Patent Application
20060252323
Fiberglass is well known for use as a component of office furniture, office partitions, and other structures used in office, school, commercial, and industrial settings.
Fiberglass has many advantages for such applications. It is relatively inexpensive, it can be worked into a variety of shapes and densities, and it has good fire-resistance properties.
Recently, however, concerns have been raised about such ubiquitous uses of fiberglass. Some have expressed concerns about health or safety risks that might occur during the manufacture of fiberglass articles. Concerns also have been raised about the use of certain volatile organic compounds, such as aldehyde compounds and formaldehyde in particular, that are typically involved in fiberglass-containing structures. Thus there has been increased customer interest in office furniture and other office products that do not include fiberglass as a component.
Agricultural fibers are gaining interest as a natural, renewable resource with potential for use in a variety of manufactured products. In particular, bast fibers such as industrial hemp, kenaf, jute, sisal and flax can be made into non-woven sheet-like products in roll form that can then be used in subsequent manufacturing processes. In some situations, bast fiber products are preferred as natural products that do not harm the environment and that do require the use of volatile organic compounds. It is known to manufacture articles using bast fibers and a thermoplastic binder, as disclosed for example, in U.S. Pat. No. 5,709,925, which discloses the use of such a composition for an interior trim panel for a motor vehicle.
Furniture and other structures intended for use in an office environment it is desirable to have a Class A fire resistance rating. This means that such products have a flame spread index of 25 or less, and a smoke generation index of 450 or less, as measured by the test procedures set forth in ASTM E 84 and UL 723. Agricultural fibers however are inherently flammable. Thus, when such agricultural fiber products are used in an office environment, the products typically include some treatment to provide for adequate flame resistance or to meet Class A requirements.
One such effort to make a fire-resistant article with natural fibers is described in U.S. Patent Application Publication No. U.S. 2004/0028958 A1, wherein a moldable batt comprises a fire-retardant cellulose, a fiber component, and a binder component, the batt being compressed and heated to form fire-resistant panels or other products that are said to be particularly useful in the office furniture industry.
It is thus one object of the invention to provide an article that can be used in the manufacture of office furniture, partitions, and other structures, which article does not include fiberglass.
It is thus another of the invention to provide an article that can be used in the manufacture of office furniture, partitions, and other structures, which article includes bast fibers as a component thereof yet which meets the standards for a Class A fire-resistance rating and which has desirable acoustical absorbing properties.
In accordance with the invention, a fire-resistant article comprises a fibrous mass having a fiber component and about 10-40 wt. % of a first fire retardant component mixed therein, the fiber component comprising about 1-50 wt. % thermoplastic binder and about 50-99 wt. % natural fiber, the fibrous mass having a coating of a second fire retardant component on the exterior surfaces thereof. By appropriate selection of the natural fibers, the thermoplastic binder, and the first and second fire retardant components, it is possible to make an article having both flame spread index values and smoke generation index values that fall within the Class A fire rating. Moreover, the article is made free of fiberglass and free of the formaldehyde commonly used with fiberglass.
In one embodiment, the fiber mass comprises about 10-50 wt. % thermoplastic binder to about 50-99 wt. % natural fiber and most preferably comprises about 10-30 wt. % thermoplastic binder and 70-90 wt. % natural fiber. In another embodiment, the fiber mass comprises about 10-40 wt. % of the first fire retardant component and most preferably about 28-32 wt. % of the first fire retardant component.
The natural fiber content of the fiber component may be made up of a variety of bast fibers, including fibers such as kenaf, jute, industrial hemp, sisal, flax, and mixtures thereof. In some embodiments a mixture of kenaf and industrial hemp is used. In other embodiments, kenaf alone is used. Natural fibers are a renewable resource, and one which does not emit potentially hazardous materials into the environment. The thermoplastic material or binder is mixed with the natural fiber in sufficient quantity to bind the fibers together upon the application of heat. Suitable thermoplastic binders or materials include polypropylene, polyethylene, polyesters, nylon, copolymers, and mixtures thereof. The thermoplastic materials may be in the form of fibers, bi-component fibers, powders, or pellets.
