EP1861524B1 - Flame resistant fiber blends - Google Patents

Flame resistant fiber blends Download PDF

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Publication number
EP1861524B1
EP1861524B1 EP05858690A EP05858690A EP1861524B1 EP 1861524 B1 EP1861524 B1 EP 1861524B1 EP 05858690 A EP05858690 A EP 05858690A EP 05858690 A EP05858690 A EP 05858690A EP 1861524 B1 EP1861524 B1 EP 1861524B1
Authority
EP
European Patent Office
Prior art keywords
fibers
fiber
blend
nylon
amorphous silica
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.)
Active
Application number
EP05858690A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP1861524A4 (en
EP1861524A2 (en
Inventor
Derek Bass
Brian Sparks
Doug Hope
William Dawson
William Edwards
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.)
Propex Operating Co LLC
Original Assignee
Propex Operating Co LLC
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
Priority claimed from US11/001,539 external-priority patent/US20060116043A1/en
Application filed by Propex Operating Co LLC filed Critical Propex Operating Co LLC
Publication of EP1861524A2 publication Critical patent/EP1861524A2/en
Publication of EP1861524A4 publication Critical patent/EP1861524A4/en
Application granted granted Critical
Publication of EP1861524B1 publication Critical patent/EP1861524B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5416—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sea-island
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
    • D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D01F2/06—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from viscose
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/443—Heat-resistant, fireproof or flame-retardant yarns or threads
    • 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
    • D04H1/4209—Inorganic fibres
    • 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
    • D04H1/4282—Addition polymers
    • D04H1/43—Acrylonitrile 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
    • D04H1/4382—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
    • D04H1/43825—Composite fibres
    • D04H1/4383—Composite fibres sea-island
    • 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
    • D04H1/43832—Composite fibres side-by-side
    • 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
    • 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
    • D04H1/43838—Ultrafine fibres, e.g. microfibres
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5414—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres side-by-side
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/555—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 by welding together the fibres, e.g. by partially melting or dissolving by ultrasonic heating
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
    • 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
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/14—Carbides; Nitrides; Silicides; Borides

Definitions

  • This invention relates to a flame resistant fiber blend useful in preparing fabrics having flame resistance, including particularly non-woven flame resistant materials such as barrier fabrics.
  • FR materials are employed in many textile applications.
  • FR materials are useful as barrier layers between the exterior fabric and the inner stuffing of furniture, comforters, pillows, and mattresses.
  • Such materials can be woven or non-woven, knitted, or laminated with other materials.
  • Flame resistance is defined by ASTM as "the property of a material whereby flaming combustion is prevented, terminated, or inhibited following application of a flaming or non-flaming source of ignition, with or without the subsequent removal of the ignition source.”
  • the material that is flame resistant may be a polymer, fiber, or fabric.
  • a flame retardant is defined by ASTM as "a chemical used to impart flame resistance.”
  • the flame resistance properties of such FR materials are typically determined according to various standard methods, such as California TB117 and TB 133 for upholstery; NFPA701 for curtains and drapes; California Test Bulletin 129, dated October 1992, concerning flammability test procedures for mattresses in public buildings, and California Test Bulletin 603 concerning mattresses for residential use.
  • the FR material does not melt or shrink away from the flame, but forms a char that helps control the burn and shield the materials surrounded by the fabric.
  • the protection required of the flame and heat barrier fabric is related to the other components used in the final assembly of the desired product.
  • mattresses normally contain layers of foam and fiber batting for cushioning and ticking for durable cover.
  • Most cushioning material is comprised of foam and fibers that burn when exposed to open flame.
  • Much of the regulatory-driven effort to date has gone towards shielding the inner cushioning layers from open flame or ignition from the heat of the open flame without compromising the comfort or aesthetics of the mattress.
  • FR barrier fabrics include a white or other neutral color so as to not contaminate the manufacturing facility or change the look of the composite article; the ability to remain unaffected by ultraviolet light so as not to yellow and change the look of light-colored mattress ticking or upholstery fabrics; being soft to the touch, thereby imparting the feel desired by the consumer; and cost effectiveness.
