Fire resistant laminates and articles made therefrom
Laminates suitable for constructing waterproof and breathable articles such as protective clothing which are both comfortable and exhibit enhanced resistance to fire are described. Particularly, flame resistant laminate constructions are described comprising a meltable textile as the outermost layer laminated to an intermediate protective layer comprising a waterproof film laminated to an innermost fabric layer comprising a thermally stable textile. Laminate constructions of the present invention exhibit breathability on the order of at least 1000 MVTR, a water entry pressure of at least 0.5 psi and have a horizontal flame break open time of at least 10 seconds.
1. A laminate comprising:
a layer of meltable face textile;
a first flame retardant adhesive material bonding said face textile to a protective layer comprising at least two layers of expanded PTFE bonded together, wherein said at least two layers of expanded PTFE are bonded together with a polyurethane adhesive;
a second flame retardant adhesive material bonding said protective layer to
a thermally stable backer textile layer, said thermally stable backer textile layer being non-meltable at temperatures up to about 265° C.
2. The laminate of claim 1 , wherein said meltable face textile layer comprises at least one material selected from the group consisting of nylon, polyester, polypropylene, modacrylic and polyethylene.
3. The laminate of claim 1 , wherein said meltable face textile layer comprises at least one material selected from the group consisting of nylon 6, nylon 6,6 and nylon 4,6.
4. The laminate of claim 1 , wherein said second flame retardant adhesive comprises at least one material selected from the group consisting of polyester and silicone.
5. The laminate of claim 1 , wherein said thermally stable backer textile layer comprises at least one material selected from the group consisting of wovens, knits, nonwovens and flock fibers adhered to a substrate.
6. The laminate of claim 1 , wherein said thermally stable backer textile layer comprises at least one material selected from the group consisting of aramids, cottons, rayon, wool, modacrylic blends, and blends and combinations thereof.
7. The laminate of claim 1 in the form of a garment.
8. The laminate of claim 1 in the form of a bivy bag.
9. The laminate of claim 1 in the form of a tent.
10. The laminate of claim 1 , wherein said laminate has an overall laminate weight of about 20 oz/yd 2 or less.
11. The laminate of claim 1 , wherein said laminate has an overall laminate weight of about 10 oz/yd 2 or less.
12. The laminate of claim 1 , wherein said laminate has an overall laminate weight of about 7 oz/yd 2 or less.
13. The laminate of claim 1 , wherein said laminate has a breathability of >4000 MVTR.
14. The laminate of claim 1 , wherein said meltable face textile comprises at least one material selected from the group consisting of polyamide and polyester.
15. The laminate of claim 1 , wherein said first flame retardant adhesive material includes at least one material selected from the group consisting of chlorinated compounds, brominated compounds, antimony oxide, organic phosphorous-based compounds, zinc borate, ammonium polyphosphate, melamine cyanurate, melamine polyphosphate, molybdenum compounds, alumina trihydrate and magnesium hydroxide.
16. The laminate of claim 1 , wherein said second flame retardant adhesive material includes at least one material selected from the group consisting of chlorinated compounds, brominated compounds, antimony oxide, organic phosphorous-based compounds, zinc borate, ammonium polyphosphate, melamine cyanurate, melamine polyphosphate, molybdenum compounds, alumina trihydrate and magnesium hydroxide.
17. The laminate of claim 1 , wherein said laminate has a water entry pressure of at least 0.7 psi.
18. The laminate of claim 1 , wherein said polyurethane adhesive comprises a continuous polyurethane adhesive layer.
19. The laminate of claim 1 , wherein said laminate has a horizontal flame break open time of at least 20 seconds.
20. The laminate of claim 1 , wherein said laminate self-extinguishes within five seconds after removal from a flame.
21. A laminate comprising:
a meltable outer textile layer comprising a member selected from the group consisting of polyamide, polyester, polypropylene and polyethylene;
a first adhesive material bonding said outer textile layer to
a protective layer comprising a waterproof film, wherein the protective layer comprises at least two layers of expanded polytetrafluoroethylene bonded together with a polyurethane adhesive;
a second adhesive material bonding said protective layer to
a thermally stable backer textile layer, said thermally stable backer textile layer being selected from the group consisting of aramids, cottons, carbon, fiberglass, rayon, wool, modacrylic blends and combinations thereof.
22. The laminate of claim 21 , wherein said laminate self-extinguishes within five seconds after removal from a flame.
23. The laminate of claim 21 , wherein at least one of said first adhesive material and said second adhesive material enhance the flame resistance of said laminate.
24. The laminate of claim 21 , wherein said outer meltable outer textile layer comprises at least one material selected from the group consisting of polyamide and polyester.
25. The laminate of claim 21 , wherein said laminate has a breathability >1000 MVTR.
26. The laminate of claim 21 , wherein said laminate has a water entry pressure of at least 0.5 psi.
27. The laminate of claim 21 , wherein said laminate has a horizontal flame break open time of at least 20 seconds.
28. A laminate comprising:
a meltable outer textile layer;
a first adhesive material bonding said outer textile layer to
a protective layer comprising at least two layers of polytetrafluoroethylene or expanded polytetrafluoroethylene, wherein the two layers of polytetrafluoroethylene or expanded polytetrafluoroethylene are bonded together with a polyurethane adhesive;
a second adhesive material bonding said protective layer to
a thermally stable backer textile layer, said thermally stable backer textile layer being thermally stable at temperatures up to about 265° C.
29. The laminate of claim 28 , wherein said laminate self-extinguishes.
30. The laminate of claim 29 , wherein said laminate self-extinguishes within five seconds after removal from a flame.
31. The laminate of claim 28 , wherein at least one of said first adhesive material and said second adhesive material enhances the flame resistance of said laminate.
32. The laminate of claim 28 , wherein said outer meltable outer textile layer comprises at least one material selected from the group consisting of polyamide and polyester.
33. The laminate of claim 28 , wherein said laminate has a horizontal flame break open time of at least 20 seconds.