CA1101177A - Flame retardant fabrics and method of producing same - Google Patents
Flame retardant fabrics and method of producing sameInfo
- Publication number
- CA1101177A CA1101177A CA313,943A CA313943A CA1101177A CA 1101177 A CA1101177 A CA 1101177A CA 313943 A CA313943 A CA 313943A CA 1101177 A CA1101177 A CA 1101177A
- Authority
- CA
- Canada
- Prior art keywords
- fibers
- matrix
- yarn
- carded
- flame retardant
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
Abstract
FLAME RETARDANT FABRICS AND METHOD OF PRODUCING SAME
Abstract A method for producing flame retardant fabrics includes steps of separately blowing and carding bundles of matrix and staple fibers, respectively, to form separate slivers of each of the two fibers. Given proportions of each fiber are then combined during a common drawing step to form a bulky blended sliver having the given proportions of matrix and staple fibers.
The blended sliver is then conventionally processed to produce a yarn suitable for knitting or weaving into an untreated flame retardant fabric.
Abstract A method for producing flame retardant fabrics includes steps of separately blowing and carding bundles of matrix and staple fibers, respectively, to form separate slivers of each of the two fibers. Given proportions of each fiber are then combined during a common drawing step to form a bulky blended sliver having the given proportions of matrix and staple fibers.
The blended sliver is then conventionally processed to produce a yarn suitable for knitting or weaving into an untreated flame retardant fabric.
Description
~ ( ( 1;1 ~1177 This invention relates generally to flame retardant fabrics and methods for producin~ same, and more particularly to a method for producing such fahrics from separate slivers of matrix and staple fibers. The invention also includes the products produced according to the method.
It has recently become a sub~ect of public concern that various items of wearing apparel, especially children's sleepwear, can be highly flammable, thus exposing the wearer to great risk in case of a fire. The problem has become so serious that the Federal Trade Commission has ordered that manufacturers Or children's sleepwear treat their products with chemicals which would produce flame-retardant qualities in the sleepwear. Such treatment methods have been known and appear, for example, in U.S. Patents Nos. 3,017,292; 3,749,599 and 3~864,156. Unfortunately, there has been increasing evi-dence that such chemicals may have deleterious effects on the wearer which, in some cases, may be carcinogenic. There has therefore been created a demand for flame retardant fabrics, especially for use in children's sleepwear, that do not include potentially dangerous chemical substances. Most preferably, it is desirable to produce flame retardant fabrics which do not require any chemical treatment at all.
Fibers which are inherently flame-retardant are well-known in the art. For example, one of such fibers (hereinafter referred to as matrix fibers~ is made of 50% vinal and 50% vinyon.
However, these matrix fibers are not strong enough to form their '- own fabrics, tend to have a non-uniform composition, are not susceptible of bein~ easily dyed, and in general, are not alone suitable for production into piece goods. On the other hand, conventional natural and synthetic fibers (hereinafter referred to as staple fibers~ which are suitable for production into
It has recently become a sub~ect of public concern that various items of wearing apparel, especially children's sleepwear, can be highly flammable, thus exposing the wearer to great risk in case of a fire. The problem has become so serious that the Federal Trade Commission has ordered that manufacturers Or children's sleepwear treat their products with chemicals which would produce flame-retardant qualities in the sleepwear. Such treatment methods have been known and appear, for example, in U.S. Patents Nos. 3,017,292; 3,749,599 and 3~864,156. Unfortunately, there has been increasing evi-dence that such chemicals may have deleterious effects on the wearer which, in some cases, may be carcinogenic. There has therefore been created a demand for flame retardant fabrics, especially for use in children's sleepwear, that do not include potentially dangerous chemical substances. Most preferably, it is desirable to produce flame retardant fabrics which do not require any chemical treatment at all.
Fibers which are inherently flame-retardant are well-known in the art. For example, one of such fibers (hereinafter referred to as matrix fibers~ is made of 50% vinal and 50% vinyon.
