US 9,650,783 B2 · Flame resistant laminate

Abstract

A flame resistant laminate is described, which distinguishes itself by its low heating value ≦3 MJ/kg according to ISO 1716 and thanks to its special multilayer structure has excellent mechanical characteristics and an extraordinarily good stability under changing climatic conditions (hot/humid/cold/dry). The laminate according to the invention comprises several mineral and glass fiber non-woven fabrics with different functionalities and components. This includes high-filled non-woven fabrics, B-stage binders and other additives. Its great mechanical strength as well as the extraordinarily good stability under changing climatic conditions (hot/humid/cold/dry) allow its reasonable use in many areas where until now exclusively laminates according to EN 438 are used and beyond.

A laminate comprising:

A) a symmetrically or asymmetrically arranged laminate core, from a matrix comprising
3-17% by weight of organic binder resin
45-85% by weight of inorganic fillers
10-25% by weight of inorganic fibers,
wherein the sum of the organic binder resin, the inorganic filler and the fibers is 100% and the laminate core has at least 3 core layers;
however, the individual core layers after the completion of the manufacturing are inseparably bonded to each other as well as with the functional layers below and above them, and furthermore,
a density of at least 1.70 g/cm3, determined according to EN ISO 1183-1:2004,
a bending strength of at least 35 MPa, determined according to EN ISO 178:2003,
a bending modulus of at least 7 MPa, determined according to EN ISO 178:2003,
B) at least one intermediate layer, which is applied onto at least one of both surfaces of the laminate core, comprising
(i) at least one stiffening layer, which is applied onto at least one of both surfaces of the laminate core, wherein the stiffening layer comprises
at least one layer made of textile fabric, which has a finally consolidated B-stage binder content of 5-30% by weight, wherein these data refer to the total weight of the textile surface with a binder after its transition to the B-stage state and fibers of the textile fabric are are ceramic fibers, mineral fibers, glass fibers or mixtures thereof, and
(ii) at least one adhesive layer, which is applied onto the surface of the stiffening layer facing away from the laminate core, wherein the adhesive layer comprises
at least one layermade of textile fabric, which has a finally consolidated B-stage binder content of 40-80% by weight, wherein these data refer to the total weight of the textile surface with a binder after its transition to the B-stage state and fibers of the textile fabric are are ceramic fibers, mineral fibers, glass fibers or mixtures thereof, or
(iii) at least one adhesive layer, which is applied onto at least one of both surfaces of the laminate core, wherein the adhesive layer comprises
at least one layer made of textile fabric, which has a finally consolidated B-stage binder content of 40-80% by weight, wherein these data refer to the total weight of the textile surface with a binder after its transition to the B-stage state and fibers of the textile fabric are are ceramic fibers, mineral fibers, glass fibers or mixtures thereof, and
(iv) at least one stiffening layer, which is applied onto the surface of the adhesive layer facing away from the laminate core, wherein the stiffening layer comprises
at least one layer made of textile fabric, which has a finally consolidated B-stage binder content of 5-30% by weight, wherein these data refer to the total weight of the textile surface with a binder after its transition to the B-stage state and fibers of the textile fabric are are ceramic fibers, mineral fibers, glass fibers or mixtures thereof, and
C) at least one decorative layer, which is applied onto the surface of the intermediate layer facing away from the laminate core.

16 more elements

Flame resistant laminate

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Flame resistant laminate

Life of this patent

Abstract

Claims12