# US 8,784,978 B2 · Multilayer flame retardant barrier films and fabrics

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- Number: US 8,784,978 B2
- Document ID: US8784978B2
- Status: Granted
- Kind: B2
- Application number: 11/562,836
- Filed: 2006-11-22
- Published: 2007-06-28
- Granted: 2014-07-22
- Earliest claimed: 2005-11-22
- Assignees: Triton Systems, Inc.
- Applicants: Shah Apoorva; Giaya Arjan; Kim Yoojeong
- Inventors: Shah Apoorva; Giaya Arjan; Kim Yoojeong
- Web page: https://patentgrep.com/patent/US8784978B2

## CPC

- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites
- C08K 3/36: Silica
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/714: Inert, i.e. inert to chemical degradation, corrosion
- B32B 2307/7244: Oxygen barrier
- B32B 2307/7246: Water vapor barrier
- B32B 2437/00: Clothing
- B32B 2571/00: Protective equipment
- Y10T 428/24612: Composite web or sheet
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The invention relates to polymer nanocomposites including either silica or non-platelet metal oxide particle and the use of these polymer noncomposites in the core layer of multilayer barrier films and laminates. The polymer nanocomposites provide high-barrier properties and low gas permeation.

## Claims

### Claim 1

A polymer nanocomposite comprising, ethylene vinyl alcohol having from about 5 mol % to about 95 mol % ethylene, and substantially spherical silica particles, wherein the particles are about 1 nm to about 500 nm in diameter and about 0.5 wt % to about 2 wt % of the total polymer nanocomposite, wherein the polymer nanocomposite includes no organosilane, and wherein said polymer nanocomposite is a cast or blown film up to about 10 mils thick.

### Claim 2 (depends on 1)

The polymer nanocomposite of claim 1, wherein the particles have a surface area of greater than about 50 m2/g.

### Claim 3 (depends on 1)

The polymer nanocomposite of claim 1, wherein the particles have surface hydroxyl groups at a concentration greater than about 2 nm−2.

### Claim 4 (depends on 1)

The polymer nanocomposite of claim 1, wherein the particles are dispersed throughout the ethylene vinyl alcohol.

### Claim 5 (depends on 1)

The polymer nanocomposite of claim 1, wherein the polymer nanocomposite provides a barrier against oxygen, carbon dioxide, water vapor, chemicals, and combinations thereof.

### Claim 6

A barrier film comprising one or more layers of a polymer nanocomposite, said polymer nanocomposite comprising, ethylene vinyl alcohol having from about 5 mol % to about 95 mol % ethylene, and substantially spherical silica particles, wherein the particles are about 1 nm to about 500 nm in diameter and about 0.5 wt % to about 2 wt % of the total polymer nanocomposite, wherein the polymer nanocomposite includes no organosilane, and wherein said barrier film is a cast or blown film up to about 10 mils thick.

### Claim 7 (depends on 6)

The barrier film of claim 6, wherein the barrier film is up to about 2 mils thick.

### Claim 8

A multi-layer barrier film comprising:
at least one core layer of a polymer nanocomposite having an upper surface and a lower surface, said polymer nanocomposite comprising, ethylene vinyl alcohol having from about 5 mol % to about 95 mol % ethylene, and substantially spherical silica particles, wherein the particles are about 1 nm to about 500 nm in diameter and about 0.5 wt % to about 2 wt % of the total polymer nanocomposite, wherein the polymer nanocomposite includes no organosilane, and wherein said core layer is a cast or blown film up to about 10 mils thick; and
at least one second layer adjacent to the upper surface of the at least one core layer; and
at least one third layer adjacent to the lower surface of the at least one core layer;
wherein said at least one second layer and at least one third layer are independently comprised of a polymer other than the polymer nanocomposite of the core layer; and
wherein adjacent layers are attached.

### Claim 9 (depends on 8)

The multi-layer barrier film of claim 8, wherein the at least one second layer and the at least one third layer independently comprise a polymer selected from polyolefins, polyamides, and copolymers and combinations thereof.

### Claim 10 (depends on 9)

The multi-layer barrier film of claim 9, wherein the polyolefins and polyamides are selected from low density polyethylene, polypropylene, Nylon 6, Nylon 6,6, MXD6 Nylon, ethylene vinyl acetate, and copolymers and mixtures thereof.

### Claim 11 (depends on 8)

The multi-layer barrier film of claim 8, wherein the at least one core, second, and third layer are independently comprised of one or more adjacent layers of the same polymer or polymer nanocomposite.

