer blocks the penetration of oils throughout the membrane with consequent loss of waterproofness. These properties are fully described in detail in U.S. Patent 4,194,041, assigned to W. L.
Gore & Associates, Inc.
The poly(urea-urethane) adhesive layer ~ in the laminate of the invention provides similar properties of waterproofness and breathability as those described in the above patent, but in addition confers a high degree of flame resistance to ePTFE
laminates made from it, since the phosphorus the adhesive contains is embodied in the molecule of a polyglycol ingredient and thus into the chains of the poly(urea-urethane) polymer molecules prepared therefrom. Cleaning, washing, and scrubbing of a garment made from a laminate containing the above adhesive thus do not remove any of the permanent flame resistant component of the adhesive and a laminate containing the adhesive.
Suitable short chain glycols up to about C12, which may be useful in the adhesive include, for example, ethylene glycol-(1,2), propylene glycol-(1,2) and -(1,3), butylene glycol-(1,4) and -(2,3), pentandiol-(1,5), hexanediol-(1,6), octandiol-(1,8), 1,7-heptanediol, neopentyl glycol.,.l,~4-bis(hydroxymethyl)cyclohexane, 2-methyl-1,3-propanediol, trimethylolpropane, diethyleneglycol, and triethyleneglycol.
Useful long chain polyglycols, of about 500-5000 mol. wt., include, for example, polyoxyethylene glycol, polyoxypropylene glycol, polyoxybutylene glycol, polytetramethylene glycol, block copolymers, such as combinations of polyoxypropylene and polyoxyethylene glycols, poly-1,2-oxybutylene and polyoxyethylene glycols, poly-1,4-tetramethylene and polyoxyethylene glycols, and copolymer glycols prepared from blends or sequential addition of two or more alkylene oxides.
Also useful may be hydroquinones and low molecular weight aliphatic ring-containing diols. Mixtures of the glycols of different chain lengths and molecular weights as well as of diols of differing chemical composition may be used. Aromatic glycols should not be used.
Certain amounts of polyester glycols may be included, such as lower molecular weight reaction products of aliphatic glycols or ethylene or propylene oxide with aliphatic dicarboxylic acids, for example.
In principle, in the invention, any aliphatic, cycloaliphatic, araliphatic aromatic and hetrocyclic di and/or polyisocyanates can be used. Specific examples include ethylene diisocyanate; 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 1,12-dodecane diisocyanate, cyclobutane 1,3-diisocyanate, cyclohexane 1,3- and 1,4-diisocyanate and any mixtures of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane, 2,4- and 2,6-hexahydrotolylene diisocyanate and any mixtures of these isomers, hexahydro-1,3- and/or-1,4-phenylene diioscyanate;
perhydro-2,4'- and/or -4,4'-diphenylmethane diisocyanate, 1,3- and 1,4-phenylene diisocyanate, 2,4- and 2,6-tolylene diisocyanate and any mixtures of these isomers, diphenylmethane 2,4'- and/or -4,4'-diisocyanate, naphthylene 1,5-diisocyanate, and t polyphenylenepolymethylene polyisocyanate (MDI). MDI is the most preferred diisocyanate used to form the adhesive.
The adhesive is prepared typically as follows:
The phosphorus-containing flame-retardant adhesive was prepared by heating 50.05 g. (0.400 equivalent) of MDI, 82.77 8.(0.112 equivalent) polyethylene-propylene) glycol, and 3.15 g.
(0.070 equivalent) 1,4-butanediol under dry nitrogen gas for two hours. To the reaction mixture was then added 32.45 g. (0.065 equivalent) HOCH2CH2[OP(O)(OCH3)OCH2CH2Jm[OP(0)(CH3)OCH2CH2]n OH, and the mixture stirred another 1.5 hours to form an isocyanate terminated phosphorus-containing urethane adhesive of viscosity 16,000 cps at 80°C., NCO group content was 3.56 wt. ~.