  • Some fibers are known to have FR properties, such as halogen-containing, phosphorus-containing, and antimony-containing materials. These materials, however, are heavier than similar types of non-FR materials, and they have reduced wear life.
  • baghouse filters are widely used to control particulate pollutants in many industries such as, food processing, cement, mineral, and aggregate processing, metal processing, power generation, and in production of various chemicals.
  • a filter fabric of this type ideally will have (1) a sufficient mechanical strength to withstand pressures developed during use and multiple cycles of flexing, (2) a resistance toward harsh chemicals for long periods of time, (3) an ability to be unaffected by continuous operating temperatures as high as 482° C (900 °F), (4) a resistance toward hot sparks, (5) less than 1% shrinkage at use temperature, (6) a high filtration efficiency, and (7) a resistance to being attacked by microorganisms.
  • Prior art document JP 2002 316009 A provides a fire-resistant filter material comprising a fiber web of intertwined and/or coupled denatured silica fibers with a fiber length of 10-100 mm, and crimped organic fibers with a fiber length of 15-100 mm.
  • the silica fiber contains (in weight %) silica (85-99), alumina (1-10), components (0-10) other than silica and alumina.
  • the fiber web contains silica fibers (5-95) and organic substance fibers (5-95).
  • Document JP 2001 262453 A discloses a felt material, which is formed by integrating a wrapping material comprising silica fibers for firing and heat-resistant organic fibers with melting point of 250 C° or more or with no sharp melting point, with a base material by needle punching, after removing soluble or organic components from the fibrils.
  • the felt material is set to a preset thickness and density, after heat processing.
  • the present invention provides a flame resistant (FR) fiber blend comprising amorphous silica fibers as defined in claim 1; and at least one fiber selected from the group consisting of FR fibers, binder fibers and mixtures thereof.
  • FR flame resistant
  • a barrier fabric can be manufactured from a blend of fibers comprising amorphous silica fibers; and at least one fiber selected from the group consisting of FR fibers, binder fibers and mixtures thereof.
  • a flame resistant fabric can be manufactured from a blend of fibers comprising amorphous silica fibers; and at least one fiber selected from the group consisting of FR fibers, binder fibers and mixtures thereof.
  • a process for protecting materials in a product from fire and heat comprises assembling a flame resistant fabric adjacent to at least one component that comprises a material susceptible to damage due to exposure to fire and heat, occasioned by exposure to open flames.
  • fiber blends containing amorphous silica show improved char strength when formed into non-woven fabric, compared to non-woven fabric not containing amorphous silica.
  • the char strength to weight ratio of non-woven fabric containing amorphous silica is also improved, when compared to non-woven fabric containing other fibers conventionally used to improve char strength, such as para-aramid fibers and melamine fibers.
  • the drawing figure is a perspective view exploded to show assembly of a tuft button test apparatus.
  • Two types of fiber blends a first, comprising amorphous silica fibers and at least one type of FR fiber and a second, comprising amorphous silica fibers and at least one type of binder fibers are disclosed.
  • the fiber blends can then be used to form fabrics, both nonwovens and woven fabrics, for a variety of uses.
  • any amorphous silica fiber that improves the char strength when added to a fiber blend may be used.
  • the term "silica” refers to silicon dioxide which occurs naturally in a variety of crystalline and amorphous forms. Silica is considered to be crystalline when the basic structure of the molecule (silicon tetrahedra arranged such that each oxygen atom is common to two tetrahedral) is repeated and symmetrical. Silica is considered to be amorphous if the molecule lacks crystalline structure. The SiO 2 molecule is randomly linked, forming no repeating pattern. Crystalline silica is not desired because of the associated health effects related to fragmentation of its brittle crystalline structure into fragments of respirable size.
  • the amorphous silica fiber is a high-content silica fiber having a silica (SiO 2 ) content of at least 90 percent by weight, based upon the total weight of the high silica fiber.
  • the high silica fibers have a silica content of at least 95 percent by weight, and in other embodiments, the high silica fibers have a silica content of at least 98 percent by weight.