### Claim 12 (depends on 8)

The multi-layer barrier film of claim 8, wherein the at least one second layer and the at least one third layer are independently up to about 4 mils thick.

### Claim 13 (depends on 8)

The multi-layer barrier film of claim 8, further comprising one or more adhesive layers comprised of an adhesive selected from ethylene methacrylic acid, ethylene acrylic acid, maleic anhydride modified polyolefin polymer, ethylene vinyl acetate, and combinations thereof.

### Claim 14 (depends on 8)

The multi-layer barrier film of claim 8, wherein at least one of the at least one second layer and the at least one third layer are flame resistant.

### Claim 15 (depends on 8)

The multi-layer barrier film of claim 8, wherein the multi-layer barrier film has an after flame of at least less than about 5 seconds as determined using an ASTM D6413 method.

### Claim 16 (depends on 8)

The multi-layer barrier film of claim 8, wherein the multi-layer barrier film is non-dripping.

### Claim 17 (depends on 8)

The multi-layer barrier film of claim 8, wherein the at least one second layer and at least one third layer further comprise one or more additives selected from at least one flame retardant, at least one anti-dripping agent, at least one antioxidant, at least one pigment, colorant, or dye, and combinations thereof.

### Claim 18 (depends on 17)

The multi-layer barrier film of claim 17, wherein the flame retardant is selected from clay, silicate clays, modified clays, antimony oxide, antimony trioxide, arsenic, octadecanoic acid, aluminum salt, aluminum tristerate, lead oxide, 1H-isoindole-1,3(2H)-dione,2,2′-(1,2-ethanediyl)BIS(4,5,6,7-tetrabromo) chlorinated parrafins, halogenated flame retardants, and phosphorous based flame retardant additives.

### Claim 19 (depends on 8)

The multi-layer barrier film of claim 8, further comprising one or more material layers to provide a multi-layer barrier laminate.

### Claim 20 (depends on 19)

The multi-layer barrier film of claim 19, wherein the material layers are between the at least one core, second, or third layer, or applied to an outer surface of the multi-layer barrier film, or a combination thereof.

### Claim 21 (depends on 19)

The multi-layer barrier film of claim 19, wherein the one or more material layers comprise at least one material selected from fabrics, scrims, woven or non-woven polymeric fibers, woven or non-woven polyolefin tape or fibers, woven slit film fabric and combinations thereof, said polymeric fibers selected from polyester, nylon, KEVLAR®, nomex, and combinations thereof, and said woven slit film comprising polyethylene, high density polyethylene (HDPE), polypropylene, and combinations thereof.

### Claim 22 (depends on 19)

The multi-layer barrier film of claim 19, wherein the barrier film is used for a liner for a tent or protective clothing.

### Claim 23 (depends on 19)

The multi-layer barrier film of claim 19, wherein the barrier film provides a barrier to chemical warfare agents.

### Claim 24 (depends on 19)

The multi-layer barrier film of claim 19, wherein one or more of the at least one second, third, or material layers further comprise a flame retardant additive.

### Claim 25 (depends on 19)

The multi-layer barrier film of claim 19, wherein the multi-layer barrier film provides a barrier against oxygen, carbon dioxide, water vapor, chemicals, and combinations thereof.

### Claim 26 (depends on 19)

The multi-layer barrier film of claim 19, wherein chemical agent breakthrough of the multi-layer barrier film is prevented for greater than about 72 hours when challenged and tested as per TOP-8-2-501 method.

### Claim 27 (depends on 8)

The multi-layer barrier film of claim 8, wherein chemical agent breakthrough of the multi-layer barrier film is prevented for a time greater than for other barrier films not having silica particles and having a thickness that is the same as the thickness of the multi-layer barrier film as measured using a TOP-8-2-501 method.

### Claim 28 (depends on 1)

The polymer nanocomposite of claim 1, wherein the ethylene vinyl alcohol has from about 25 mol % to about 45 mol % ethylene.

### Claim 29 (depends on 6)

The barrier film of claim 6, wherein the ethylene vinyl alcohol has from about 25 mol % to about 45 mol % ethylene.

### Claim 30 (depends on 8)

The multi-layer barrier film of claim 8, wherein the polymer nanocomposite comprises ethylene vinyl alcohol having from about 25 mol % to about 45 mol % ethylene.

### Claim 31 (depends on 1)

The polymer nanocomposite of claim 1, wherein the silica particles are organically modified silica particles.