EP1846604A1 - Flame resistant fabric useful as a batting in mattresses and upholstery - Google Patents

Flame resistant fabric useful as a batting in mattresses and upholstery

Info

Publication number
EP1846604A1
EP1846604A1 EP20060719131 EP06719131A EP1846604A1 EP 1846604 A1 EP1846604 A1 EP 1846604A1 EP 20060719131 EP20060719131 EP 20060719131 EP 06719131 A EP06719131 A EP 06719131A EP 1846604 A1 EP1846604 A1 EP 1846604A1
Authority
EP
European Patent Office
Prior art keywords
fabric
range
wool
weight
sample
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.)
Withdrawn
Application number
EP20060719131
Other languages
German (de)
English (en)
French (fr)
Inventor
Warren F. Knoff
Walter Randall Hall, Iii
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Publication of EP1846604A1 publication Critical patent/EP1846604A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/208—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/001—Fireproof means
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D04H1/4342—Aromatic polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—Composite fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00—Domestic or personal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y10T442/698—Containing polymeric and natural strand or fiber materials

Definitions

  • This invention relates to a fire resistant fabric particularly useful as a fire-blocking batting in a mattress and furniture.
  • a fire barrier into a mattress
  • one of the existing layers of material be converted to one that can act as a fire blocking layer.
  • most mattresses have a high loft fiber batting, and this batting can provide additional fuel if made from flammable materials. Replacing this high loft material with material having a low thermal performance temperature typically represents an acceptable solution.
  • Fire resistant cellulosic fibers can be used effectively to thermally protect a mattress, however these battings are typically dense and not soft to the touch.
  • PCT Publication WO 03/023108 discloses a nonwoven high loft flame barrier for use in mattresses and upholstered furniture. These barriers have very low density, ranging from 5 to 50 kilograms per cubic meter, most preferably 7.5 to 15 kilograms per cubic meter.
  • the preferred nonwoven high loft flame barrier comprises a blend of fibers including fibers that are inherently fire resistant and resistant to shrinkage by direct flame, and fibers from polymers made with halogenated monomers.
  • United States Patent Application Publication US 2004/0060119 discloses a fire barrier fabric having a fire barrier layer and a thermally insulating layer.
  • the fire barrier layer can be composed of a blend of aramid and modacrylic fibers and the thermally insulating layers can be composed derived from fire resistant viscose and modacrylic fibers.
  • This invention relates to a fire-resistant fabric useful as a batting in fire blocking an article such as a mattress or upholstery and a method of incorporating the fabric into an article.
  • the fabric comprises:
  • the fabric will have a least one of the following: (a) a thermal performance temperature in a range from 125°C to 500°C.
  • the present invention also relates to a method of incorporating the fabric into a final article of manufacture such as a batting in a mattress or furniture.
  • a preferred cellulose fiber is one formed from viscose fiber containing hydrated silicon dioxide in the form of a silicic acid with aluminum silicate sites.
  • Viscose fiber containing silicic acid is sold under the trademark Visil® by Sateri Oy Company of Finland.
  • a second necessary material in the present invention is animal wool such as from sheep and goats. Sheep's wool is preferred due to availability and cost.
  • the amount of wool present in the fabric will be in a range from 15 to 70% by weight on a basis of the cellulosic fiber and wool.
  • the wool will be in a range from 20 to 50 % on the same basis of cellulosic fiber and wool.
  • the fire-resistant fabric will have a thermal performance temperature in a range from 125°C to 500°C. More preferably the range will be from 200 to 400°C.
  • thermal performance temperature is measured using the same instrument employed for NFPA1971 Standard on
  • a further desirable property in a preferred embodiment of the flame resistant fabric is that it is perceived as soft and comfortable.
  • One way of describing such comfort is its capability to compress at a minimum applied load. Although this property may be measured in different ways, in the present case, compression is measured in ASTM standard D 6571-01 but modified with use of a 17.6 pound (8 kilogram) weight, a fabric sample size of twelve by twelve inches (30.4 x 30.4 centimeters).
  • the fabric as a batting in a mattress when tested according to the State of California test standard TB603 can result in a peak rate of heat release less than 200 kW during the 30 minutes test duration and a total heat release less than 25 MJ within 10 minutes of test start.
  • An important property which can be obtained with fabrics of the present invention is an ability of the fabric to be evaluated as soft. It is understood that softness is a subjective term and it will vary from person to person. Also, there is no sharp line between a fabric which is perceived as soft as opposed to not being soft. Also, a fabric perceived as soft such as in use as upholstery may not be perceived as soft as part of a mattress construction.
  • a soft fabric has a compression of at least 40% when measured in accordance with modified ASTM D6571-01 as previously described. If higher thermal performance is required, the total basis weight of the cellulose and wool batting can be increased. If higher thermal performance combined with increased structural integrity during the flame resistant test is required, it may be desirable to add a further material to the cellulose fiber and wool.
  • these materials are heat resistant and include aramid, especially para-aramid, polybenzazole polybenzimidazole and polyimide. Generally, the material will be present as a fiber.
  • a suitable basis weight is in a range of 3 to 18 ounces per square yard (102 to 610 grams per square meter and more preferably 4 to 12 ounces per square yard (136 to 407 grams per square meter). Basis weight can be measured in accordance with ASTM D6242-98.
  • flame resistant fabric is employed as a batting and additional durability or strength is desired, such fabric can be contacted and joined with another fabric such a woven or nonwoven scrim fabric such as by sewing or use of an adhesive.
  • fire resistant type 33 AP Visil® cellulose fiber having cellulose having an individual filament denier of 3.5 dpf (3.9 dtex) and average cut length of 2 inches (51 mm) available from Sateri Oy.
  • aramid poly(paraphenylene terephthalamide) supplied as Kevlar® Type 970 by E. I. du Pont de Nemours and Company having an individual filament denier of 2.25 dpf (2.50 dtex) average cut length of 2 inches (51 mm).
  • the program profile consists of equilibrating the sample to 50 degrees C, placing the sample in a 500 microliter ceramic cup (PN 952018.910) sample container and ramping the temperature of the air, as measured by a thermocouple placed directly above the lip of the sample container, at 20 degrees C per minute from 50 to 1000 degrees C, using air supplied at 10 ml/minute.
  • the testing procedure is as follows.
  • the TGA was programmed using the TGA screen on the TA Systems 2900 Controller.
  • the sample ID was entered and the planned temperature ramp program of 20 degrees per minute selected.
  • the empty sample cup was tared using the tare function of the instrument.
  • the fiber sample was cut into approximately 1/16" (0.16 cm) lengths and the sample pan was loosely filled with the sample.
  • Fabrics in the form of battings as set forth in Table 1 were blended using conventional carding/garnet machines and crosslappers that opened and blended the fibers.
  • the fabrics were heat set using a through-air oven and then cooled at room temperature.
  • Table 2 contains % compression data obtained in accordance with modified ASTM D 6571-01 described above
  • Thickness values are in inches (centimeters)
  • Sample A was 80% cellulose and 20% binder (i.e. 0% wool).
  • Sample D was 40% wool, 40% cellulose and 20% binder
  • Sample G was 40% cellulose, 20% binder and 40% aramid
  • Sample H was 29% wool, 29% cellulose, 13% binder and 29% aramid (i.e. 50% wool on basis of wool and cellulose)
  • Sample A (which did not contain wool or aramid) and Sample H (which did not contain wool but contained aramid) did not reach a minimum compression of at least 40%
  • Sample D (which contained wool but did not contain aramid) and Sample H (which contained both wool and aramid) had a compression of 50%.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
  • Woven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Bedding Items (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Artificial Filaments (AREA)
EP20060719131 2005-01-31 2006-01-20 Flame resistant fabric useful as a batting in mattresses and upholstery Withdrawn EP1846604A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/047,211 US20060172649A1 (en) 2005-01-31 2005-01-31 Flame resistant fabric useful as a batting in mattresses and upholstery
PCT/US2006/002167 WO2006083593A1 (en) 2005-01-31 2006-01-20 Flame resistant fabric useful as a batting in mattresses and upholstery

