Fire retardant laminate

Abstract

A fire retardant laminate includes a resin impregnated decorative layer, a fire barrier formed from a fiber reinforced veil and a layer of fiberboard. A method of making a fire retardant laminate is also provided.

1 . A fire retardant laminate, comprising: 
 a resin impregnated decorative layer;    a first fire barrier formed from a fiber reinforced veil; and    a layer of fiberboard.    
   
   
       2 . The laminate of  claim 1 , wherein said first fiber reinforced veil includes fibers selected from a group consisting of glass fibers, basalt fibers, metal fibers, inorganic fibers, silica fibers, carbide fibers, nitride fibers, carbon fibers and mixtures thereof.  
   
   
       3 . The laminate of  claim 1 , wherein said first fiber reinforced veil includes glass fibers selected from a group of fibers including boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and mixtures thereof.  
   
   
       4 . The laminate of  claim 1 , wherein said first fiber reinforced veil includes a binder comprising a B-stageable resin.  
   
   
       5 . The laminate of  claim 1 , wherein said first fiber reinforced veil includes a binder selected from a group consisting of polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin, polyamide-amine epichlorohydrin resin and mixtures thereof.  
   
   
       6 . The laminate of  claim 1 , wherein said first fiber reinforced veil includes a filler selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, general intumescent systems and mixtures thereof.  
   
   
       7 . The laminate of  claim 1 , wherein said first fiber reinforced veil is nonwoven.  
   
   
       8 . The laminate of  claim 1 , further including a second fire barrier formed from a fiber reinforced veil, said layer of fiberboard being sandwiched between said first and second fire barriers.  
   
   
       9 . The laminate of  claim 8 , wherein said fiber reinforced veils of said first and second fire barriers following resin impregnation include between about 5 to about 95 weight percent reinforcement fibers, about 5 to about 75 weight percent binder and 0 to about 80 weight percent filler.  
   
   
       10 . The laminate of  claim 9 , wherein said fiber reinforced veils of said first and second fire barriers include a resin binder selected from a group consisting of polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin, polyamide-amine epichlorohydrin resin and mixtures thereof.  
   
   
       11 . The laminate of  claim 10 , wherein said fiber reinforced veils of said first and second fire barriers include a filler selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads, ethylenediaminephosphate, guanidinephosphates, melamine borate, melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly) phosphate, dicyandiamide condensates, general intumescent systems and mixtures thereof.  
   
   
       12 . The laminate of  claim 9  wherein said fiber reinforced veils of said first and second fire barriers following impregnation and prior to pressing have a weight per unit area of between about 20 and about 500 g/m 2 .  
   
   
       13 . The laminate of  claim 1 , wherein said layer of fiberboard is a wood-based panel.  
   
   
       14 . The laminate of  claim 1 , wherein said layer of fiberboard is selected from a group of materials consisting of high density fiberboard, medium density fiberboard, oriented strand board, chipboard and mixtures thereof.  
   
   
       15 . The laminate of  claim 1 , further including a layer of resin impregnated overlay paper overlying said resin impregnated decorative layer and a resin impregnated backing layer underlying said layer of fiberboard.  
   
   
       16 . The laminate of  claim 15 , further including a resin impregnated backing layer underlying said layer of fiberboard.  
   
   
       17 . The laminate of  claim 16 , wherein said resin impregnated decorative layer and said resin impregnated backing layer are both made from decorative paper.  
   
   
       18 . The laminate of  claim 1 , wherein said laminate is a flooring laminate.  
   
   
       19 . The laminate of  claim 1 , wherein said laminate is classified in impact class 3 (IC3).  
   
   
       20 . A method of making a fire retardant laminate, comprising: 
 pressing a resin impregnated overlay layer, a resin impregnated decorative layer, a fire barrier formed from a resin impregnated, fiber reinforced veil, a layer of fiberboard and a resin impregnated backing layer together at a pressure of between about 1050 N/m 2  and about 5250 N/m 2  while simultaneously heating to a temperature of between about 150 to about 225 degrees C. for a time period of between about 10 to about 50 seconds.    
   
   
       21 . The method of  claim 20 , further including a step of providing a resin binder in said fiber reinforced veil selected from a group consisting of polyvinyl alcohol, acrylates, styrene acrylates, melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated polyesters, crosslinkable acrylic resin, polyurethane resin, polyamide-amine epichlorohydrin resin and mixtures thereof.  
   
   
       22 . The method of  claim 21 , further including a step of providing a filler in said fiber reinforced veil selected from a group consisting of aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenated additive, antimony trioxide, metal hydroxide, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass microbeads and mixtures thereof.  
   
   
       23 . The method of  claim 20 , including providing a second fire barrier formed from a resin impregnated, fiber reinforced veil between said layer of fiberboard and said resin impregnated backing layer.