One embodiment of the inventive method of making a fire-resistant article comprises the steps of providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, dispersing a first fire retardant component in the fibrous mass, compressing and heating the fibrous mass to form a shaped article, and applying a coating of a second fire retardant component to the shaped article, The first fire retardant component may be in a powder form that is either blown through the fibrous mass or drawn through under reduced pressure. After the first fire retardant is dispersed through the fibrous mass, the mass is heated to a temperature above the softening temperature of the thermoplastic material but below the temperature where undesired thermal degradation occurs, and then compressed. Suitable compression apparatus include, for example, platens, nip, rollers, or flat bed laminators. The second fire retardant may be applied to the outer surfaces of the compressed mass such as in a solution or liquid medium. In one embodiment of the method, the article may be heated again to drive off any water used in the solution or liquid medium.
In an alternative method, the first flame retardant component may be dispersed through the fibrous mass, the second flame retardant component can be applied to the outer surfaces of the fibrous mass, and the mass can be compressed with heat to both soften the thermoplastic materials to bind the natural fibers and drive off any water used in the solution or liquid medium from the application of the second flame retardant component.
Through appropriate choices of materials and processing conditions, the resulting article can be made to have a flame propagation index and smoke generation index low enough to merit a Class A rating, as well as having desirable acoustical absorbing properties. The article can be used in the manufacture of office dividers or partition panels, ceiling tiles, bulletin boards, and other structures requiring a Class A rating that are used in office, school, commercial and industrial settings.
The present invention can be more readily understood by reference to the drawings, wherein:
A fire-resistant article of the present invention comprises a fibrous mass having a fiber component and about 10-40 wt. % of a first fire retardant component mixed therein; the fiber component comprising about 1-50 wt. % thermoplastic and about 50-99 wt. % natural fiber, the fibrous mass having a coating of a second fire retardant component on the exterior surfaces thereof.
The fibrous mass used in the manufacture of the fire-resistant article can be provided in the form of long sheets shipped as rolls. Such rolls may be commercially fabricated to include natural fibers and thermoplastic materials to a purchaser's specifications.
The natural fiber component of the fibrous mass is derived from the family of bast fiber plants in which a plant stalk has bast fibers and a core. The preferred bast fiber plants will be those in which the bast fibers are readily separated from the core of the stalk. Particularly suitable bast fiber plants for this purpose include kenaf, jute, industrial hemp, sisal, and flax. Any of these plant materials may be used alone or in combination with each other, and in various proportions. The selection of the plant materials to be used will be based on ease of manufacture into the fibrous mass for use in the invention, cost, availability, and fire resistance in the finished article based on empirical tests. In one embodiment, a mixture of kenaf and industrial hemp is used. In another embodiment, only kenaf is used. Further, while various proportions of the different fibers can be used, a fibrous mass in which the natural fiber component comprises kenaf and industrial hemp fibers in about equal proportions by weight is used.
The thermoplastic material or component should have a softening temperature below a temperature that would cause undesired thermal degradation of the natural fibers. Suitable thermoplastic components can be selected from the group consisting of polypropylene, polyethylene, polyesters, nylon, copolymers, and mixtures thereof. Of these, polypropylene is suitable because of its ready availability and its low cost. The thermoplastic component in the form of fibers may be readily incorporated in the fibrous mass in the initial manufacture thereof. In one embodiment, the fibers may include bicomponent fibers, in which fibers of a first thermoplastic material are coated or encased within a second thermoplastic material having a lower softening temperature. Alternatively, the thermoplastic component may be in other forms such as powders or pellets that can be readily incorporated in the fibrous mass.
Because of the inherent flammability of both the natural fibers and the thermoplastic materials used in the fibrous mass, a first fire-retardant is dispersed throughout the fibrous mass. The first fire retardant component may be selected from materials such as borates, polyborates, boric acid, borax, phosphates, or mixtures of these materials. Of these, sodium polyborate is suitable.
A second fire retardant is applied as a coating to the exterior surfaces of the fibrous mass. Sodium silicate has been found to be well suited to this purpose.
The present invention further encompasses alternative methods of making the fire resistant article. One inventive method comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) dispersing a first fire retardant component in the fibrous mass, (c) heating the fibrous mass to a temperature above the softening temperature of the thermoplastic material, (d) compressing the fibrous mass to form a shaped article, (e) applying a coating of a second fire retardant component to the shaped article; and (f) drying the coating.
