U.S. patent application number 11/370607 was filed with the patent office on 2006-10-19 for fire retardant laminate.
Invention is credited to Robert W.M. Huusken.
Application Number | 20060234027 11/370607 |
Document ID | / |
Family ID | 38802418 |
Filed Date | 2006-10-19 |
United States Patent
Application |
20060234027 |
Kind Code |
A1 |
Huusken; Robert W.M. |
October 19, 2006 |
Fire retardant laminate
Abstract
A fire retardant laminate includes a resin impregnated
decorative layer, a fire barrier formed from a fiber reinforced
veil and a layer of fiberboard. A method of making a fire retardant
laminate is also provided.
Inventors: |
Huusken; Robert W.M.; (De
Lutte, NL) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
38802418 |
Appl. No.: |
11/370607 |
Filed: |
March 8, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11108340 |
Apr 18, 2005 |
|
|
|
11370607 |
Mar 8, 2006 |
|
|
|
Current U.S.
Class: |
428/292.1 |
Current CPC
Class: |
B32B 2607/02 20130101;
B32B 2260/046 20130101; B32B 33/00 20130101; B32B 2262/10 20130101;
B32B 5/024 20130101; B32B 2264/102 20130101; B32B 2264/104
20130101; B32B 2307/54 20130101; B32B 2260/021 20130101; B32B
2307/306 20130101; B32B 27/04 20130101; B32B 2305/08 20130101; B32B
29/00 20130101; B32B 5/10 20130101; B32B 2305/30 20130101; B32B
5/26 20130101; B32B 2264/12 20130101; B32B 2607/00 20130101; B32B
2262/101 20130101; B32B 2307/31 20130101; B32B 19/06 20130101; B32B
2601/00 20130101; B32B 5/022 20130101; B32B 2264/101 20130101; B32B
29/02 20130101; B32B 2250/40 20130101; B32B 2260/028 20130101; B32B
2262/14 20130101; Y10T 428/249924 20150401; B44C 5/0469 20130101;
B32B 2309/12 20130101; B32B 2307/5825 20130101; B32B 2309/02
20130101; B32B 2317/125 20130101; B32B 2479/00 20130101 |
Class at
Publication: |
428/292.1 |
International
Class: |
D04H 3/00 20060101
D04H003/00 |
Claims
1. A fire retardant laminate, comprising: a resin impregnated
decorative layer; a first fire barrier formed from a fiber
reinforced veil; and a layer of fiberboard.
2. The laminate of claim 1, wherein said first fiber reinforced
veil includes fibers selected from a group consisting of glass
fibers, basalt fibers, metal fibers, inorganic fibers, silica
fibers, carbide fibers, nitride fibers, carbon fibers and mixtures
thereof.
3. The laminate of claim 1, wherein said first fiber reinforced
veil includes glass fibers selected from a group of fibers
including boron-free glass, E-glass, ECR-glass, C-glass, AR-glass,
S2-glass and mixtures thereof.
4. The laminate of claim 1, wherein said first fiber reinforced
veil includes a binder comprising a B-stageable resin.
5. The laminate of claim 1, wherein said first fiber reinforced
veil includes a binder selected from a group consisting of
polyvinyl alcohol, acrylates, styrene acrylates,
melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde,
epoxy resin, unsaturated polyesters, crosslinkable acrylic resin,
polyurethane resin, polyamide-amine epichlorohydrin resin and
mixtures thereof.
6. The laminate of claim 1, wherein said first fiber reinforced
veil includes a filler selected from a group consisting of aluminum
trihydrate, magnesium hydroxide, melamine cyanurate, halogenated
additive, antimony trioxide, metal hydroxide, metal carbonate,
titanium dioxide, calcined clay, barium sulfate, magnesium sulfate,
aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite,
felspar, mica, nepheline syenite, pyrophyllite, silica, talc,
wollastonite, montmorillonite, hectorite, saponite, calcium
carbonate, magnesium carbonate, aluminum oxide, iron oxide, glass
microbeads, ethylenediaminephosphate, guanidinephosphates, melamine
borate, melamine (mono, pyro, poly) phosphate, ammonium (mono,
pyro, poly) phosphate, dicyandiamide condensates, general
intumescent systems and mixtures thereof.
7. The laminate of claim 1, wherein said first fiber reinforced
veil is nonwoven.
8. The laminate of claim 1, further including a second fire barrier
formed from a fiber reinforced veil, said layer of fiberboard being
sandwiched between said first and second fire barriers.