  • the high silica fibers may contain 98 percent by weight silica, with the balance predominantly containing alumina.
  • the amount of halogen in the high silica fiber is de minimus, less than 120 parts per million by weight.
  • the silica fibers are substantially amorphous. While the fibers may contain some crystalline material, a substantial amount of crystallinity is not desired. Suitable silica fiber is commercially available, for example from Polotsk-Steklovokno, Ecuador.
  • the starting material composition for the high silica fibers is: from 72 to 77% SiO 2 , from 2.5 to 3.5% Al 2 O 3 , from 20 to 25% Na 2 O, from 0.01 to 1.0% CoO and from 0.01 to 0.5% SO 3 , all percents by weight, based upon the total weight of the composition.
  • the composition may be melted at 1480 ⁇ 10°C to form a continuous fiber.
  • This fiber may then be leached using hot sulfuric acid having a concentration of 2N at a temperature of 98 ⁇ 2° C with a dwell time of 60 minutes.
  • the fiber may then be rinsed with tap water until the pH is 3-5.
  • the resulting fiber has a SiO 2 content of from 95 to 99% ⁇ 1 percent by weight, with the remainder being predominantly Al 2 O 3 .
  • a high silica glass composition and process for making high silica fibers is described in Russian Pat. No. 2,165,393 (the '393 patent), the disclosure of which is hereby incorporated by reference herein.
  • the high silica fibers of the '393 patent are described as having a lower coefficient of variation in the strength of the basic filaments, which gives the possibility to stabilize the strength characteristics of the resultant fiber, especially at exposure to high temperature.
  • the following description of high silica fibers is taken from the '393 patent for exemplary purposes.
  • a precursor glass composition may include SiO 2 , Al 2 O 3 and Na 2 O, as well as CoO and SO 3 in the following proportions (percent mass): Al 2 O 3 : 2.5-3.5 Na 2 O: 20-25 CoO: 0.01-1.0 SO 3 : 0.01-1.0 SiO 2 : remaining
  • the glass may further contain at least one oxide from the group CaO, MgO, ZrO 2 , TiO 2 , Fe 2 O 3 in the following quantities (percent mass) : CaO: 0.01-0.5 MgO: 0.01-0.5 TiO 2 : 0.01-0.1 Fe 2 O 3 : 0.01-0.5 ZrO 2 : 0.01-0.5
  • a resultant, high-temperature silica fiber from the glass composition about would then include SiO 2 and Al 2 O 3 , but also would contain Na 2 O, CoO and SO 3 in the following proportions (percent mass): SiO 2 : 94-96 Al 2 O 3 : 3-4 Na 2 O: 0.01-1.0 CoO: 0.01-1.0 SO 3 : 0.01-1.0
  • the silica fiber may also contain at least one oxide from the group CaO, MgO, TiO 2 , Fe 2 O 3 , ZrO 2 in the following quantities (percent mass) : CaO: 0.01-0.5 MgO: 0.01-0.5 TiO 2 : 0.01-0.1 Fe 2 O 3 : 0.01-0.5 ZrO 2 : 0.01-0.5
  • the silica fibers are substantially free of any metal oxide coating.
  • Diameter of the silica fibers may range from 5.6 microns to 12.6 microns and, in one embodiment, the diameter is 8 microns.
  • Length of the silica fibers may range from 50 millimeters to 125 millimeters and, in one embodiment, the length is 75 millimeters, (shorter and longer fibers are available by adjusting the cut length of the fiber, but are not practical for needlepunch applications) .
  • One method of preparation of the silica fibers according to the aforementioned Russian patent, No. 2,165,393 , as set forth in Example 1 hereinbelow, may be conducted as follows: To produce continuous filament glass fiber of the proposed composition, a vessel containing (percent mass) SiO 2 :72.39, Al 2 O 3 :2.5, Na 2 O:25, CoO:0.01, SO 3 :0.1 may be prepared. The vessel may be loaded into a furnace, and the composition melted at a temperature of 1480 ⁇ 10°C. From the molten glass mass, a continuous glass fiber may be formed with a diameter of 6-9 microns at a temperature of 1260 ⁇ 50°C using 400-hole glass-forming aggregates. The resultant fiber has been shown to have a strength of 1030 Mpa and a surface tension of 0.318 H/m.
