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WO2021154182A1 - A fabric coating emulsion - Google Patents

A fabric coating emulsion Download PDF

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Publication number
WO2021154182A1
WO2021154182A1 PCT/TR2021/050072 TR2021050072W WO2021154182A1 WO 2021154182 A1 WO2021154182 A1 WO 2021154182A1 TR 2021050072 W TR2021050072 W TR 2021050072W WO 2021154182 A1 WO2021154182 A1 WO 2021154182A1
Authority
WO
WIPO (PCT)
Prior art keywords
coating emulsion
coating
fire retardant
fabric
emulsion
Prior art date
Application number
PCT/TR2021/050072
Other languages
French (fr)
Inventor
Burak KIRAYOĞLU
Original Assignee
Kirayteks Tekstil Sanayi Ve Ticaret A.S.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kirayteks Tekstil Sanayi Ve Ticaret A.S. filed Critical Kirayteks Tekstil Sanayi Ve Ticaret A.S.
Priority to EP21747569.8A priority Critical patent/EP4097327A4/en
Publication of WO2021154182A1 publication Critical patent/WO2021154182A1/en

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/30—Ink jet printing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/46—Oxides or hydroxides of elements of Groups 4 or 14 of the Periodic Table; Titanates; Zirconates; Stannates; Plumbates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/68—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with phosphorus or compounds thereof, e.g. with chlorophosphonic acid or salts thereof
    • D06M11/72—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with phosphorus or compounds thereof, e.g. with chlorophosphonic acid or salts thereof with metaphosphoric acids or their salts; with polyphosphoric acids or their salts; with perphosphoric acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/73—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof
    • D06M11/74—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon or graphite; with carbides; with graphitic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/04—Processes in which the treating agent is applied in the form of a foam
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
    • D06N3/0045—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers obtained by applying a ready-made foam layer; obtained by compressing, crinkling or crushing a foam layer, e.g. Kaschierverfahren für Schaumschicht
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0063—Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B9/00—Screening or protective devices for wall or similar openings, with or without operating or securing mechanisms; Closures of similar construction
    • E06B9/24—Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blinds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/73—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof
    • D06M11/76—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon oxides or carbonates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
    • D06M2200/30—Flame or heat resistance, fire retardancy properties
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/08—Properties of the materials having optical properties
    • D06N2209/0853—Opaque
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/125—Awnings, sunblinds