The first fire retardant may be dispersed through the fibrous mass by any of several methods. Where the first fire retardant is provided in the form of a powder, such methods can include blowing the fire retardant powder into sheets of the fibrous mass, or drawing the fire retardant powder through sheets of the fibrous mass with a reduction in pressure on one side thereof, or using a combination of blowing on one side of the sheet of fibrous mass and creating a region of reduced pressure on the other side. Alternatively, the first fire-retardant can be incorporated into the fibrous mass during the production thereof such as by pre-mixing with the natural fiber component, pre-mixing with the thermoplastic component, or by mixing together with the natural fiber and thermoplastic component, prior to or during the formation of the fibrous mass. After the first fire retardant is dispersed in the fibrous mass, the fibrous mass is then heated to a temperature above the softening temperature of the thermoplastic component to allow the thermoplastic material to soften and bind the natural fibers of the mass. The heated mass is compressed to a desired thickness and then optionally cooled for a period of time while in the compressed state so that the mass retains the desired thickness and achieves the desired rigidity.
The exterior surfaces of the compressed mass are then coated with a second fire retardant composition. In one embodiment, the second fire retardant is present in a solution of liquid medium as either a solution, a suspension or a mixture. This composition may be applied onto the surfaces of the compressed fibrous mass by techniques such as spraying, brushing, roll coating, curtain coating, froth coating and dipping. In one embodiment, the coating is applied by spraying an aqueous solution of above 40% sodium silicate. The coating is then allowed to dry, optionally with heating to drive off the water from the aqueous solution so that the coating sets.
One method of making the fire-resistant article of the present invention is schematically illustrated in
Another method of making a fire-resistant article of the present invention comprises the steps of (a) providing a fibrous mass comprising a mixture of thermoplastic material and natural fibers, (b) dispersing a first fire retardant component in the fibrous mass, (c) applying a coating of a second fire retardant component to the fibrous mass, (d) heating the fibrous mass, and (e) compressing the fibrous mass to form a shaped article, and allowing the compressed mass to cool. In this method, the heating and compression steps can be conducted separately or simultaneously. The materials that can be used in this second method are the same as those that can be used in the first method. This method is illustrated in
Another method of making the fire-resistant article of the present invention is schematically illustrated in
The fire-resistant and/or acoustical absorbing article disclosed herein avoids the use of fiberglass and formaldehyde. The article so made can be used in the manufacture of furniture, office partition panels, ceiling tiles, bulletin boards, and other articles and structures useful in office, school, and industrial environments that require Class A fire-resistant structure and/or noise control.
A fibrous mass is provided comprising about 20% by weight of polypropylene fibers and about 80% by weight of a natural fiber component, the component containing 50 percent by weight of kenaf fiber and 50 percent by weight of industrial hemp fiber. Sodium polyborate powder is blown through the mass. The mass is heated to a temperature of about 375°-380° F. for about 10-15 minutes in a conventional oven. The mass is compressed to a desired thickness and allowed to cool The compressed mass is sprayed on all surfaces with a 40% by weight aqueous solution of sodium silicate, at about 1-2 oz. solution per square foot of surface area. The mass is then heated to a temperature of about 375° for about 1-2 minutes to drive off the water and allow the sodium silicate coating to set. The resulting article can be used in the manufacture of a structure having a flame spread index of less than 25 and a smoke generation index of less than 450, which meets the requirement for a Class A rated fire resistant article. Structures made with the article can be useful in furniture, office partitions, ceiling tiles, and the like.
Modifications and variations of the inventive article and methods are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
This application claims the benefit of U.S. application Ser. No. 11/058,462, filed Feb. 14, 2005, entitled “Fire-Resistant Fiber-Containing Article and Method of Manufacture,” the entire disclosure of which is incorporated by reference herein. This invention relates to a fire-resistant and/or acoustical absorbing article comprising a portion of natural fibers. More particularly, this invention relates to a fire-resistant and/or acoustical absorbing article having a portion of natural fibers and being suitable for use in the manufacture of fire-retardant and/or acoustical absorbing structures, and to a method of manufacturing such an article.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11058462 | Feb 2005 | US |
| Child | 11421328 | May 2006 | US |