  • Leaching of the continuous glass fiber may then take place using a hot sulfuric acid solution having a concentration of 2N (10%) at a temperature of 98 ⁇ 2°C. Contact time for the fiber in the solution is 60 minutes. The leaching solution, reaction products, and sizing remains are then washed away from the leached fiber with tap water until the pH is at 3-5. Final washing of the fiber is conducted with deionized water and simultaneous dehydration.
  • Example 2 The preparation of the glass composition, its processing and leaching for Examples 2 and 3 below are analogous to that as set forth above for Example 1, but with different amounts of starting materials.
  • Table 1 presents the starting amounts for the glass as well as the amounts of materials for the resultant silica compositions.
  • Table 2 presents the characteristics of the molten product, the characteristics of processing, and the characteristics of the glass and silica fibers.
  • Table 3 provides strength characteristics of the silica materials after exposure to 1000° C.
  • Tables 1- 3 also provide data confirming the introduction of cobalt and SO 3 into the glass composition increases the heterogeneity of the glass mass, lowers its surface tension, decreases the fragility of the fiber during processing and also increases the stability of the technical characteristics of the silica fiber and resultant materials based on this fiber.
  • Tables 4 and 5 show various glass fiber compositions from which it can be seen that the silica fibers taught by the Russian Pat. No. 2,165,393 differ from all other glass fiber types by the presence of trace amounts of CoO and SO 3 .
  • TABLE 4 VARIOUS GLASS FIBER COMPOSITIONS FOR PRODUCING HIGH SILICA FIBERS Glass Type Country Org.
  • amorphous silica component the additive fibers will be discussed next. As noted hereinabove, two embodiments, one employing flame resistant (FR) fibers and another employing binder fibers are disclosed. In the following discussion, use of the term "silica fiber” shall be understood to mean those fibers containing amorphous (as opposed to crystalline) silica.
  • the amount of silica fiber in the fiber blend can vary, depending upon the other fibers used.
  • the amount of silica fiber in the blend is from 5 to 65 weight percent, based upon the total weight of the blend.
  • the amount of silica fiber in the blend is from 15 to 50 weight percent.
  • the amount of silica fiber in the blend is from 20 to 30 weight percent.
  • the remaining fibers in the blend include the necessary amount of non-amorphous fibers, namely the FR fibers, to equal 100 weight percent.
  • the FR fibers may be an inherent flame resistant fiber or a fiber (natural or synthetic) that is coated with an FR resin.
  • the inherent flame resistant fibers are not coated, but have an FR component incorporated within the structural chemistry of the fiber.
  • the term FR fiber, as used herein, includes both the inherent flame resistant fibers as well as fibers that are not inherently flame resistant, but are coated with FR resins. Accordingly, by way of example, a polypropylene fiber coated with an FR resin would be an FR polypropylene fiber.
  • Suitable inherently flame resistant fibers include polymer fibers having a phosphorus-containing group, an amine, a modified aluminosilicate, or a halogen-containing group.
  • Examples of inherently flame resistant fibers include melamines, meta-aramids, para-aramids, polybenzimidazole, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novoloids, poly(p-phenylene benzobisoxazoles), poly (p-phenylenebenzothiazoles), polyphenylene sulfides, flame retardant viscose rayons; ( e.g ., a viscose rayon based fiber containing 30% aluminosilicate modified silica, SiO 2 +Al 2 O 3 ), polyetheretherketones, polyketones, polyetherimides, and combinations thereof).
  • Melamines include those sold under the tradenames Basofil by McKinnon-Land-Moran LLC.
  • Meta-aramids include poly (m-phenylene isophthalamide), for example sold under the tradenames NOMEX ® by E.I. Du Pont de Nemours and Co., TEIJINCONEX ® and CONEX ® by Teijin Limited and FENYLENE ® by Russian State Complex.
  • Para-aramids include poly (p-phenylene terephthalamide), for example sold under the tradename KEVLAR ® by E.I.