Definitions

  • the invention relates to a fabric coating emulsion that provides elasticity feature even at low temperatures, fire retardation and blackout features to fabrics.
  • the invention relates to roller blind fabric coating emulsion, which has high breaking strength against cold by addition of polyurethane, fire retardant feature by addition of bromine based chemicals, blackout feature by application of crushed foam coating technique.
  • blackout curtains In environments such as hotels, bedrooms, laboratories, hospitals, offices, meeting rooms, where daylight should not enter when desired, it is quite common to use blackout curtains.
  • these blackout curtains can be made from woven or knitted fabric using the crushed foam coating method.
  • Roller blinds which have been used frequently in recent years, are generally produced by coating acrylic material on polyester fabric. Coating is one of the production methods of textile products that stand out with their technical performance and functional properties rather than their appearance and aesthetic features.
  • the performance and functional characteristics of fabrics produced by the coating method differ depending on the coating material used, the technique applied and the construction and characteristics of the textile surface.
  • chemicals are transferred to the fabric in powder, paste or foam form and a film layer is formed on the fabric. While the fabrics used on the ground provide properties such as rupture, tearing and elongation in the final product, the coating material provides porosity, protection of the fabric from chemical and environmental effects and in some cases, appearance improvement.
  • the most used materials in coating silicone, PTFE, PVC, EVA, Polyurethane, Acrylic and Fluoroelastomer.
  • the most used ground fabrics in coating It is produced from yarn types such as cotton, polyester, polyamide, polyethylene, polypropylene, aramid and fiber glass.
  • the method to be applied for the coating process, as well as the ground fabric and coating material, determines the performance characteristics of the final product.
  • the techniques used in coating are;
  • the classic coating is plasma technology and sol-gel technology.
  • the basis of classical coating techniques is absorption and subsequent drying of a constant width in dry hot air environment and mostly in the stenter.
  • the utility model no TR201508328 relates to a waterproof blackout roller blind fabric configuration which is waterproof, washable, ironable, scratchproof, undeformable in the curtain sector, which is used in homes, offices, hotels and especially in the meeting rooms of workplaces, bedrooms, children's rooms, photo studios or laboratories where it is required to avoid light, and most importantly, no light.
  • the blackout roller blind fabric configuration mentioned in the document consists of three layers, namely the fabric lower surface layer, the fabric upper surface layer and the blackout membrane interlayer.
  • the blackout membrane interlayer is made of thermoplastic polyurethane.
  • a coloring chemical active substance called masterbatch is used in its content. This substance is a granular color that is involved in the plastic raw material during the melting and forming of thermoplastic polymers. By means of this coloring chemical active substance, the darkening membrane has the property of opaque. In the document, it is included to gain the properties of being light-proof and soft. However, there is no mention of properties relating to retention of elastic structure and fire retardancy at low temperatures.
  • polyester fiber with low light transmission and fire retardant properties.
  • the polyester fiber comprises: phosphorus-based fire retardant 0.05-5% by weight, based on phosphorus atom; and inorganic particles having 0.05 - 1 pm average particle size 1-5% by weight, based on fiber weight.
  • the polyester fiber according to the document is prepared from polyester polymer having Intrinsic viscosity of 0.55-0.75 dl/g and the Intrinsic viscosity difference of between the fiber and polymer (IV drop) is within 0.03 dl/g and it exhibits the excellent fire retardant and light shielding characteristic. Therefore, it can be applied to polyester fiber fabrics, blackout curtains.
  • this method can only be produced from certain polyester yarns in a limited way and will not show the full blackout feature in any way as it does not contain a covering coating on the fabric surface.
  • it also features reduced light transmission and fire retardant properties, but does not mention the strength to breakage, which is the flexibility.
  • KR20080094460 A
  • a multi-functional fire-retardant fabric which allows functions of insulation, light shielding and sound insulation as well as fire retarding function and to simplify manufacturing process of the fabric is mentioned. It contains polyurethane-resin mixture with fire retardant material. However, breaking strength is not mentioned.
  • the aim of the present invention is to provide a fabric coating emulsion that gives elasticity feature even at low temperatures, fire retardation and blackout features to fabrics.
  • Water based fabric coating emulsion of the invention provides a fabric coating emulsion that gives elasticity feature even at low temperatures, fire retardation and blackout features to fabrics and it comprises; between 15% to 65% by weight ratio acrylic polymer between 5% to 40% by weight ratio polyurethane polymer between 3% to 15% by weight ratio titanium dioxide between 1% to 10% by weight ratio clay between 0.5% and 5% by weight ratio melamine formaldehyde between 1% to 15% by weight ratio ammonium stearate between 0.5% to 5% by weight ratio ammonium hydroxide between 10% to 45% by weight ratio decabrom diphenyl ethane between 10% to 40% by weight ratio water.
  • the invention discloses a a fabric coating emulsion with fire retardant and blackout properties that solves the problem of the fire-retardant coatings losing their flexibility due to changes in ambient temperature and can maintain their flexibility even at low temperatures.
  • Yarns used for roller blind fabrics include polyester, nylon and cotton. Although not limited to these, polyester yarns are preferred, especially for fire retardant blackout curtain fabrics.
  • crushed foam used as the coating method is the coating layer that is mechanically pressed and crushed to reduce the thickness of the coating after the coating is rubbed on the fabric and dried.
  • the foam to be crushed initially has a wet foam density between 100 g/lt and 600 g/lt. It is applied at an average thickness in the range of about 200 pm to 1500 pm, preferably between 300 pm and 900 pm.
  • the temperature value and drying time to be applied in the process of drying the wet foam coated on the fabric surface varies depending on the type of fabric to be coated and the thickness of the coating, but generally varies between about 1 minute and 15 minutes at a temperature between 80°C and 140°C.
  • the crushing process is done right after the drying process.
  • one or more crushed foam coated layers are formed.
  • the emulsion and processing steps of the coating for each layer applied are as mentioned above.
  • the resulting coating is preferably fixed by heat. Fixation is the temperature-heating step. In this way, cross links are formed between the layers and the reaction on the fabric.
  • the acrylic binder polymer is a polymer present in mentioned water based coating emulsion as particles or a combination thereof in dissolved or dispersed form. These binder polymers form a coating layer that bonds to the fabric by applying a layer of the water based coating emulsion under the usage conditions of the present invention.
  • the ratio by weight of the total amount of solid acrylic polymer in the water based coating emulsion to the total weight of the coating emulsion ranges between 20% - 70%. It will preferably be in the range between 35% - 55%.
  • pigments or fillers such as kaolin-type clay, calcium carbonate, talc, titanium dioxide, carbon black or both should be included in the water based coating emulsion.
  • the amount of total solid pigments or fillers or both in the water based coating emulsion is between 3% - 30% by weight of the coating emulsion to the total weight. It will preferably be in the range between 5% - 20%.
  • Various metal salts such as aluminum hydrate, ammonium polyphosphate or fire retardant materials such as bromine based chemicals should be included.
  • the proportion by weight of the total amount of fire retardant additives in the water based coating emulsion to the total weight ranges between 15% - 50%. It will preferably be in the range between 20% - 40%.
  • the proportion by weight of the total amount of solid polyurethane polymer in the water based coating emulsion is in the range of 3 to 40%, preferably between 5 - 20%.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Structural Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Laminated Bodies (AREA)
  • Paints Or Removers (AREA)