However, these matrix fibers are not strong enough to form their '- own fabrics, tend to have a non-uniform composition, are not susceptible of bein~ easily dyed, and in general, are not alone suitable for production into piece goods. On the other hand, conventional natural and synthetic fibers (hereinafter referred to as staple fibers~ which are suitable for production into
-2-(~ ( 11t~1177 piece goods, for example, polyester, nylon, cotton, flax, linen and rayon, are not inherently flame~retardant.
One known solution to the problem of producing an untreated flame retardant yarn has been to initially combine flame-retardant matrix fibers and staple fibers in specific proportions, the fibers being purchased in bales of short slivers normally under two inches in length, and then processing the combined slivers to produce the blended yarn. It has been found, however, that such a procedure tends to produce yarns having non-uniform cross-sectional areas and, therefore, non-uniform flame-retardant characteristics; that is, there may be areas which are not flame-retardant within a fabric made from the yarn. Conventional techniques for producing blended staple yarns such as disclosed in U.S. Patents Nos. 3,067,471 and
One known solution to the problem of producing an untreated flame retardant yarn has been to initially combine flame-retardant matrix fibers and staple fibers in specific proportions, the fibers being purchased in bales of short slivers normally under two inches in length, and then processing the combined slivers to produce the blended yarn. It has been found, however, that such a procedure tends to produce yarns having non-uniform cross-sectional areas and, therefore, non-uniform flame-retardant characteristics; that is, there may be areas which are not flame-retardant within a fabric made from the yarn. Conventional techniques for producing blended staple yarns such as disclosed in U.S. Patents Nos. 3,067,471 and
3,176,351 have not been successfully employed to produce a flame retardant composite yarn, as far as is known.
Broadly, it is an object o the present invention to provide a method for producing a flame-retardant yarn having fibers of cross-sectional uniformity, knitting and weaving reliability, good tensile burst strength, susceptibilitY to dye and other desirable characteristics.
It is a further object of this invention to provide a method which allows for the prior removal of impurities from each of the source fibers, separate and apart from one another.
~5 It is yet another object of this invention to provide a method which is reliable, efficient and convenient to use, yet simple and economical in that it uses existing conventional apparatus.
In accordance with an illustrative embodiment demon-strating objects and features of the present invention, a methodfor producing flame retardant yarn of substantially uniform 11~11~77 cross section from independent sources of matrix and staple fibers provides ~or independent air blowing and cleaning of the matrix and staple fibers, respectively. This blo~,ring step removes impurities, including soil, lint and the like separately from each of the fibers to produce laps which are neY~ sepa-xately carded to orient the fibers therein in a uniform direc-tion. Separate, small slivers of each of the fibers as obtained after the carding steps are then blended in a drawing step to form composite bulky slivers. ~he compbsite slivers are then preferably comingled on a speed frame to form thick slivers or ropes of the blended fibers. The fiber ropes are then spun into a yarn as by, for example, a ring or spinning frame. It is important, however, that the spinning step be performed at speeds sufficient~y slow such as to allow for the yarn to maintain a desired cross section. A variation in cross section of the yarn could result in localized burning of a fabric produced therefrom, , . . .
poor burst strength and poor fabric quality. If desired, the -yarn may next be wound into a frustro-conical configuration for ease of handling.
The finished yarn can be knitted or woven on conven-tional machinery. Again, care must be taken to operate at speeds which will not cause reduced cross sections in the yarn, and corresponding potentially flammable segments of fabric produced from the yarn.
; ~5 The above brief description, as well as further ob-jects, features and advantages of the pxesent invention, will be more appreciated by reference to the following detailed description of a presently preferred, but nonetheless illus-trati~e, embodiment in accordance with the invention, with ~30 reference being had to the accompanying block diagram 10 which represents the process.
Broadly, it is an object o the present invention to provide a method for producing a flame-retardant yarn having fibers of cross-sectional uniformity, knitting and weaving reliability, good tensile burst strength, susceptibilitY to dye and other desirable characteristics.
It is a further object of this invention to provide a method which allows for the prior removal of impurities from each of the source fibers, separate and apart from one another.