  • Du Pont de Nemours and Co. and poly (diphenylether para-aramid), for example sold under the tradename TECHNORA ® by Teijin Limited, and under the tradenames TWARON ® by Acordis and FENYLENE ST ® ( Russian State Complex).
  • Polybenzimidazole is sold under the tradename PBI by Hoechst Celanese Acetate LLC.
  • Polyimides include those sold under the tradenames P-84 ® by Inspec Fibers and KAPTON ® by E.I. Du Pont de Nemours and Co.
  • Polyamideimides include for example those sold under the tradename KERMEL ® by Rhone-Poulenc.
  • Partially oxidized polyacrylonitriles include, for example, those sold under the tradenames FORTAFIL OPF ® by Fortafil Fibers Inc., AVOX ® by Textron Inc., PYRON ® by Zoltek Corp., PANOX ® by SGLtechnik, THORNEL ® by American Fibers and Fabrics and PYROMEX ® by Toho Rayon Corp.
  • Novoloids include, for example, phenol-formaldehyde novolac, such as that sold under the tradename KYNOL ® by Gun Ei Chemical Industry Co.
  • Poly (p-phenylene benzobisoxazole) (PBO) is sold under the tradename ZYLON ® by Toyobo Co.
  • Poly (p-phenylene benzothiazole) is also known as PBT.
  • Polyphenylene sulfide (PPS) includes those sold under the tradenames RYTON ® by American Fibers and Fabrics, TORAY PPS ® by Toray Industries Inc., FORTRON ® by Kureha Chemical Industry Co. and PROCON ® by Toyobo Co.
  • Flame retardant viscose rayons include, for example, those sold under the tradenames LENZING FR ® by Lenzing A. G. and VISIL ® by Sateri Oy Finland.
  • Polyetheretherketones (PEEK) include, for example, that sold under the tradename ZYEX ® by Zyex Ltd.
  • Polyketones (PEK) include, for example, that sold under the tradename ULTRAPEK ® by BASF.
  • Polyetherimides (PEI) include, for example, that sold under the tradename ULTEM ® by General Electric Co.
  • Modacrylic fibers are made from copolymers of acrylonitrile and other materials such as vinyl chloride, vinylidene chloride or vinyl bromide. Flame retardant materials such as antimony oxide can be added to further enhance flame resistant property. Modacrylic fibers are manufactured by Kaneka under the product names KANECARON PBX and PROTEX-M, PROTEX-G, PROTEX-S and PROTEX-PBX. The latter products contain at least 75% of acrylonitile - vinylidene chloride copolymer. SEF PLUS by Solutia is a modacrylic fiber as well with flame retardant properties.
  • inherent FR fibers suitable for use in the blend of the present invention include polyester with phosphalane such as that sold under the trademark TREVIRA CS ® fiber or AVORA ® PLUS FIBER by KoSa.
  • chloropolymeric fibers such as those sold under the tradenames THERMOVYL ® L9S & ZCS, FIRBRAVYL ® L9F, RETRACTYL ® L9R, ISOVYL ® MPS by Rhovyl S.A., PIVIACID ® , Thueringische, VICLON ® by Kureha Chemical Industry Co., TEVIRON ® by Teijin Ltd., ENVILON ® by Toyo Chemical Co., VICRON ® , SARAN ® by Pittsfield Weaving, KREHALON ® by Kureha Chemical Industry Co., OMNI-SARAN ® by Fibrasomni, S.A.
  • Fluoropolymeric fibers such as polytetrafluoroethylene (PTFE), poly(ethylene-chlorotrifluoroethylene (E-CTFE), polyvinylidene fluoride (PVDF), polyperfluoroalkoxy (PFA), and polyfluorinated ethylene-propylene (FEP) and combinations thereof are also useful.
  • PTFE polytetrafluoroethylene
  • E-CTFE poly(ethylene-chlorotrifluoroethylene
  • PVDF polyvinylidene fluoride
  • PFA polyperfluoroalkoxy
  • FEP polyfluorinated ethylene-propylene
  • Natural or synthetic fibers coated with an FR resin are also useful in the fiber blend of the present invention.