The adhesive was applied to a relatively thick ePTFE membrane by doctor blades or roller methods commonly used in the lamination arts and the adhesive covered with the thinner ePTFE membrane to form a laminate. The thickness of the adhesive layer can be from 0.1 to 5.0 mils. This laminate was cured at ambient condition for at least two days to allow the adhesive to convert by moisture to a phosphorus-containing poly(urea-urethane) layer. Use of a very thin, almost gossamer layer of ePTFE to cover the adhesive on the thick ePTFE layer allows the laminate to be rolled up for storage while the adhesive cures over about two days. Otherwise the adhesive would stick to other layers or materials it might contact until it is cured to the non-tacky stage.
Flame Test Three specimens of the cured laminate prepared above were tested for flame-retardance according to standard method FTM 191-5903.1. The flame-resistance method is a vertical flame test using a mixed gas flame and 12-second flame impingement on the samples.
Any after flame, after glow, and char length are recorded for each speciment. The average results were:
- - - .,~; A 02156630 1999-02-22 Y
WO 94/21453 ~ PCT/~JS93/03877 Y-_ _6_ _ After flame (seconds) 0 After glow (seconds) 0 Char length (inches) 4.1 EXA!lPLE 2 Another phosphorus-containing flame-retardant adhesive was prepared according to the same procedure as for Example 1, except the following starting materials were used: 50.059 (0.400 equivalent) MDI; 82.779 (0.112 equivalent) poly(ethylene-propylene)glycol, 4.739 (0.080 equivalent) 1,4-butanediol, and (0.045 equivalent) 14.729 phosphorus-containing glycol [HO(C3H60)x-P(0)(OC4Hg)-OC3H60-P(0)(OC4Hg)-0(C3H60),yH]. The adhesive prepared from these starting materials had a viscosity of 7500 cps at 80°C.
and an NCO content of 3.98 wt. X.
A laminate of a thick and a thin ePTFE membrane, similar to the one described in Example 1, were made using the above adhesive.
After moisture curing for two days, these ePTFE membranes were further laminated onto*Nomex III fabric.
Flame Test The fabric-membranes laminate was subjected to the same vertical flame test (FTM 191-5903.1) as in Example 1. After five washing cycles at 140 ø/- 5°F., the laminate was tested again. The results of both before and after washing are given below. Each number is the average result of five tests.
Before Bash After Wash liary Fi 11 warn Fi 11 After Flame (seconds) 0.0 0.0 0.0 0.0 After Glow (seconds) 1.6 1.5 1.4 1.5 Char Length (inches) 1.8 1.6 1.9 1.7 The laminate of the invention is useful for clothing used in fire fighting, military uniforms, protective clothing for rescue * TRADE MARK
workers, and for infant garments and bedding. Since the fire-retardant components of the laminate are built into the polymer chains of the adhesive uniting the ePTFE membranes, which are themselves somewhat fire-retardant, the fire-retardant materials advantageously do not wash out of garments when they are washed, dry cleaned, or heavily used. This laminate may be further ' laminated onto Nomex meta-substituted polyaramide or other flame-resisting fabrics for use in protective clothing.
i SUMMARY OF THE INVENTION
The invention comprises a flame-retardant, waterproof and breathable laminate of a first layer of porous expanded polytetrafluoroethylene (ePTFE) membrane adhered to a second layer of ePTFE by a phosphorus-containing poly(urea-urethane) adhesive.
One layer of ePTFE may vary from the other considerably in thickness. The adhesive comprises a reaction product of at least one long chain polyglycol, at least one short chain glycol, at least one phosphorus ester containing polyglycol, and excess polyisocyanate. This adhesive is preferably moisture cured to become a solid piece of poly(urea-urethane) sheet adhered to the ePTFE sheets. Mixtures of several long chain polyglycols, several short chain glycols, several phosphorus ester containing polyglycols may be used as well as mixtures of several polyisocyanates. The long chain polyglycol is preferably selected from various polyether and polyester polyglycols of varying molecular weight and degrees of polymerization. The short chain glycol is preferably selected from straight, branched, and ring containing aliphatic C1_10 diols. The polyisocyanate is preferably a diiocyanate but may contain some isocyanate having more than two isocyanate groups. A preferred isocyanate is MDI (polymethylene polyphenylene diisocyate).