~5 It is yet another object of this invention to provide a method which is reliable, efficient and convenient to use, yet simple and economical in that it uses existing conventional apparatus.
In accordance with an illustrative embodiment demon-strating objects and features of the present invention, a methodfor producing flame retardant yarn of substantially uniform 11~11~77 cross section from independent sources of matrix and staple fibers provides ~or independent air blowing and cleaning of the matrix and staple fibers, respectively. This blo~,ring step removes impurities, including soil, lint and the like separately from each of the fibers to produce laps which are neY~ sepa-xately carded to orient the fibers therein in a uniform direc-tion. Separate, small slivers of each of the fibers as obtained after the carding steps are then blended in a drawing step to form composite bulky slivers. ~he compbsite slivers are then preferably comingled on a speed frame to form thick slivers or ropes of the blended fibers. The fiber ropes are then spun into a yarn as by, for example, a ring or spinning frame. It is important, however, that the spinning step be performed at speeds sufficient~y slow such as to allow for the yarn to maintain a desired cross section. A variation in cross section of the yarn could result in localized burning of a fabric produced therefrom, , . . .
poor burst strength and poor fabric quality. If desired, the -yarn may next be wound into a frustro-conical configuration for ease of handling.
The finished yarn can be knitted or woven on conven-tional machinery. Again, care must be taken to operate at speeds which will not cause reduced cross sections in the yarn, and corresponding potentially flammable segments of fabric produced from the yarn.
; ~5 The above brief description, as well as further ob-jects, features and advantages of the pxesent invention, will be more appreciated by reference to the following detailed description of a presently preferred, but nonetheless illus-trati~e, embodiment in accordance with the invention, with ~30 reference being had to the accompanying block diagram 10 which represents the process.
-4-l ( ( 11~1177 Process 10 commences with independent air blowing steps 12 and 14. In step 12, matrix ~ibers are ~lown in a conventional hopper type blower such as, ~or example, a Trutzschler type 4. A preferred matrix comprises equal parts of vinal and vinyon fibers, each abou~ 2 to 2-1/2 inches in length, as may ordinarily be purchased in large bales. In blowing step 12, lint, dirt, filth and other impurities are removed from the matrix fibers. Such impurities, if left combined with the matrix fibers, would adversely affect their -10 flame resistance and render any yarn produced therefrom unfit for use in-a flame retardant fabric.
Laps of the blown, disoriented matrix fibers are next carded, as represented by block 16. A conventional carding machine such as, for example, a Crosrol high speed type machine can be used. This step brushes the matrix fiber laps so as to produce slivers wherein the fibers are uniformly oriented.
Blowing of the selected staple fibers is done sepa-rate and apart from the blowing of the matrix fibers, as represented by block 14. In this step, conventional staple fibers such as, for example, cotton, flax, linen, polyester, nylon and rayon are cleaned and formed into laps which are subsequently carded as indicated by block 18. The blowing step 14 may also be performed in a conven~ional apparatus such as the Trutzschler type 4 but, as already stressed, must be per-formed independently of the blowing of the matrix fibers,according to the present invention. Carding of the laps of staple fibers may be done by an Ashworth type AHP~lC carder, for example.
Slivers of matrix and staple fibers, as obtained from the separate carding steps 16 and 18, respectively, are first drawn together by a drawing frame as represented by blocX 20.
11(~1177 A conventional drawing frame machine such as, for example, Platt type 740, can be used to perform this step wherein bulky, blended slivers of matrix and staple fibers are formed. rt i5 important, during this step 20, that the proportions of matrix and staple fibers drawn together be closely maintained. For example, for a polyester matrix blend yarn according to the present invention, it is desired and preferred that a proportion of no more than about 35 percent polyester sliver be maintained when combined with a vinal-vinyon matrix sliver in drawing step 20, while for -10 cotton matrix yarn, preferably no more th~n about 15 percent cotton sliver is combined with the vinal-vinyon sliver.