9. The laminate of claim 8, wherein said fiber reinforced veils of
said first and second fire barriers following resin impregnation
include between about 5 to about 95 weight percent reinforcement
fibers, about 5 to about 75 weight percent binder and 0 to about 80
weight percent filler.
10. The laminate of claim 9, wherein said fiber reinforced veils of
said first and second fire barriers include a resin binder selected
from a group consisting of polyvinyl alcohol, acrylates, styrene
acrylates, melamine-formaldehyde, urea-formaldehyde,
phenol-formaldehyde, epoxy resin, unsaturated polyesters,
crosslinkable acrylic resin, polyurethane resin, polyamide-amine
epichlorohydrin resin and mixtures thereof.
11. The laminate of claim 10, wherein said fiber reinforced veils
of said first and second fire barriers include a filler selected
from a group consisting of aluminum trihydrate, magnesium
hydroxide, melamine cyanurate, halogenated additive, antimony
trioxide, metal hydroxide, metal carbonate, titanium dioxide,
calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate,
zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica,
nepheline syenite, pyrophyllite, silica, talc, wollastonite,
montmorillonite, hectorite, saponite, calcium carbonate, magnesium
carbonate, aluminum oxide, iron oxide, glass microbeads,
ethylenediaminephosphate, guanidinephosphates, melamine borate,
melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly)
phosphate, dicyandiamide condensates, general intumescent systems
and mixtures thereof.
12. The laminate of claim 9 wherein said fiber reinforced veils of
said first and second fire barriers following impregnation and
prior to pressing have a weight per unit area of between about 20
and about 500 g/m.sup.2.
13. The laminate of claim 1, wherein said layer of fiberboard is a
wood-based panel.
14. The laminate of claim 1, wherein said layer of fiberboard is
selected from a group of materials consisting of high density
fiberboard, medium density fiberboard, oriented strand board,
chipboard and mixtures thereof.
15. The laminate of claim 1, further including a layer of resin
impregnated overlay paper overlying said resin impregnated
decorative layer and a resin impregnated backing layer underlying
said layer of fiberboard.
16. The laminate of claim 15, further including a resin impregnated
backing layer underlying said layer of fiberboard.
17. The laminate of claim 16, wherein said resin impregnated
decorative layer and said resin impregnated backing layer are both
made from decorative paper.
18. The laminate of claim 1, wherein said laminate is a flooring
laminate.
19. The laminate of claim 1, wherein said laminate is classified in
impact class 3 (IC3).
20. A method of making a fire retardant laminate, comprising:
pressing a resin impregnated overlay layer, a resin impregnated
decorative layer, a fire barrier formed from a resin impregnated,
fiber reinforced veil, a layer of fiberboard and a resin
impregnated backing layer together at a pressure of between about
1050 N/m.sup.2 and about 5250 N/m.sup.2 while simultaneously
heating to a temperature of between about 150 to about 225 degrees
C. for a time period of between about 10 to about 50 seconds.
21. The method of claim 20, further including a step of providing a
resin binder in said fiber reinforced veil selected from a group
consisting of polyvinyl alcohol, acrylates, styrene acrylates,
melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde,
epoxy resin, unsaturated polyesters, crosslinkable acrylic resin,
polyurethane resin, polyamide-amine epichlorohydrin resin and
mixtures thereof.
22. The method of claim 21, further including a step of providing a
filler in said fiber reinforced veil selected from a group
consisting of aluminum trihydrate, magnesium hydroxide, melamine
cyanurate, halogenated additive, antimony trioxide, metal
hydroxide, metal carbonate, titanium dioxide, calcined clay, barium
sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin
clay, chlorite, diatomite, felspar, mica, nepheline syenite,
pyrophyllite, silica, talc, wollastonite, montmorillonite,
hectorite, saponite, calcium carbonate, magnesium carbonate,
aluminum oxide, iron oxide, glass microbeads and mixtures
thereof.
23. The method of claim 20, including providing a second fire
barrier formed from a resin impregnated, fiber reinforced veil
between said layer of fiberboard and said resin impregnated backing
layer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No.
11/108,340 filed Apr. 18, 2005.
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0002] This invention relates generally to fire retardant laminates
such as utilized for flooring.
BACKGROUND OF THE INVENTION
[0003] Laminated flooring formed from boards having a wood basis
such as chipboard or fiberboard are known in the aft. The present
invention relates to a novel laminate characterized by improved
fire and impact resistance.