The phosporus-containing polyglycols useful in the invention to provide flame retardancy to the adhesive and to the laminate as a whole comprise one or more of:
HO(C3H50)x-P(0)(OR)-OC3H60-P(O)(OR1)-0(C3H60)yH, where x + y = 2-10, R=C1_6 alkyl, R1=C1_6 alkyl, and HOCH2CH2 [OP(0)(OR)OCH2CH2]m [OP(0)(R1)OCH2CH2]n OH, where: R=C1_6 alkyl, R1=C1_6 alkyl, n »m, and n + m = 2-20.
~O 94/21453 3 PCT/US93/03877 BRIEF DESCRIPTION OF THE DRAWING
The figure shows a cross-sectional view of a laminate of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The figure describes a laminate of the invention in which a first relatively thick layer 1 of ePTFE membrane is adhered to a relatively thin layer 3 of ePTFE membrane by a layer of poly(urea-urethane) adhesive 2_ which contains phosphorus ester groups as an integral part of the polymer chain of the adhesive 2_.
The ePTFE membranes used to form a laminate of the invention are those disclosed and described in detail in U.S. Patents 3,953,566, 3,962,153, 4,096,227, 4,187,390, 4,902,423, and 4,478,665, assigned to W. L. Gore & Associates, Inc. The porous membranes of ePTFE have a microstructure characterized by nodes interconnected by fibrils and are highly porous and of high strength. The ePTFE membranes are waterproof and breathable owing to the high resistance to wetting of ePTFE by water and to their high porosity. When coated with a hydrophilic layer, particularly of hydrophilic polyurethane, they remain waterproof and oil resistant, retaining their waterproofness as the hydrophilic layer blocks the penetration of oils throughout the membrane with consequent loss of waterproofness. These properties are fully described in detail in U.S. Patent 4,194,041, assigned to W. L.
Gore & Associates, Inc.
The poly(urea-urethane) adhesive layer ~ in the laminate of the invention provides similar properties of waterproofness and breathability as those described in the above patent, but in addition confers a high degree of flame resistance to ePTFE
laminates made from it, since the phosphorus the adhesive contains is embodied in the molecule of a polyglycol ingredient and thus into the chains of the poly(urea-urethane) polymer molecules prepared therefrom. Cleaning, washing, and scrubbing of a garment made from a laminate containing the above adhesive thus do not remove any of the permanent flame resistant component of the adhesive and a laminate containing the adhesive.
Suitable short chain glycols up to about C12, which may be useful in the adhesive include, for example, ethylene glycol-(1,2), propylene glycol-(1,2) and -(1,3), butylene glycol-(1,4) and -(2,3), pentandiol-(1,5), hexanediol-(1,6), octandiol-(1,8), 1,7-heptanediol, neopentyl glycol.,.l,~4-bis(hydroxymethyl)cyclohexane, 2-methyl-1,3-propanediol, trimethylolpropane, diethyleneglycol, and triethyleneglycol.
Useful long chain polyglycols, of about 500-5000 mol. wt., include, for example, polyoxyethylene glycol, polyoxypropylene glycol, polyoxybutylene glycol, polytetramethylene glycol, block copolymers, such as combinations of polyoxypropylene and polyoxyethylene glycols, poly-1,2-oxybutylene and polyoxyethylene glycols, poly-1,4-tetramethylene and polyoxyethylene glycols, and copolymer glycols prepared from blends or sequential addition of two or more alkylene oxides.
Also useful may be hydroquinones and low molecular weight aliphatic ring-containing diols. Mixtures of the glycols of different chain lengths and molecular weights as well as of diols of differing chemical composition may be used. Aromatic glycols should not be used.
