Construction Sheets Made of High-Performance Flame-Retardant Nonwoven Fabrics and Combustion-Resistant Polyurethane Foam: Preparation Process and Property Evaluations

Bing-Chiuan Shiu; Chen-Hung Huang; Hua-Lin Yang; Yueh-Sheng Chen; Ching-Wen Lou; Jia-Horng Lin

doi:10.3390/polym15040953

Polymers (Feb 2023)

Construction Sheets Made of High-Performance Flame-Retardant Nonwoven Fabrics and Combustion-Resistant Polyurethane Foam: Preparation Process and Property Evaluations

Bing-Chiuan Shiu,
Chen-Hung Huang,
Hua-Lin Yang,
Yueh-Sheng Chen,
Ching-Wen Lou,
Jia-Horng Lin

Affiliations

Bing-Chiuan Shiu: College of Material and Chemical Engineering, Minjiang University, Fuzhou 350108, China
Chen-Hung Huang: Department of Aerospace and Systems Engineering, Feng Chia University, Taichung 407102, Taiwan
Hua-Lin Yang: Laboratory of Fiber Application and Manufacturing, Advanced Medical Care and Protection Technology Research Center, Department of Fiber and Composite Materials, Feng Chia University, Taichung 40724, Taiwan
Yueh-Sheng Chen: Department of Bioinformatics and Medical Engineering, Asia University, Taichung City 413305, Taiwan
Ching-Wen Lou: Fujian Key Laboratory of Novel Functional Fibers and Materials, Minjiang University, Fuzhou 350108, China
Jia-Horng Lin: College of Material and Chemical Engineering, Minjiang University, Fuzhou 350108, China

DOI: https://doi.org/10.3390/polym15040953
Journal volume & issue: Vol. 15, no. 4
p. 953

Abstract

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In this study, nonwoven fabrics, rigid polyurethane foam (RPUF), Basalt woven fabrics, and an aluminum foil film mold are used to produce multi-functional composite sheets with flame-retardant, sound-absorbing, and electromagnetic-shielding functions. The nonwoven layer is composed of Nomex fibers, flame-retardant PET fibers, and low-melting-point (LMPET) fibers via the needle rolling process. The optimal Nomex fiber/flame-retardant PET fiber/LMPET fiber (N/F/L) nonwoven fabrics are then combined with rigid polyurethane (PU) foam, Basalt woven fabric, and an aluminum foil film mold, thereby producing nonwoven/rigid polyurethane foam/Basalt woven fabric composite sheets that are wrapped in the aluminized foil film. The test results indicate that formed with a foaming density of 60 kg/m3 and 10 wt% of a flame retardant, the composite sheets exhibit electromagnetic interference shielding efficacy (EMI SE) that exceeds 40 dB and limiting oxygen index (LOI) that is greater than 26. The efficient and highly reproducible experimental design proposed in this study can produce multifunctional composite sheets that feature excellent combustion resistance, sound absorption, and EMI SE and are suitable for use in the transportation, industrial factories, and building wall fields.

Published in Polymers

ISSN: 2073-4360 (Online)
Publisher: MDPI AG
Country of publisher: Switzerland
LCC subjects: Science: Chemistry: Organic chemistry
Website: http://www.mdpi.com/journal/polymers/

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