US 12,330,398 B2
Flame retardant multilayer material, method of manufacture, and uses thereof
Loni Decelles, Brooklyn, CT (US); and Joseph Puglisi, Brooklyn, CT (US)
Assigned to ROGERS CORPORATION, Chandler, AZ (US)
Filed by ROGERS CORPORATION, Chandler, AZ (US)
Filed on Oct. 21, 2022, as Appl. No. 17/970,733.
Claims priority of provisional application 63/272,292, filed on Oct. 27, 2021.
Prior Publication US 2023/0127270 A1, Apr. 27, 2023
Int. Cl. B32B 27/06 (2006.01); B32B 5/18 (2006.01); B32B 27/20 (2006.01); B32B 27/36 (2006.01); B32B 27/40 (2006.01)
CPC B32B 27/065 (2013.01) [B32B 5/18 (2013.01); B32B 27/36 (2013.01); B32B 27/20 (2013.01); B32B 2264/10 (2013.01); B32B 2264/203 (2020.08); B32B 2264/303 (2020.08); B32B 2266/0221 (2013.01); B32B 2266/0228 (2013.01); B32B 2266/0235 (2013.01); B32B 2266/0242 (2013.01); B32B 2266/025 (2013.01); B32B 2266/0257 (2013.01); B32B 2266/0264 (2013.01); B32B 2266/0271 (2013.01); B32B 2266/0278 (2013.01); B32B 2266/0285 (2013.01); B32B 2307/3065 (2013.01); B32B 2307/72 (2013.01); B32B 2307/732 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A dual layer material, comprising
a compressible polymer foam layer, wherein the compressible polymer foam layer has
a density of less than 400 kg/m3,
a compression force deflection of 5 to 1,035 kPa at 25% deflection determined in accordance with ASTM D3574-17, and
a thickness of less than 3.5 millimeters; and
a solid, polymeric flame retardant layer disposed on a first side of the compressible polymer foam layer, wherein the flame retardant layer has
a thickness of less than 0.3 millimeters, wherein the thickness of the compressible polymer foam layer is at least two times greater than the thickness of the flame retardant layer;
wherein each of the compressible polymer foam layer and the flame retardant layer comprises a flame retardant composition,
wherein the flame retardant composition of the flame retardant layer comprises a metal hydroxide, a metal oxide, a metal borate, a metal carbonate, an expandable graphite, or a combination thereof, and
wherein the dual layer material has
a thickness of 3.5 millimeters or less, and
a UL-94 rating of V1, HF1, or a combination thereof.