Abstract

The invention relates to a fabric coating emulsion that provides elasticity feature even at low temperatures, fire retardation and blackout features to fabrics. More specifically, the invention relates to roller blind fabric coating emulsion, which has high breaking strength against cold by adding polyurethane, fire retardant feature by adding bromine based chemicals, blackout feature by applying crushed foam coating technique.

Description

A FABRIC COATING EMULSION
DESCRIPTION
Technical Field
The invention relates to a fabric coating emulsion that provides elasticity feature even at low temperatures, fire retardation and blackout features to fabrics.
More specifically, the invention relates to roller blind fabric coating emulsion, which has high breaking strength against cold by addition of polyurethane, fire retardant feature by addition of bromine based chemicals, blackout feature by application of crushed foam coating technique.
Prior Art
Today, advanced technological studies continue in the textile sector as in every field. These studies are generally on the issues of reducing the heat and light transmittance of the fabric, increasing its strength to fire and preserving its flexibility against breakage under low temperature conditions.
Since textile products are first flammable materials in a possible fire, it has become a necessity for textile products to be fire retardant in order to minimize the damages in such a situation. Various methods are used to produce fire retardant fabrics. These are using fire-retardant fibres, modifying the structure of fibers by copolymerization and chemical modification, or adding fire-retardant chemicals to synthetic polymer to obtain fire-retardant fibers or treating fabrics with non-flammable chemicals. Recently, nanotechnology, microencapsulation and plasma technology have been used as new methods.
In environments such as hotels, bedrooms, laboratories, hospitals, offices, meeting rooms, where daylight should not enter when desired, it is quite common to use blackout curtains. Today, these blackout curtains can be made from woven or knitted fabric using the crushed foam coating method.
Roller blinds, which have been used frequently in recent years, are generally produced by coating acrylic material on polyester fabric. Coating is one of the production methods of textile products that stand out with their technical performance and functional properties rather than their appearance and aesthetic features. The performance and functional characteristics of fabrics produced by the coating method differ depending on the coating material used, the technique applied and the construction and characteristics of the textile surface. In the coating process, chemicals are transferred to the fabric in powder, paste or foam form and a film layer is formed on the fabric. While the fabrics used on the ground provide properties such as rupture, tearing and elongation in the final product, the coating material provides porosity, protection of the fabric from chemical and environmental effects and in some cases, appearance improvement. The most used materials in coating; silicone, PTFE, PVC, EVA, Polyurethane, Acrylic and Fluoroelastomer. The most used ground fabrics in coating; It is produced from yarn types such as cotton, polyester, polyamide, polyethylene, polypropylene, aramid and fiber glass. The method to be applied for the coating process, as well as the ground fabric and coating material, determines the performance characteristics of the final product. The techniques used in coating are; The classic coating is plasma technology and sol-gel technology. The basis of classical coating techniques is absorption and subsequent drying of a constant width in dry hot air environment and mostly in the stenter.
Today, pure acrylic or acrylic copolymer materials are used in products made with the crushed foam coating method. Acrylic materials are not enough for stand-alone use, both in terms of flexibility performance at low temperature and fire retardation.
Curtains, which are frequently used by many people especially in crowded environments, are expected to have high resistance to deformation against force. However, with the combination of blackout and fire retardant properties on the same fabric, the durability of such products decreases considerably. Mixing chemicals that add fire-retardant properties to binder resin in coating emulsion opens the resin's intermolecular bonds and creates a more brittle coating layer. Therefore, they are easily affected by changes in ambient temperatures and lose their flexibility. Especially for such fabrics that are planned to be used as roller blinds, a problem arises in wrapping the curtain on the pipe. This situation made it necessary to develop a fabric that is not affected by ambient temperature, that is flexible even at low temperatures and allows to be wrapped, has fire retardant and blackout properties, and a fabric coating emulsion thereof.
In the document US4001158 (A) crushed foam-backed fabrics possessing improved dry cleaning resistance and cold crack resistance are provided using aqueous emulsion copolymers of ethylene and vinyl acetate. However, fire retardation is not mentioned here.
The utility model no TR201508328 relates to a waterproof blackout roller blind fabric configuration which is waterproof, washable, ironable, scratchproof, undeformable in the curtain sector, which is used in homes, offices, hotels and especially in the meeting rooms of workplaces, bedrooms, children's rooms, photo studios or laboratories where it is required to avoid light, and most importantly, no light. The blackout roller blind fabric configuration mentioned in the document consists of three layers, namely the fabric lower surface layer, the fabric upper surface layer and the blackout membrane interlayer. The blackout membrane interlayer is made of thermoplastic polyurethane. A coloring chemical active substance called masterbatch is used in its content. This substance is a granular color that is involved in the plastic raw material during the melting and forming of thermoplastic polymers. By means of this coloring chemical active substance, the darkening membrane has the property of opaque. In the document, it is included to gain the properties of being light-proof and soft. However, there is no mention of properties relating to retention of elastic structure and fire retardancy at low temperatures.