Certain amounts of polyester glycols may be included, such as lower molecular weight reaction products of aliphatic glycols or ethylene or propylene oxide with aliphatic dicarboxylic acids, for example.
In principle, in the invention, any aliphatic, cycloaliphatic, araliphatic aromatic and hetrocyclic di and/or polyisocyanates can be used. Specific examples include ethylene diisocyanate; 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 1,12-dodecane diisocyanate, cyclobutane 1,3-diisocyanate, cyclohexane 1,3- and 1,4-diisocyanate and any mixtures of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane, 2,4- and 2,6-hexahydrotolylene diisocyanate and any mixtures of these isomers, hexahydro-1,3- and/or-1,4-phenylene diioscyanate;
perhydro-2,4'- and/or -4,4'-diphenylmethane diisocyanate, 1,3- and 1,4-phenylene diisocyanate, 2,4- and 2,6-tolylene diisocyanate and any mixtures of these isomers, diphenylmethane 2,4'- and/or -4,4'-diisocyanate, naphthylene 1,5-diisocyanate, and t polyphenylenepolymethylene polyisocyanate (MDI). MDI is the most preferred diisocyanate used to form the adhesive.
The adhesive is prepared typically as follows:
The phosphorus-containing flame-retardant adhesive was prepared by heating 50.05 g. (0.400 equivalent) of MDI, 82.77 8.(0.112 equivalent) polyethylene-propylene) glycol, and 3.15 g.
(0.070 equivalent) 1,4-butanediol under dry nitrogen gas for two hours. To the reaction mixture was then added 32.45 g. (0.065 equivalent) HOCH2CH2[OP(O)(OCH3)OCH2CH2Jm[OP(0)(CH3)OCH2CH2]n OH, and the mixture stirred another 1.5 hours to form an isocyanate terminated phosphorus-containing urethane adhesive of viscosity 16,000 cps at 80°C., NCO group content was 3.56 wt. ~.
The adhesive was applied to a relatively thick ePTFE membrane by doctor blades or roller methods commonly used in the lamination arts and the adhesive covered with the thinner ePTFE membrane to form a laminate. The thickness of the adhesive layer can be from 0.1 to 5.0 mils. This laminate was cured at ambient condition for at least two days to allow the adhesive to convert by moisture to a phosphorus-containing poly(urea-urethane) layer. Use of a very thin, almost gossamer layer of ePTFE to cover the adhesive on the thick ePTFE layer allows the laminate to be rolled up for storage while the adhesive cures over about two days. Otherwise the adhesive would stick to other layers or materials it might contact until it is cured to the non-tacky stage.
Flame Test Three specimens of the cured laminate prepared above were tested for flame-retardance according to standard method FTM 191-5903.1. The flame-resistance method is a vertical flame test using a mixed gas flame and 12-second flame impingement on the samples.
Any after flame, after glow, and char length are recorded for each speciment. The average results were:
- - - .,~; A 02156630 1999-02-22 Y
WO 94/21453 ~ PCT/~JS93/03877 Y-_ _6_ _ After flame (seconds) 0 After glow (seconds) 0 Char length (inches) 4.1 EXA!lPLE 2 Another phosphorus-containing flame-retardant adhesive was prepared according to the same procedure as for Example 1, except the following starting materials were used: 50.059 (0.400 equivalent) MDI; 82.779 (0.112 equivalent) poly(ethylene-propylene)glycol, 4.739 (0.080 equivalent) 1,4-butanediol, and (0.045 equivalent) 14.729 phosphorus-containing glycol [HO(C3H60)x-P(0)(OC4Hg)-OC3H60-P(0)(OC4Hg)-0(C3H60),yH]. The adhesive prepared from these starting materials had a viscosity of 7500 cps at 80°C.
and an NCO content of 3.98 wt. X.