SUMMARY OF THE INVENTION
[0004] The fire retardant laminate of the present invention
comprises a resin impregnated decorative layer, a fire barrier
formed from a fiber reinforced veil and a layer of fiberboard. The
fiber reinforced veil includes fibers selected from a group
consisting of glass fibers, basalt fibers, metal fibers, inorganic
fibers, silica fibers, carbide fibers, nitride fibers, carbon
fibers and mixtures thereof. Glass fibers utilized for the fiber
reinforced veil may be selected from a group of materials
consisting of boron-free glass, E-glass, ECR-glass, C-glass,
AR-glass, S2-glass and mixtures thereof.
[0005] The fiber reinforced veil also includes a binder comprising
a B-stageable resin. Suitable binders include but are not limited
to self-crosslinkable polyacrylates, polyamide-amine
epichlorohydrin resin (PAE), polyvinyl alcohol, acrylates, styrene
acrylates, melamine-formaldehyde, urea-formaldehyde,
phenol-formaldehyde, epoxy resin, unsaturated polyesters,
crosslinkable acrylic resin, polyurethane resin and mixtures
thereof. The fiber reinforced veil also includes a filler selected
from a group consisting of aluminum trihydrate, magnesium
hydroxide, melamine cyanurate, halogenated additive, antimony
trioxide, metal hydroxide, metal carbonate, titanium dioxide,
calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate,
zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica,
nepheline syenite, pyrophyllite, silica, talc, wollastonite,
montmorillonite, hectorite, saponite, calcium carbonate, magnesium
carbonate, aluminum oxide, iron oxide, glass microbeads,
ethylenediaminephosphate, guanidinephosphates, melamine borate,
melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly)
phosphate, dicyandiamide condensates, general intumescent systems
(systems which foam during fire and therefore generate in situ an
insulating layer) and mixtures thereof.
[0006] In one possible embodiment the fiber reinforced veil is
nonwoven. Following resin impregnation, the fiber reinforced veil
includes between about 5 to about 95 weight percent reinforcement
fibers, about 5 to about 75 weight percent binder and about 0 to
about 80 weight percent filler. Following impregnation and prior to
pressing, the fiber reinforced veil has a weight per unit area of
between about 20 and about 500 g/m.sup.2.
[0007] The layer of fiberboard in the laminate may be generally
described as a wood-based panel. The fiberboard may be constructed
from a material selected from the group consisting of high density
fiberboard, medium density fiberboard, oriented strand board,
chipboard and mixtures thereof. In addition the laminate may
include a layer of resin impregnated overlay paper overlying the
resin impregnated decorative paper and/or a resin impregnated
backing layer underlying the layer of fiberboard. Both the resin
impregnated decorative layer and the resin impregnated backing
layer may be made from a decorative paper of a type known in the
art.
[0008] In accordance with an additional aspect of the present
invention a method is provided for making a fire retardant
laminate. The method comprises pressing a resin impregnated overlay
layer, a resin impregnated decorative layer, a fire barrier formed
from a fiber reinforced veil, a layer of fiberboard and a resin
impregnated backing layer together at a pressure of between about
1050 N/m.sup.2 and about 5250 N/m.sup.2 while simultaneously
heating to a temperature of between about 150 to about 225 degrees
C. for a time period of between about 10 to about 50 seconds. That
method may be further described as including a step of providing a
binder in the fiber reinforced veil selected from a group
consisting of polyvinyl alcohol, acrylates, styrene acrylates,
melamine-formaldehyde, urea-formaldehyde, phenol-formaldehyde,
epoxy resin, unsaturated polyesters, crosslinkable acrylic resin,
polyurethane resin, polyamide-amine epichlorohydrin resin and
mixtures thereof.
[0009] Still further the method may include the step of providing a
filler in the fiber reinforced veil selected from a group
consisting of aluminum trihydrate, magnesium hydroxide, melamine
cyanurate, halogenated additive, antimony trioxide, metal
hydroxide, metal carbonate, titanium dioxide, calcined clay, barium
sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin
clay, chlorite, diatomite, felspar, mica, nepheline syenite,
pyrophyllite, silica, talc, wollastonite, montmorillonite,
hectorite, saponite, calcium carbonate, magnesium carbonate,
aluminum oxide, iron oxide, glass microbeads,
ethylenediaminephosphate, guanidinephosphates, melamine borate,
melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly)
phosphate, dicyandiamide condensates, general intumescent systems
and mixtures thereof.
