What is claimed is:
1. A cover layer for engine compartment lining comprising:
at least one binder-bonded nonwoven layer, the nonwoven layer being bonded using a binder having a thermoplastic behavior in the temperature range of 20 to 200 C. and a thermosetting behavior above 200 C.
2. The cover layer as recited in claim 1, wherein the binder is capable of condensing upon crosslinking and being pre-crosslinked at a temperature of up to 200 C. and cured at a temperature above 200 C.
3. The cover layer as recited in claim 1, wherein the binder is selected from the group of the acrylic acid copolymers or ter-polymers with styrene, butadiene, andor acrylonitrile.
4. The cover layer as recited in claim 3, wherein the binder is selected from the group of the acrylic acid copolymers with styrene.
5. The cover layer as recited in claim 1, wherein the binder contains flame retardant agents, water repellent agents, andor oil repellent agents.
6. The cover layer as recited in claim 1, wherein the nonwoven layer includes halogen-free and heavy metal-free phosphorous compounds containing nitrogen as a flame retardant.
7. The cover layer as recited in claim 6, wherein the flame retardant is a nitrogen-containing phosphonic acid derivative having an elemental content of 10 wt. % of nitrogen and 5 wt. % of phosphorous.
8. The cover layer as recited in claim 1, wherein the nonwoven layer includes rayon fibers, polyester fibers, cellulose fibers, polyamide fibers, polyolefine fibers, andor pre-oxidized polyacrylonitrile fibers.
9. The cover layer as recited in claim 1, wherein the cover layer has a mass per unit area of 20 gm2 to 200 gm2, and the nonwoven layer includes fibers in a weight ratio between the fibers employed per square meter and the binder employed per square meter being in the range of 0.5:1 to 2:0.5.
10. The cover layer as recited in claim 1, further comprising a coating on one side of the nonwoven layer, the coating including a hot-setting adhesive made of a polyolefin resin, polyester resin, phenolic resin, or melamine resin.
11. A method for manufacturing a cover layer as recited in claim 1 the method comprising the steps of:
combining staple fibers having a length of 20 mm to 200 mm and a fiber count of 0.8 to 40 decitex to form a nonwoven having a mass per unit area of 10 gm2 to 200 gm2; and
impregnating the non-woven using a binder which has a thermoplastic behavior in the temperature range of 20 to 200 C. and a thermosetting behavior above 200 C.
12. The method as recited in claim 11, wherein the binder is applied in the form of foam.
13. The method as recited in claim 11, wherein the formation of the nonwoven takes place in such a way that a ratio of the flexibility across the machine direction to the flexibility in the machine direction is in the range of 4:1 to 1:2.
14. The method as recited in claim 11, further comprising applying a hot-setting adhesive layer is applied to the nonwoven layer in such a quantity that represents at least 10% of a base material composed of the nonwoven and the binder.
15. The method as recited in claim 14, wherein the base material includes flame retardant agents, water repellent agents, andor oil repellent agents.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A compound, which is represented by a following General Formula (1),
wherein
in General Formula (1), R1 to R3 are alkyl groups having 1 to 4 carbon atoms and R1 to R3 may be the same or different from each other.
2. The compound according to claim 1, which is represented by a following Structural Formula.
3. The compound according to claim 2, wherein the compound is plant derived.
4. A flame retardant comprising the compound according to claim 1.
5. A resin composition comprising resin and the flame retardant according to claim 4.
6. A resin composition containing aromatic polyester, a styrene polymer, a dripping inhibitor, and the flame retardant according to claim 4, wherein
a content of the aromatic polyester is 40 wt % or more and 90 wt % or less when a total weight of the resin composition is 100 wt %,
a content of the styrene polymer is 5 wt % or more and 30 wt % or less when the total weight of the resin composition is 100 wt %,
a content of the dripping inhibitor is 0.1 wt % or more and 1.0 wt % or less when the total weight of the resin composition is 100 wt %, and
a content of the flame retardant is 10 wt % or more and 25 wt % or less when the total weight of the flame retardant composition is 100 wt %.
7. The resin composition according to claim 6, wherein the aromatic polyester is aromatic polycarbonate.
8. The resin composition according to claim 6, wherein the styrene polymer is an acrylonitrile-butadiene-styrene copolymer or an acrylonitrile-styrene copolymer.
9. The resin composition according to claim 6, wherein the dripping inhibitor is a compound containing polytetrafluoroethylene.
10. A molded article, which is obtained by molding the resin composition according to claim 6.
11. The molded article according to claim 10, wherein the aromatic polyester and the styrene polymer are obtained from recovered resin.
12. The molded article according to claim 10, wherein flame retardancy is equal to or higher than V-1 in a V test of UL94 standard.
13. An image forming apparatus, comprising:
a photoconductor; and
a housing for accommodating the photoconductor, wherein
the housing is the molded article according to claim 10.
14. A resin composition comprising resin and a flame retardant, wherein the frame retardant is the compound according to claim 3.
15. A resin composition containing aromatic polyester, a styrene polymer, a dripping inhibitor, and a flame retardant; the frame retardant is the compound according to claim 3, wherein
a content of the aromatic polyester is 40 wt % or more and 90 wt % or less when a total weight of the resin composition is 100 wt %,
a content of the styrene polymer is 5 wt % or more and 30 wt % or less when the total weight of the resin composition is 100 wt %,
a content of the dripping inhibitor is 0.1 wt % or more and 1.0 wt % or less when the total weight of the resin composition is 100 wt %, and
a content of the flame retardant is 10 wt % or more and 25 wt % or less when the total weight of the flame retardant composition is 100 wt %.
16. A method for manufacturing a resin composition containing aromatic polyester, a styrene polymer, a fluorine compound, and a flame retardant represented by a following General Formula (1), the method comprising:
mixing the aromatic polyester with a weight of 40% by weight or more and 90% by weight or less, the styrene polymer with a weight of 5% by weight or more and 30% by weight or less, the dripping inhibitor with a weight of 0.1% by weight or more and 1.0% by weight or less, and the flame retardant with a weight of 10% by weight or more and 25% by weight or less based on 100% by weight of the total weight of the resin composition; and then
heating the aromatic polyester, the styrene polymer, the dripping inhibitor, and the flame retardant.
wherein
in General Formula (1), R1 to R3 are alkyl groups having 1 to 4 carbon atoms and R1 to R3 may be the same or different from each other.
17. A method for manufacturing a molded article containing a flame retardant composition, the method comprising:
preparing a flame retardant composition, and
molding the flame retardant composition, wherein
the flame retardant composition is obtained by the method for manufacturing a flame retardant composition according to claim 16.
18. The method for manufacturing a molded article according to claim 17, wherein the molding of the flame retardant composition is extrusion molding or injection molding.