A laminate of a thick and a thin ePTFE membrane, similar to the one described in Example 1, were made using the above adhesive.
After moisture curing for two days, these ePTFE membranes were further laminated onto*Nomex III fabric.
Flame Test The fabric-membranes laminate was subjected to the same vertical flame test (FTM 191-5903.1) as in Example 1. After five washing cycles at 140 ø/- 5°F., the laminate was tested again. The results of both before and after washing are given below. Each number is the average result of five tests.
Before Bash After Wash liary Fi 11 warn Fi 11 After Flame (seconds) 0.0 0.0 0.0 0.0 After Glow (seconds) 1.6 1.5 1.4 1.5 Char Length (inches) 1.8 1.6 1.9 1.7 The laminate of the invention is useful for clothing used in fire fighting, military uniforms, protective clothing for rescue * TRADE MARK
workers, and for infant garments and bedding. Since the fire-retardant components of the laminate are built into the polymer chains of the adhesive uniting the ePTFE membranes, which are themselves somewhat fire-retardant, the fire-retardant materials advantageously do not wash out of garments when they are washed, dry cleaned, or heavily used. This laminate may be further ' laminated onto Nomex meta-substituted polyaramide or other flame-resisting fabrics for use in protective clothing.
Claims (7)
1. A waterproof and breathable flame-retardant laminate comprising:
(a) a first layer of porous expanded polytetrafluoroethylene membrane adhered to a (b) second layer of porous expanded polytetrafluoroethylene membrane by a layer of (c) phosphorus-containing poly(urea-urethane) adhesive.
(a) a first layer of porous expanded polytetrafluoroethylene membrane adhered to a (b) second layer of porous expanded polytetrafluoroethylene membrane by a layer of (c) phosphorus-containing poly(urea-urethane) adhesive.
2. A laminate of Claim 1 wherein said poly(urea-urethane) adhesive comprises a reaction product of at least one long chain polyglycol of molecular weight of about 500 to about 5000, at least one short chain glycol of up to about 12 carbon atoms, at least one phosphorus ester containing polyglycol, and excess polyisocyanate.
3. A laminate of Claim 2 wherein said long chain polyglycol is selected from the group consisting essentially of a polyethylene glycol, a polypropylene glycol and a polyester glycol and combinations and mixtures thereof.
4. A laminate of Claim 2 wherein said short chain glycol is selected from the group consisting essentially of aliphatic straight, branched chain, or ring-containing C1-10 diols.
5. A laminate of Claim 2 wherein said phosphorus containing polyglycol comprises one or more of:
HO(C3H60)X-P(O)(OR)-OC3H60-P(O)(OR1)-O(C3H6O)yH, where x + y - 2-10, R-C1-6 alkyl, R1-C1-6 alkyl.
and HOCH2CH2[OP(O)(OR)OCH2CH2]m[OP(O)(R1)OCH2CH2]n OH, where: R-C1-6 alkyl, R1-C1-6 alkyl, nm, and n + m - 2-20.
HO(C3H60)X-P(O)(OR)-OC3H60-P(O)(OR1)-O(C3H6O)yH, where x + y - 2-10, R-C1-6 alkyl, R1-C1-6 alkyl.
and HOCH2CH2[OP(O)(OR)OCH2CH2]m[OP(O)(R1)OCH2CH2]n OH, where: R-C1-6 alkyl, R1-C1-6 alkyl, nm, and n + m - 2-20.