[0010] As mentioned, the laminate may be used in a laminate
flooring application wherein the laminate is formed from boards
having a wood basis such as chipboard, fiberboard including high
and medium density fiberboard, and oriented strand board.
Additional applications for the laminate include, but are not
limited to, wall linings, ceilings, interior shop fittings, and
decoration panels such as those found in ships, trains, and
buildings.
[0011] In the following description there is shown and described
one possible embodiment of the invention simply by way of
illustration of one of the modes best suited to carry out the
invention. As it will be realized, the invention is capable of
other different embodiments and its several details are capable of
modification in various, obvious aspects all without departing from
the invention. Accordingly, the drawings and descriptions will be
regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING
[0012] The accompanying drawing incorporated in and forming a part
of this specification, illustrates several aspects of the present
invention, and together with the description serves to explain
certain principles of the invention. In the drawing:
[0013] FIG. 1 is a side elevational view of one possible embodiment
of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Reference is now made to FIG. 1 illustrating one possible
embodiment of the laminate 10 of the present invention. As
illustrated the laminate 10 includes a resin impregnated overlay
paper 12 overlying a resin impregnated decorative layer 14. The
decorative layer 14 overlies a first fire barrier formed from a
fiber reinforced veil 16. The veil 16 overlies a layer of
fiberboard 18. Finally, a backing layer 20 underlies the fiberboard
18. The laminate 10 may also include a second fire barrier, formed
from a fiber reinforced veil 22, between the fiberboard 18 and the
backing layer 20. This second veil 22 further enhances the fire
retardant properties of the laminate 10 and insures that heat is
transferred at about the same rate from the top or the bottom.
[0015] More specifically describing the invention, the fiber
reinforced veil 16 may include fibers selected from a group
consisting of glass fibers, basalt fibers, metal fibers, inorganic
fibers, silica fibers, carbide fibers, nitride fibers, carbon
fibers and mixtures thereof. Where glass fibers are utilized in the
fiber reinforced veil, they may, for example, be selected from a
group of fibers including boron-free glass, E-glass, ECR-glass,
C-glass, AR-glass, S2-glass and mixtures thereof. Advantex.RTM.
glass fibers, commercially available from Owens Corning (Toledo,
Ohio), may be used.
[0016] The fiber reinforced veils 16 and 22 following resin
impregnation includes between about 5 to about 95 weight percent
reinforcement fibers, about 5 to about 75 weight percent
resin/binder and 0 to about 80 weight percent filler. The binder
utilized may be a B-stageable resin which may be reactivated during
the pressing step to reach its final properties. The binder may be
selected from a group of resins consisting of polyvinyl alcohol,
acrylates, styrene acrylates, melamine-formaldehyde,
urea-formaldehyde, phenol-formaldehyde, epoxy resin, unsaturated
polyesters, crosslinkable acrylic resin, polyurethane resin,
polyamide-amine epichlorohydrin resin and mixtures thereof. The
filler utilized in the fiber reinforced veil 16 may be selected
from a group consisting of aluminum trihydrate, magnesium
hydroxide, melamine cyanurate, halogenated additive, antimony
trioxide, metal hydroxide, metal carbonate, titanium dioxide,
calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate,
zinc oxide, kaolin clay, chlorite, diatomite, felspar, mica,
nepheline syenite, pyrophyllite, silica, talc, wollastonite,
montmorillonite, hectorite, saponite, calcium carbonate, magnesium
carbonate, aluminum oxide, iron oxide, glass microbeads,
ethylenediaminephosphate, guanidinephosphates, melamine borate,
melamine (mono, pyro, poly) phosphate, ammonium (mono, pyro, poly)
phosphate, dicyandiamide condensates, general intumescent systems
(systems which foam during fire and therefore generate in situ an
insulating layer) and mixtures thereof. Advantageously, the fire
barrier formed from the fiber reinforced veil 16 imparts improved
fire retarding and impact characteristics to the laminate above and
beyond those achieved with wood based laminates of the prior art
not incorporating a fire barrier of fiber reinforced veil.
[0017] The fiber reinforced veils 16 and 22 are typically
constructed from nonwoven glass fibers or mixed fibers. The veils
16, 22 may include directionally oriented fibers if desired. Both
continuous and chopped fibers may be utilized. The continuous
fibers typically have a diameter of between about 3 and about 30.
The chopped fibers typically have a length of between about 2 and
about 100 mm and a diameter of between about 3 and about 30 .mu.m.
The fiber reinforced veil 16 following impregnation and prior to
pressing typically has a weight per unit area of between about 20
and about 500 g/m.sup.2.
[0018] The fiberboard 18 utilized in the present laminate is a wood
based panel. The fiberboard 18 may, for example, be made from
materials including high density fiberboard, medium density
fiberboard, oriented strand board, chipboard and mixtures
thereof.
[0019] The decorative layer 14 and backing layer 20 may be made
from decorative paper as is known in the art. The overlay paper 12
may be made from cellulose as is also known in the art. The overlay
paper 12, the decorative layer 14 and the backing layer 20 may all
be impregnated with the same resin/binder as the fiber reinforced
veil 16.
[0020] The laminate 10 is made by pressing the resin impregnated
overlay layer 12, the resin impregnated decorative layer 14, the
first fire barrier formed from the resin impregnated, fiber
reinforced veil 16, the layer of fiberboard 18, the second fire
barrier formed from the resin impregnated fiber reinforced veil 22
(if present) and the resin impregnated backing layer 20 together at
a pressure of between about 1050 N/M.sup.2 while simultaneously
heating to a temperature of between about 225 degrees C. for a time
period of between about 10 to about 50 seconds. Such processing may
be completed in-line utilizing equipment that is presently
available in the commercial marketplace.
EXAMPLES
[0021] Table 1 shows fifteen samples of glass veil, prior to
impregnation with additional binder and a flame retarder. All
samples contain a poly(vinyl alcohol) (PVA) binder. The glass
fibers in the veil include Advantex.RTM. glass fibers manufactured
by Owens Corning, Toledo, Ohio, USA. TABLE-US-00001 TABLE 1 glass
Ni weight binder SAMPLE FIBER TYPE g/m2 perc % 1 Advantex; 47 15 11
um-6 mm 2 Advantex; 46 15 11 um-6 mm 3 Advantex; 47 15 11 um-6 mm 4
Advantex; 47 15 11 um-6 mm 5 Advantex; 46 15 11 um-6 mm 6 Advantex;
46 15 11 um-6 mm 7 Advantex; 47 15 11 um-6 mm 8 Advantex/silica 33
10 (85:15) 9 Advantex/silica 54 10 (85:15) 10 Advantex/silica 76 10
(85:15) 11 Advantex/silica 48 10 (85:15) 12 Advantex/silica 47 10
(85:15) 13 silica 100% 81 12 14 Advantex; 35 15 11 um-6 mm 15
Advantex; 35 15 11 um-6 mm
[0022] Table 2 shows samples 1-15 after they have been impregnated
with additional binder and flame retardant. The "Add on" column
shows the amount of fire retarder/filler per m2 impregnated into
each sample. TABLE-US-00002 TABLE 2 GLASS VEIL IMPREGNATION End
Sample Binder Flame Add on weight No. type retarder (g/M2) (g/M2) 1
PVA melamine 26 73 phosphate 2 PVA Melamine 25 71 pyrophosphate 3
PVA Melamine 26 73 cyanurate 4 PVA Ammonium 25 72 polyphosphate 5
chlorine- Aluminum 25 71 acrylate trihydrate 6 chlorine- ATH + APP
24 70 acrylate 7 PVA none 0 47 8 none none 0 33 9 none none 0 54 10
none none 0 76 11 PVA APP 23 71 12 PVA Melamine 24 71 polyphosphate
13 none none 0 81 14 PVA ATH 7 42 15 PVA intumescent 7 42
formulation
[0023] Table 3 shows the fire properties of samples 1-15 when each
of the samples were exposed to flame. Samples 1-15 were lit above a
Bunsen burner where the flame temperature reached about 950.degree.
C. Distance to the flame was fixed, about 20 mm, for all the
samples to ensure that the samples were exposed to the same
temperature. Samples were observed for smoke development then the
samples were removed from the flame and observed for
self-extinguishing behavior. TABLE-US-00003 TABLE 3 FIRE PROPERTIES
Smoke Self- Burn-through Sample No. Development* Extinguishing**
times (s) 1 + +++ 40 2 + +++ 20 3 ++ +++ 3 4 + +++ 159 5 + ++ 3 6 +
+++ 130 7 - + 1 8 -- +++ 600 9 -- +++ 170 10 -- +++ 300 11 + +++
250 12 + +++ 26 13 -- +++ >600 14 + +++ 1 15 ++ +++ 250 *Smoke
development: --: no smoke development -: hardly any smoke
development +: moderate smoke development ++: significant smoke
development **Self-extinguishing behavior +: poor
self-extinguishing properties ++: moderate self-extinguishing
properties +++: significant self-extinguishing properties
[0024] The samples were then placed at a fixed distance, about 10
mm, above a Bunsen burner (Flame temperature at about 950.degree.