Publications (1)

Publication Number Publication Date
EP1846604A1 true EP1846604A1 (en) 2007-10-24

Family

ID=36581947

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20060719131 Withdrawn EP1846604A1 (en) 2005-01-31 2006-01-20 Flame resistant fabric useful as a batting in mattresses and upholstery

Country Status (9)

Country Link
US (2) US20060172649A1 (https=)
EP (1) EP1846604A1 (https=)
JP (1) JP2008530378A (https=)
KR (1) KR20070100822A (https=)
CN (1) CN101155954A (https=)
BR (1) BRPI0606552A2 (https=)
CA (1) CA2596072A1 (https=)
MX (1) MX2007009002A (https=)
WO (1) WO2006083593A1 (https=)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2542333B (en) * 2015-08-20 2019-02-27 So4Bed Ltd A method of forming a fire retardant fabric without the need to apply a fire retardant composition
US12364300B2 (en) * 2022-09-13 2025-07-22 Paka Apparel Inc Insulating fill material composition and methods of preparation

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Title
See references of WO2006083593A1 *

Also Published As

Publication number Publication date
CA2596072A1 (en) 2006-08-10
KR20070100822A (ko) 2007-10-11
MX2007009002A (es) 2007-09-18
BRPI0606552A2 (pt) 2009-06-30
WO2006083593A1 (en) 2006-08-10
US20060172649A1 (en) 2006-08-03
JP2008530378A (ja) 2008-08-07
US20090083910A1 (en) 2009-04-02
CN101155954A (zh) 2008-04-02

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