The bulky, composite slivers as obtained after drawing step 20, above, are preferably thickened on a speed frame ap-paratus as indicated by block 22. Such apparatus may be, for example, a Marzoli type BC-3. The purpose of this step is to form a relatively heavy sliver or rope of blended fibers in preparation for a subsequent spinning step in which the desiréd blended yarn is formed.
Ropes of the blended fibers obtained from the speed frame step 22 are spun on a ring or spinning frame machine such as, for example, a Platt type 800. During this step, represented by block 24 in diagram 10, it is important that the spinning rate not exceed 10,000 RPM. It has been discovered that spin-ning of the ropes at higher conventional speeds such as from 16,000 to 20,000 RPM has deliterious effects on the spun yarn such as would impair its desired flame retardant properties.
In particular, as mentioned above, it has been found that spin-ning at the higher speed range causes reduced cross sections in the spun yarn, while operating below the maximum preferred ; 30 speed overcomes this problem. A preferred operating range for the spinning step 24 according to the present invention is from about 8,000 to 10,000 RPM.
( ~ ~
Continuing, the spun yarn is then con~entionally pro-cessed such as by, for example, a twisting machine (block 26) for crimping the yarn to a suitable degree depending upon whether it is to be later knitted or woven,and a coning machine ~block S 28). which arranges the crimpe~ yarn in the form of oonventional cones for ease of use when knitting or weaving therewith.
Should the flame retardant blended yarn produced accord~ng to the present invention be later used in producing a knitted fabric, care must again be taken to operate at speeds which will not cause reduced cross-sections in the yarn, and corresponding potentially flammable segments o~ yarn in the-finished fabric~ Also, the knitting machine must be ~ept sub-stantially free from flammable contaminates (e.g~ cotton lint) which might otherwise be trapped in the fabric.
:15 m e yarn formed as a result of the present process will be easy to knit or weave, have good tensile strength, will ..
i . be readily susceptible to dyeing and, most important, will have uniform flame-retardant.characteristics.
. Although a specific embodiment of the invention has been disclosed for illustrative purposes, it will be appreciated by one skilled in the art that many additions, substitutions and modi~ications are possible without departing from the scope and spirit of the invention as aefined by the accompanying claims.
,~
.
Laps of the blown, disoriented matrix fibers are next carded, as represented by block 16. A conventional carding machine such as, for example, a Crosrol high speed type machine can be used. This step brushes the matrix fiber laps so as to produce slivers wherein the fibers are uniformly oriented.
Blowing of the selected staple fibers is done sepa-rate and apart from the blowing of the matrix fibers, as represented by block 14. In this step, conventional staple fibers such as, for example, cotton, flax, linen, polyester, nylon and rayon are cleaned and formed into laps which are subsequently carded as indicated by block 18. The blowing step 14 may also be performed in a conven~ional apparatus such as the Trutzschler type 4 but, as already stressed, must be per-formed independently of the blowing of the matrix fibers,according to the present invention. Carding of the laps of staple fibers may be done by an Ashworth type AHP~lC carder, for example.
Slivers of matrix and staple fibers, as obtained from the separate carding steps 16 and 18, respectively, are first drawn together by a drawing frame as represented by blocX 20.
11(~1177 A conventional drawing frame machine such as, for example, Platt type 740, can be used to perform this step wherein bulky, blended slivers of matrix and staple fibers are formed. rt i5 important, during this step 20, that the proportions of matrix and staple fibers drawn together be closely maintained. For example, for a polyester matrix blend yarn according to the present invention, it is desired and preferred that a proportion of no more than about 35 percent polyester sliver be maintained when combined with a vinal-vinyon matrix sliver in drawing step 20, while for -10 cotton matrix yarn, preferably no more th~n about 15 percent cotton sliver is combined with the vinal-vinyon sliver.
The bulky, composite slivers as obtained after drawing step 20, above, are preferably thickened on a speed frame ap-paratus as indicated by block 22. Such apparatus may be, for example, a Marzoli type BC-3. The purpose of this step is to form a relatively heavy sliver or rope of blended fibers in preparation for a subsequent spinning step in which the desiréd blended yarn is formed.