C.) and the time (in seconds) was recorded when the flame burned
through the veil samples.
[0025] Flooring Laminate Examples
[0026] Specimens 7 and 14 were evaluated as an effective fire
barrier in a laminate flooring panel. An unmodified flooring
laminate was taken as a reference. The laminate flooring panels
were evaluated on impact resistance and fire resistance.
[0027] Method of Making the Laminate Flooring Panel:
[0028] Specimens 7 and 14 were impregnated with melamine resin to
ensure a good bonding with the decorative paper and with the fiber
board. Specimens 7 and 14 were impregnated to final weights of
approximately 150 g/m2.
[0029] The melamine-impregnated specimens 7 and 14 were pressed
(function as a fire barrier between the decorative paper and the
fiber board) onto the 8 mm high density fiber board (pressing
conditions: 180.degree. C.; 40 kg/cm2; 20 s) to produce the
laminate flooring panel. The final laminate flooring panel was
subjected to two critical tests; impact resistance and fire
resistance and tested with a reference laminate flooring panel, see
Table 4. TABLE-US-00004 TABLE 4 Code C: Code A: Code B: Specimen 14
Unmodified Specimen 7 fire barrier standard fire barrier laminate
laminate laminate flooring Norm flooring panel flooring panel panel
Small ball EN 438 <15 16.82 18.84 impact (N) Large ball EN 438
<1600 >1600 >1600 impact (mm) Fire NF P 92- M3 M2 M2
resistance 501 Impact class IC1 or IC 2 IC 3 IC 3 (see FIG. 2)
[0030] As shown in Table 4, laminate flooring panels A, B and C
were tested using the small and large ball impact tests described
below. In the small ball impact test, the panels with their
decorative surfaces were subjected to the impact of a 5 mm steel
ball mounted at one end of a spring-loaded bolt. The minimum spring
force (N) needed to cause visible damage was used to measure
resistance to impact. In the large ball impact test, the laminate
flooring panels A, B and C were covered with a sheet of carbon
paper and subjected to the impact of a large steel ball (324 g;
diameter of 42.8 mm) which was allowed to fall from a known height.
In the large ball test, the height is increased in 50 mm intervals
until the ball creates an impact imprint larger than 10 mm. This
height determines the large ball impact resistance in mm. Impact
resistance is expressed as the maximum drop height (mm) which can
be achieved without incurring visible surface cracking or producing
an imprint greater than a 10 mm diameter.
[0031] Fire Resistance
[0032] The Epiradiateur test (NF P 92-501) is the national fire
test for France and is mandatory for many building and construction
materials.
[0033] The size of the specimens (7 and 14) tested was 300
mm.times.400 mm.times.max 120 mm and the specimens were positioned
at an incline of 45.degree. on an 8 mm fixed, self-supporting
frame. The specimens were ignited, from above and below, using an
electrical radiator (inclined at 45.degree.) at 500 W. Two butane
pilot flames were used to ignite the fiber board panels above and
below the specimen for 20 minutes.
[0034] FIG. 2 shows the impact classification ratings using both
the small ball impact test and the large ball impact test.
[0035] The foregoing description of a preferred embodiment of the
present invention has been presented for purposes of illustration
and description. It is not intended to be exhaustive or to limit
the invention to the precise form disclosed. Obvious modifications
or variations are possible in light of the above teachings. For
example, the second fire barrier and the backing layer could be
combined into a single layer if desired.
[0036] The embodiment was chosen and described to provide the best
illustration of the principles of the invention and its practical
application to thereby enable one of ordinary skill in the art to
utilize the invention in various embodiments and with various
modifications as are suited to the particular use contemplated. All
such modifications and variations are within the scope of the
invention as determined by the appended claims when interpreted in
accordance with the breadth to which they are fairly, legally and
equitably entitled. The drawings and preferred embodiments do not
and are not intended to limit the ordinary meaning of the claims
and their fair and broad interpretation in any way.
* * * * *