Fire and Smoke Suppressing Surface for Substrates

Abstract

This invention relates generally to fabrics, films, sheets and other supporting media that contain and transport fire retarding materials. These transport media deliver fire retarding and smoke suppressing constituents to the surface of fiber reinforced polymer (FRP) composite substrates during a manufacturing process. Upon exposure to open flame or radiant heat, the resultant manufactured product has much lower surface flammability and smoke development characteristics than would otherwise be achieved by the substrate material alone. By economizing the fire retardant constituents at the surface only, cost is reduced while also avoiding deleterious adulteration of the substrate material. When fire is prevented from penetrating the surface, combustion of the entire part is delayed or prevented. By embedding fire retardant within the surface using the native resin, no peeling or chipping occurs (as with paint), and the finish will be essentially as hard and durable as an untreated part.

What is claimed is: 
     
         1 . A fire resistant structure comprising a porous fabric encapsulated within and at the surface of a resin-reinforced structure comprising a polymer resin, said porous fabric wetted or saturated with said polymer resin, and said porous fabric comprising a fire resistant composition. 
     
     
         2 . The structure of  claim 1  wherein the resin-reinforced structure is selected from the group consisting of a polymer pultrusion, a reinforced thermoplastic, and a reinforced thermoset. 
     
     
         3 . The structure of  claim 1  wherein said fire resistant composition comprises a fire resistant powder. 
     
     
         4 . The structure of  claim 3  wherein said fire resistant composition comprises said powder mixed with a binder. 
     
     
         5 . The structure of  claim 4  wherein said binder is selected from the group consisting of adhesive, hot melt adhesive, polymer resin, resin, adhesive resin, styrenic, olefinic, acrylic, cellulosic, polyester, phenolic, rosin, shellfish resin, polyamide, aliphatic adhesive binding compound, aromatic organic adhesive binding compound, thermoset resin, curable resin, and thermoplastic. 
     
     
         6 . The structure of  claim 4  wherein said fire resistant composition comprises a dried slurry comprising said powder and said binder. 
     
     
         7 . The structure of  claim 6  wherein said slurry is disposed substantially on a surface of said porous fabric. 
     
     
         8 . The structure of  claim 3  wherein said fire resistant composition comprises said powder mixed with said polymer resin. 
     
     
         9 . The structure of  claim 1  wherein said porous fabric comprises a material selected from the group consisting of cloth, fabric, non-woven fabric, woven fabric, knitted fabric, air texturized fabric, rovings, woven rovings, woven yarn, veil, surfacing matte, basalt fabric, air texturized fabric, needle punched fabric, felt, fleece, crochet, knotted fabric, tufted fabric, lace, pile, twill fabric, glass fabric, carbon fabric, polyamide fabric, aramide fabric, ceramic fabric, mineral fabric, metal fabric, thermoset fabric, and thermoplastic fabric. 
     
     
         10 . The structure of  claim 1  wherein said porous fabric comprises a material selected from the group consisting of Kevlar® fabric, Nomex® fabric, TWINTEX® fabric, and POLYSTRAND® fabric. 
     
     
         11 . The structure of  claim 1  wherein said porous fabric comprises woven commingled glass filaments and/or thermoplastic filaments. 
     
     
         12 . The structure of  claim 1  wherein said fire resistant composition is intumescent. 
     
     
         13 . The structure of  claim 12  wherein said fire resistant composition comprises a constituent selected from the group consisting of a fire retardant smoke suppressant, cement, a ceramic, graphite, silica, silica flour, aluminum trihydrate, and a combination thereof. 
     
     
         14 . The structure of  claim 1  wherein said polymer resin is flammable.