In EP1831442 (A1), a polyester fiber with low light transmission and fire retardant properties is mentioned. The polyester fiber comprises: phosphorus-based fire retardant 0.05-5% by weight, based on phosphorus atom; and inorganic particles having 0.05 - 1 pm average particle size 1-5% by weight, based on fiber weight. The polyester fiber according to the document is prepared from polyester polymer having Intrinsic viscosity of 0.55-0.75 dl/g and the Intrinsic viscosity difference of between the fiber and polymer (IV drop) is within 0.03 dl/g and it exhibits the excellent fire retardant and light shielding characteristic. Therefore, it can be applied to polyester fiber fabrics, blackout curtains. However, this method can only be produced from certain polyester yarns in a limited way and will not show the full blackout feature in any way as it does not contain a covering coating on the fabric surface. In addition, it also features reduced light transmission and fire retardant properties, but does not mention the strength to breakage, which is the flexibility.
In KR20080094460 (A), a multi-functional fire-retardant fabric which allows functions of insulation, light shielding and sound insulation as well as fire retarding function and to simplify manufacturing process of the fabric is mentioned. It contains polyurethane-resin mixture with fire retardant material. However, breaking strength is not mentioned.
Objectives and Short Description of the Invention
The aim of the present invention is to provide a fabric coating emulsion that gives elasticity feature even at low temperatures, fire retardation and blackout features to fabrics.
Another aim of the present invention is to solve the problem of fire retardant coatings losing their flexibility by being affected by changes in ambient temperature and to obtain a fabric coating emulsion that can maintain its flexibility even at low air temperatures and has fire retardant and blackout properties. Water based fabric coating emulsion of the invention provides a fabric coating emulsion that gives elasticity feature even at low temperatures, fire retardation and blackout features to fabrics and it comprises; between 15% to 65% by weight ratio acrylic polymer between 5% to 40% by weight ratio polyurethane polymer between 3% to 15% by weight ratio titanium dioxide between 1% to 10% by weight ratio clay between 0.5% and 5% by weight ratio melamine formaldehyde between 1% to 15% by weight ratio ammonium stearate between 0.5% to 5% by weight ratio ammonium hydroxide between 10% to 45% by weight ratio decabrom diphenyl ethane between 10% to 40% by weight ratio water.
Detailed Description of the Invention
The invention discloses a a fabric coating emulsion with fire retardant and blackout properties that solves the problem of the fire-retardant coatings losing their flexibility due to changes in ambient temperature and can maintain their flexibility even at low temperatures.
Yarns used for roller blind fabrics include polyester, nylon and cotton. Although not limited to these, polyester yarns are preferred, especially for fire retardant blackout curtain fabrics.
The term "crushed foam" used as the coating method is the coating layer that is mechanically pressed and crushed to reduce the thickness of the coating after the coating is rubbed on the fabric and dried.
The foam to be crushed initially has a wet foam density between 100 g/lt and 600 g/lt. It is applied at an average thickness in the range of about 200 pm to 1500 pm, preferably between 300 pm and 900 pm.
The temperature value and drying time to be applied in the process of drying the wet foam coated on the fabric surface varies depending on the type of fabric to be coated and the thickness of the coating, but generally varies between about 1 minute and 15 minutes at a temperature between 80°C and 140°C.
The crushing process is done right after the drying process. In addition to the surface of the first layer of crushed foam coating formed on the fabric surface, one or more crushed foam coated layers are formed. The emulsion and processing steps of the coating for each layer applied are as mentioned above.
After all of the crushed foam coating layers are formed, the resulting coating is preferably fixed by heat. Fixation is the temperature-heating step. In this way, cross links are formed between the layers and the reaction on the fabric.
The acrylic binder polymer is a polymer present in mentioned water based coating emulsion as particles or a combination thereof in dissolved or dispersed form. These binder polymers form a coating layer that bonds to the fabric by applying a layer of the water based coating emulsion under the usage conditions of the present invention. The ratio by weight of the total amount of solid acrylic polymer in the water based coating emulsion to the total weight of the coating emulsion ranges between 20% - 70%. It will preferably be in the range between 35% - 55%.
In order to obtain a crushed foam coating that will prevent the sunlight and provide a blackout feature; pigments or fillers such as kaolin-type clay, calcium carbonate, talc, titanium dioxide, carbon black or both should be included in the water based coating emulsion. The amount of total solid pigments or fillers or both in the water based coating emulsion is between 3% - 30% by weight of the coating emulsion to the total weight. It will preferably be in the range between 5% - 20%.
To provide fire retardant properties to crushed foam coating layer; Various metal salts such as aluminum hydrate, ammonium polyphosphate or fire retardant materials such as bromine based chemicals should be included. The proportion by weight of the total amount of fire retardant additives in the water based coating emulsion to the total weight ranges between 15% - 50%. It will preferably be in the range between 20% - 40%.
To increase the breaking strength of the coating layer against low temperatures, it is necessary to include a suitable proportion of polyurethane polymer in the coating emulsion. The proportion by weight of the total amount of solid polyurethane polymer in the water based coating emulsion is in the range of 3 to 40%, preferably between 5 - 20%.