Ropes of the blended fibers obtained from the speed frame step 22 are spun on a ring or spinning frame machine such as, for example, a Platt type 800. During this step, represented by block 24 in diagram 10, it is important that the spinning rate not exceed 10,000 RPM. It has been discovered that spin-ning of the ropes at higher conventional speeds such as from 16,000 to 20,000 RPM has deliterious effects on the spun yarn such as would impair its desired flame retardant properties.
In particular, as mentioned above, it has been found that spin-ning at the higher speed range causes reduced cross sections in the spun yarn, while operating below the maximum preferred ; 30 speed overcomes this problem. A preferred operating range for the spinning step 24 according to the present invention is from about 8,000 to 10,000 RPM.
( ~ ~
Continuing, the spun yarn is then con~entionally pro-cessed such as by, for example, a twisting machine (block 26) for crimping the yarn to a suitable degree depending upon whether it is to be later knitted or woven,and a coning machine ~block S 28). which arranges the crimpe~ yarn in the form of oonventional cones for ease of use when knitting or weaving therewith.
Should the flame retardant blended yarn produced accord~ng to the present invention be later used in producing a knitted fabric, care must again be taken to operate at speeds which will not cause reduced cross-sections in the yarn, and corresponding potentially flammable segments o~ yarn in the-finished fabric~ Also, the knitting machine must be ~ept sub-stantially free from flammable contaminates (e.g~ cotton lint) which might otherwise be trapped in the fabric.
:15 m e yarn formed as a result of the present process will be easy to knit or weave, have good tensile strength, will ..
i . be readily susceptible to dyeing and, most important, will have uniform flame-retardant.characteristics.
. Although a specific embodiment of the invention has been disclosed for illustrative purposes, it will be appreciated by one skilled in the art that many additions, substitutions and modi~ications are possible without departing from the scope and spirit of the invention as aefined by the accompanying claims.
,~
.
Claims (7)
1. A method for producing a flame retardant yarn of substantially uniform cross section from a source of flame retardant matrix fibers and a source of staple fibers, said method comprising the steps of air blowing the matrix fibers to remove impurities therefrom, air blowing the staple fibers to remove impurities therefrom in an environment isolated from said matrix fiber blowing step, carding said air blown matrix fibers to orient said matrix fibers, carding said air blown staple fibers to orient said staple fibers in an environment isolated from that of said matrix fiber carding step, drawing given proportions of said carded matrix fibers and said carded staple fibers together to produce a blended fiber sliver, form-ing said blended sliver into a rope and spinning said rope to form a blended yarn, said spinning step being performed at no greater than the maximum spinning rate at which a uniform cross section is maintained in said blended yarn.
2. The method according to Claim 1, further includ-ing the step of knitting said blended yarn into a fabric, said knitting being performed at no greater than the maximum knitting rate at which a uniform cross section is maintained in said blended yarn.
3. The method of Claim 1, wherein said spinning step is performed at a rate in the range of from 8,000 to 10,000 revolutions per minute.
4. A flame-retardant yarn produced in accordance with the process of Claim 3.
5. The flame-retardant yarn of Claim 4, wherein said given proportions of said carded matrix fibers and said carded staple fibers are in the range of about 65 to 85 percent and 15 to 35 percent, respectively.
6. The flame retardant yarn of Claim 4, wherein said carded matrix fiber comprises about 85 percent vinal-vinyon in equal parts and said carded staple fiber comprises about 15 percent cotton.
7. The flame retardant yarn of Claim 4, wherein said carded matrix fiber comprises about 65 percent vinal-vinyon in equal parts and said carded staple fiber comprises about 35 percent polyester.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US85331477A | 1977-11-21 | 1977-11-21 | |
| US853,314 | 1977-11-21 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1101177A true CA1101177A (en) | 1981-05-19 |
Family
ID=25315702
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA313,943A Expired CA1101177A (en) | 1977-11-21 | 1978-10-23 | Flame retardant fabrics and method of producing same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1101177A (en) |
-
1978
- 1978-10-23 CA CA313,943A patent/CA1101177A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |