US4778544A — Low toxic navy board facing

Claim 1

Independent Claim 111 words

A process for manufacturing a coated fabric that is rigid, slitable, cleanable, paintable with both oil based and latex paints, substantially non-flammable and is useful as a Navy board facing and the like, the process comprising: (1) applying to at least one face of a fabric substrate a uniform layer of a thickened flame-retardant, non-cellular, water-based coating substantially devoid of halogen-containing components and containing a pigment, a flame-retardant and a resin, the coating contacting and encapsulating substantially all of the yarns of the substrate with a tough, adherent film, the coating composition, when exposed to heat or flame, emitting vapors of low-toxicity and low smoke, and (2) drying the thus-coated substrate.

Claim 2

Dependent Claim 111 words

A process for manufacturing a coated fabric that is rigid, slitable, cleanable, paintable with both oil based and latex paints, substantially non-flammable and is useful as a Navy board facing and the like, the process comprising: (1) applying to at least one face of a fabric substrate a uniform layer of a thickened flame-retardant, non-cellular, water-based coating substantially devoid of halogen-containing components and containing a pigment, a flame-retardant and a resin, the coating contacting and encapsulating substantially all of the yarns of the substrate with a tough, adherent film, the coating composition, when exposed to heat or flame, emitting vapors of low-toxicity and low smoke, and (2) drying the thus-coated substrate.

Claim 3

Dependent Claim 17 words

The process of claim 1 in which the textured fabric is a tightly woven glass greige fabric.

Claim 4

Dependent Claim 20 words

The process of claim 1 in which the coating is applied by padding an aqueous composition onto the fabric substrate.

Claim 5

Dependent Claim 34 words

The process of claim 3 in which the layer is applied to the substrate to provide a total add-on at the completion of drying of at least one ounce per square yard of fabric.

Claim 6

Dependent Claim 19 words

The process of claim 4 in which the total add-on is up to about 1.5 ounces per square yard.

Claim 7

Dependent Claim 23 words

The process of claim 1 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of halogens.

Claim 8

Dependent Claim 25 words

The process of claim 1 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of aldehyde as HCHO.

Claim 9

Dependent Claim 23 words

The process of claim 1 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of ammonia.

Claim 10

Dependent Claim 30 words

The process of claim 1 in which the fabric when exposed to thermal decomposition emits less than 50 parts per million of oxides of nitrogen measured as NO 2 .

Claim 11

Dependent Claim 25 words

The process of claim 1 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of cyanides as HCN.

Claim 12

Dependent Claim 21 words

A process for producing a coated, Navy board comprising laminating the coated, flame-resistant fabric of claim 1 onto a board substrate.

Claim 13

Dependent Claim 33 words

A smooth fabric suitable for use as a Navy board facing having a thick, opaque flame-retardant coating adhered substantially evenly to the yarns of the fabric produced by the process of claim 1.

Claim 14

Dependent Claim 88 words

A Navy board facing that is rigid, slitable, cleanable, paintable with both oil based and latex paints, substantially non-flammable consisting of a woven glass fiber having thereon a uniform, thickened, flame-retardant, non-cellular coating containing pigment, at least one flame retardant and a non-toxic resin contacting and securing the coating to the glass fiber fabric with a tough, adherent film, the coating having been derived from a water-based coating and being substantially completely devoid of halogen-containing components, and, when exposed to heat or flame, emitting only low-toxic, low-smoke vapor.

Claim 15

Dependent Claim 88 words

A Navy board facing that is rigid, slitable, cleanable, paintable with both oil based and latex paints, substantially non-flammable consisting of a woven glass fiber having thereon a uniform, thickened, flame-retardant, non-cellular coating containing pigment, at least one flame retardant and a non-toxic resin contacting and securing the coating to the glass fiber fabric with a tough, adherent film, the coating having been derived from a water-based coating and being substantially completely devoid of halogen-containing components, and, when exposed to heat or flame, emitting only low-toxic, low-smoke vapor.

Claim 16

Dependent Claim 34 words

The Navy board facing of claim 13 in which the toxicity of the vapors emitted by the coating is no more toxic than wood when exposed to the same conditions of heat and/or flame.

Claim 17

Dependent Claim 25 words

The Navy board facing of claim 13 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of halogens.

Claim 18

Dependent Claim 27 words

The Navy board facing of claim 13 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of aldehyde as HCHO.

Claim 19

Dependent Claim 25 words

The Navy board facing of claim 13 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of ammonia.

Claim 20

Dependent Claim 27 words

The Navy board facing of claim 13 in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of cyanides as HCN.

Claim 21

Dependent Claim 31 words

The Navy board facing of claim 13 which the fabric when exposed to thermal decomposition emits less than 50 parts per million of oxides of nitrogen measured as NO 2 .

Claim 22

Dependent Claim 17 words

The Navy board facing of claim 13 that satisfies the requirements of MIL-C-20079, Type I, Class 2.

Claim 23

Dependent Claim 124 words

A process for manufacturing a coated fabric that is rigid, slitable, cleanable, paintable with both oil and latex points substantially non-flammable and is useful as a Navy board facing and the like, the process comprising: (1) applying to at least one face of a fabric substrate a uniform layer of a thickened, flame-retardant, non-cellular coating substantially devoid of halogen-containing components and containing a pigment, a water-based silicone-containing resin, at least an equal amount by weight of an acrylic resin and a hydrated salt flame retardant, the coating contacting and encapsulating substantially all of the yarns of the substrate with a tough, adherent film, the coating composition, when exposed to heat or flame, emitting vapors of low-toxicity and low-smoke, and (2) drying the thus-coated substrate.

Claim 24

Dependent Claim 124 words

A process for manufacturing a coated fabric that is rigid, slitable, cleanable, paintable with both oil and latex points substantially non-flammable and is useful as a Navy board facing and the like, the process comprising: (1) applying to at least one face of a fabric substrate a uniform layer of a thickened, flame-retardant, non-cellular coating substantially devoid of halogen-containing components and containing a pigment, a water-based silicone-containing resin, at least an equal amount by weight of an acrylic resin and a hydrated salt flame retardant, the coating contacting and encapsulating substantially all of the yarns of the substrate with a tough, adherent film, the coating composition, when exposed to heat or flame, emitting vapors of low-toxicity and low-smoke, and (2) drying the thus-coated substrate.

Claim 25

Dependent Claim 17 words

The process of claim 21, in which the textured fabric is a tightly woven glass greige fabric.

Claim 26

Dependent Claim 20 words

The process of claim 21, in which the coating is applied by padding an aqueous composition onto the fabric substrate.

Claim 27

Dependent Claim 34 words

The process of claim 23, in which the layer is applied to the substrate to provide a total add-on at the completion of drying of at least one ounce per square yard of fabric.

Claim 28

Dependent Claim 19 words

The process of claim 24, in which the total add-on is up to about 1.5 ounces per square yard.

Claim 29

Dependent Claim 23 words

The process of claim 21, in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of halogens.

Claim 30

Dependent Claim 25 words

The process of claim 21, in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of aldehyde as HCHO.

Claim 31

Dependent Claim 23 words

The process of claim 21, in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of ammonia.

Claim 32

Dependent Claim 30 words

The process of claim 21, in which the fabric when exposed to thermal decomposition emits less than 50 parts per million of oxides of nitrogen measured as NO 2 .

Claim 33

Dependent Claim 24 words

The process of claim 21, in which fabric when exposed to thermal decomposition emits less than 100 parts per million of cyanides as HCN.

Claim 34

Dependent Claim 21 words

A process for producing a coated, Navy board comprising laminating the coated, flame-resistant fabric of claim 21 onto a board substrate.

Claim 35

Dependent Claim 33 words

A smooth fabric suitable for use as a Navy board facing having a thick, opaque flame-retardant coating adhered substantially evenly to the yarns of the fabric produced by the process of claim 21.

Claim 36

Dependent Claim 110 words

A Navy board facing that is rigid, slitable, cleanable, paintable with both oil based and latex paints, and is substantially non-flammable, the facing consisting of a woven glass fiber fabric having thereon a uniform, thickened, flame-retardant, non-cellular coating containing pigment, a non-toxic, silicone-containing resin binder, at least an equal amount by weight of an acrylic resin binder and a hydrated salt flame retardant, the resin binders contacting and securing the coating to the glass fiber fabric with a tough, adherent film, the coating having been derived from a water-based composition and being substantially completely devoid of halogen-containing components and, when exposed to heat or flame, emitting only low-toxic, low-smoke vapor.

Claim 37

Dependent Claim 110 words

A Navy board facing that is rigid, slitable, cleanable, paintable with both oil based and latex paints, and is substantially non-flammable, the facing consisting of a woven glass fiber fabric having thereon a uniform, thickened, flame-retardant, non-cellular coating containing pigment, a non-toxic, silicone-containing resin binder, at least an equal amount by weight of an acrylic resin binder and a hydrated salt flame retardant, the resin binders contacting and securing the coating to the glass fiber fabric with a tough, adherent film, the coating having been derived from a water-based composition and being substantially completely devoid of halogen-containing components and, when exposed to heat or flame, emitting only low-toxic, low-smoke vapor.

Claim 38

Dependent Claim 34 words

The Navy board facing of claim 33, in which the toxicity of the vapors emitted by the coating is no more toxic than wood when exposed to the same conditions of heat and/or flame.

Claim 39

Dependent Claim 25 words

The Navy board facing of claim 33, in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of halogens.

Claim 40

Dependent Claim 27 words

The Navy board facing of claim 33, in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of aldehyde as HCHO.

Claim 41

Dependent Claim 25 words

The Navy board facing of claim 33, in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of ammonia.

Claim 42

Dependent Claim 27 words

The Navy board facing of claim 33, in which the fabric when exposed to thermal decomposition emits less than 100 parts per million of cyanides as HCN.

Claim 43

Dependent Claim 32 words

The Navy board facing of claim 33, in which the fabric when exposed to thermal decomposition emits less than 50 parts per million of oxides of nitrogen measured as NO 2 .

Claim 44

Dependent Claim 17 words

The Navy board facing of claim 33, that satisfies the requirements of MIL-C-20079, Type I, Class 2.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-10-18	1992-04-18	1992-10-18	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-10-18	1996-04-18	1996-10-18	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-10-18	2000-04-18	2000-10-18	$7700.00	Window Closed / Lapsed

Low toxic navy board facing

Abstract

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