6. A laminate of Claim 1 wherein said adhesive is moisture-cured.
7. A laminate of Claim 1 wherein said first layer of porous expanded polytetrafluoroethylene membrane is significantly thicker than said second layer of porous expanded polytetrafluoroethylene.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/033,652 | 1993-03-16 | ||
US08/033,652 US5418054A (en) | 1993-03-16 | 1993-03-16 | Flame-retardant, waterproof and breathable expanded PTFE laminate |
PCT/US1993/003877 WO1994021453A1 (en) | 1993-03-16 | 1993-04-23 | Flame-retardant, waterproof and breathable laminate |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2156630A1 CA2156630A1 (en) | 1994-09-29 |
CA2156630C true CA2156630C (en) | 2000-04-18 |
Family
ID=21871654
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002156630A Expired - Lifetime CA2156630C (en) | 1993-03-16 | 1993-04-23 | Flame-retardant, waterproof and breathable laminate |
Country Status (6)
Country | Link |
---|---|
US (1) | US5418054A (en) |
EP (1) | EP0689500B1 (en) |
JP (1) | JP3165154B2 (en) |
CA (1) | CA2156630C (en) |
DE (1) | DE69305658T2 (en) |
WO (1) | WO1994021453A1 (en) |
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US9782947B2 (en) * | 2007-05-25 | 2017-10-10 | W. L. Gore & Associates, Inc. | Fire resistant laminates and articles made therefrom |
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US10364527B2 (en) | 2007-10-24 | 2019-07-30 | W. L. Gore & Associates, Inc. | Burn protective materials |
US20090110919A1 (en) * | 2007-10-24 | 2009-04-30 | Dattatreya Panse | Burn protective materials |
JP5156504B2 (en) * | 2008-06-25 | 2013-03-06 | 日本ゴア株式会社 | Composite membrane and moisture adjustment module using the same |
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CN102470631A (en) * | 2009-07-21 | 2012-05-23 | 日本毛织株式会社 | Waterproof moisture-permeable sheet with fire protection performance and fire-protecting clothing using same |
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WO2012100840A1 (en) | 2011-01-28 | 2012-08-02 | W.L. Gore & Associates Gmbh | Laminar structure providing adaptive thermal insulation |
KR20140009327A (en) | 2011-01-28 | 2014-01-22 | 더블유.엘.고어 앤드 어소시에이츠 게엠베하 | Laminar structure providing adaptive thermal insulation |
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JP2012206062A (en) | 2011-03-30 | 2012-10-25 | Nihon Gore Kk | Composite membrane |
US9927061B2 (en) | 2012-07-27 | 2018-03-27 | W. L. Gore & Associates Gmbh | Envelope for a laminar structure providing adaptive thermal insulation |
EP2879537B1 (en) | 2012-07-31 | 2016-07-20 | W.L.Gore & Associates Gmbh | Combination of an envelope for a laminar structure providing adaptive thermal insulation and a heat protection shield |
EP2879538B1 (en) | 2012-07-31 | 2016-05-18 | W.L.Gore & Associates Gmbh | Envelope for a laminar structure providing adaptive thermal insulation |
KR20150034247A (en) | 2012-07-31 | 2015-04-02 | 더블유.엘.고어 앤드 어소시에이츠 게엠베하 | Envelope for a laminar structure providing adaptive thermal insulation |
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-
1993
- 1993-03-16 US US08/033,652 patent/US5418054A/en not_active Expired - Lifetime
- 1993-04-23 WO PCT/US1993/003877 patent/WO1994021453A1/en active IP Right Grant
- 1993-04-23 EP EP93919801A patent/EP0689500B1/en not_active Expired - Lifetime
- 1993-04-23 DE DE69305658T patent/DE69305658T2/en not_active Expired - Lifetime
- 1993-04-23 CA CA002156630A patent/CA2156630C/en not_active Expired - Lifetime
- 1993-04-23 JP JP52099094A patent/JP3165154B2/en not_active Expired - Lifetime
Also Published As
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JPH08507732A (en) | 1996-08-20 |
CA2156630A1 (en) | 1994-09-29 |
WO1994021453A1 (en) | 1994-09-29 |
EP0689500B1 (en) | 1996-10-23 |
DE69305658D1 (en) | 1996-11-28 |
US5418054A (en) | 1995-05-23 |
DE69305658T2 (en) | 1997-03-20 |
JP3165154B2 (en) | 2001-05-14 |
EP0689500A1 (en) | 1996-01-03 |
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