Flexible, flame-retardant composite material

Abstract

A flexible, flame-retardant composite material includes a fabric layer; and at least one impregnated or coated Polyvinyl Butyral (PVB) coating layer, which is integral with said fabric layer. The PVB coating layer contains 20 to 60% by weight of PVB, at least one plasticizer in an amount of 5 to 40% by weight of the coating layer, and at least one flame retardant in a total amount of 5 to 75% by weight with respect to the coating layer. A manufacturing method thereof is also described, and includes an impregnation or coating of a water-based dispersion of PVB onto the fabric layer, and a further curing.

1 . A flexible, flame-retardant composite material comprising:
 a fabric layer; and   at least one impregnated or coated Polyvinyl Butyral (PVB) coating layer, which is integral with said fabric layer; the PVB coating layer containing 20 to 60% by weight of PVB, at least one plasticizer in an amount of 5 to 40% by weight of the coating layer, and at least one flame retardant in a total amount of 5 to 75% by weight with respect to the coating layer.   
     
     
         2 . The flexible, flame-retardant composite material according to  claim 1 , wherein said flame retardant is a mixture of antimony trioxide Sb 2 O 3  and at least one halogenated organic compound as flame retardant in a total amount of 5 to 45%, by weight with respect to the coating layer, and in a ratio of 0.1 to 5, part of antimony trioxide Sb 2 O 3  per part of halogenated organic compound. 
     
     
         3 . The flexible, flame-retardant composite material according to  claim 1 , wherein said flame retardant is constituted by melamine cyanurate and ammonium polyphosphate. 
     
     
         4 . The flexible, flame-retardant composite material according to  claim 1 , wherein said material is a rollable fabric. 
     
     
         5 . The flexible, flame-retardant composite material according to  claim 1 , wherein the fabric is a textile-based substrate comprising fibers chosen from the group consisting of polyester, polyamide, polyacrylic, polyethylene, polypropylene, glass, wool, cotton, rayon, linen, bamboo, carbon, steel, copper, and aramid fibers and their mixtures. 
     
     
         6 . The flexible, flame-retardant composite material according to  claim 1 , wherein the PVB coating layer further comprises at least one mineral flame retardant, the mineral flame retardant being present in an amount of 0 to 40% by weight with respect to the coating layer, the flame retardant being chosen from aluminum trihydrate, magnesium hydroxide, zinc borate, sodium borate, sodium metaborate, borax, huntite, hydromagnesite, and their mixtures. 
     
     
         7 . The flexible, flame-retardant composite material according to  claim 1 , wherein the plasticizer is present in an amount of 5 to 25% with respect to the coating layer. 
     
     
         8 . The flexible, flame-retardant composite material according to  claim 1 , wherein the plasticizer originates from recycled PVB waste. 
     
     
         9 . The flexible, flame-retardant composite material according to  claim 1 , wherein the plasticizer is chosen from triethylene glycol, triethylene glycol di(2-ethylhexoate), alkyl phthalate, dibutyl maleate, dibutyl adipate, dibutyl sebacate, tris (2-ethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, triphenyl phosphate, and their mixtures. 
     
     
         10 . The flexible, flame-retardant composite material according to  claim 1 , wherein the PVB of the PVB coating layer is partially crosslinked. 
     
     
         11 . The flexible, flame-retardant composite material according to  claim 1 , wherein the composite material has been manufactured by a manufacturing method comprising:
 Providing a fabric layer,   Providing at least one water-based dispersion of PVB containing the PVB, the plasticizer, at least one crosslinker, and at least one flame retardant;   Impregnating or coating at least one side of the fabric layer with the water-based dispersion of PVB;   Curing the thus impregnated or coated fabric at a temperature of 100 to 200° C.   
     
     
         12 . A manufacturing method for forming the flexible, flame-retardant composite material according to  claim 1 , wherein said method comprises:
 Providing a fabric layer,   Providing at least one water-based dispersion of PVB containing the PVB, the plasticizer, at least one crosslinker, and at least one flame retardant;   Impregnating or coating at least one side of the fabric layer with the water-based dispersion of PVB;   Curing the thus impregnated or coated fabric at a temperature of 100 to 200° C.   
     
     
         13 . The manufacturing method according to  claim 12 , wherein the PVB originates from recycled PVB waste. 
     
     
         14 . The manufacturing method according to  claim 12 , wherein a drying step is carried out after the impregnation step and before the curing step. 
     
     
         15 . The manufacturing method according to  claim 12 , wherein the crosslinker is chosen from blocked isocyanates, isocyanates, carbodiimides and their mixtures, and is present in an amount from more than 0% up to 20% by weight based on the weight of the PVB polymer in the water-based dispersion.