Claims

1. A water based fabric coating emulsion characterized by inclusion of pigments or fillers such as kaolin-type clay, calcium carbonate, talc, titanium dioxide, carbon black or both in the water-based coating emulsion for preventing the sunlight and providing the blackout property, and the proportion by weight of total fire retardant additives in the water based coating emulsion is being in the range of 15% to 50%, preferably between 20% - 40% inclusion of various metal salts such as aluminum hydrate, ammonium polyphosphate or fire retardant materials such as decabromium diphenyl ethane for providing fire retardant properties, the proportion of total fire retardant additives in the water-based coating emulsion is being in the range of 15% to 50% by weight, preferably in the range between 20% - 40% inclusion of polyurethane polymer in the coating emulsion for increasing the breaking strength of the coating layer against low temperatures, and the total amount of solid polyurethane polymer is being in the range of 3% to 40% by weight, preferably between 5% - 20%.
PCT/TR2021/050072 2020-01-28 2021-01-27 A fabric coating emulsion WO2021154182A1 (en)

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TR2020/01260 2020-01-28
TR2020/01260A TR202001260A2 (en) 2020-01-28 2020-01-28 A FABRIC COATING EMULSION

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KR100736437B1 (en) * 2006-06-27 2007-07-09 이상민 Semi-black screen and the method of manufacturing the same coated with a multilayer polymer resin layer on the fiber
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EP4097327A1 (en) 2022-12-07
TR202001260A2 (en) 2021-08-23

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