  • Suitable fibers coated with an FR resin include those where the resin contains one or more of phosphorus, phosphorus compounds, red phosphorus, esters of phosphorus, and phosphorus complexes; amine compounds, boric acid, bromide, urea-formaldehyde compounds, phosphate-urea compounds, ammonium sulfate, or halogen based compounds.
  • Non-resin coatings like metallic coating are not generally employed for the present invention, because they tend to flake-off after continuous use of the product.
  • Suitable commercially available FR resins are sold under the trade names GUARDEX FR ® , and FFR ® by Glotex Chemicals in Spartanburg, S.C.
  • the FR resin is a liquid product that can be applied as a spray.
  • the FR resin is a solid that may be applied as a hot melt product to the fibers, or as a solid powder that is then melted into the fibers.
  • the FR resin is applied to the fibers in an amount of from 6 to 25 weight %, based upon the total weight of the coated fibers.
  • the amount of coated FR fiber in the blend can vary, but is from 35 to 95 weight percent, based upon the total weight of the blend. In one embodiment, the amount of coated FR fiber in the blend is from 40 to 90 weight percent. In another embodiment, the amount of coated FR fiber in the blend is from 45 to 85 weight percent.
  • the denier of the FR fibers is from 1.5 to 15 dpf (denier per filament).
  • the foregoing listing of FR fibers illustrates the fact that any FR fiber known can be employed with an amorphous silica fiber and utilized.
  • fiber types includes multifilament and monofilament yarns, having a variety of cross-sections and shapes as well as fibrillated yarns, typically manufactured from slit films or tapes.
  • the fiber blend of the present invention may further contain one or more non-FR fibers.
  • the non-FR fibers may be synthetic or natural fibers. Suitable non-FR synthetic fibers include polyester such as polyethylene terephthalate (PET); cellulosics, such as rayon and/or lyocell; nylon; polyolefin such as polypropylene fibers; acrylic; melamine and combinations thereof.
  • the lyocell fibers are a generic classification for solvent-spun cellulosic fibers. These fibers are commercially available under the name TENCEL ® . Natural fibers include flax, kenaf, hemp, cotton and wool. In one embodiment, non-FR fibers are employed to enhance certain characteristics such as loft, resilience or springiness, tensile strength, and thermal retention.
  • the fiber blend includes amorphous silica fiber and at least one type of FR fiber. Therefore, a fiber blend that contains amorphous silica fiber, an FR fiber, optionally additional FR fibers, and optionally one or more non-FR fibers is used.
  • the fiber blend includes: modacrylic fiber; a cellulosic fiber, lyocell, and amorphous silica fiber.
  • the fiber blend further includes more than one type of FR fiber.
  • the fiber blend includes amorphous silica fiber, modacrylic fiber, and VISIL.
  • the fiber blend includes modacrylic fiber, FR rayon fiber, and amorphous silica fiber.
  • the fiber blend includes modacrylic fibers, VISIL (FR viscose rayon) fibers, amorphous silica fibers, and FR polypropylene fibers.
  • the amounts of each component can vary; however, advantageous char strength is obtained when a needlepunched fabric is prepared from a blend containing 40 weight percent modacrylic, 40 weight percent VISIL, 15 weight percent amorphous silica, and 5 weight percent FR polypropylene fibers.
  • the fibers of the present invention can be used to manufacture fabrics, where FR properties are desired or would be useful.
  • any type of fabric, produced from fibers, such as non-woven fabrics; woven fabrics, both open and closed weave; knitted fabrics and various laminates can be made using the fibers of the present invention.
  • the manufacture of such fabrics is not limited to a particular method or apparatus.
  • woven fabrics it is possible to employ amorphous silica fibers in the machine direction or the cross machine direction, alternating with one or more of the FR fibers.
  • the fibers can be alternated in the machine direction and woven with either an amorphous or an FR fiber in the cross machine direction.
  • woven fabrics can comprise the compositions stated above for the blend of amorphous and FR fibers.
  • the non-woven fabric may be produced by mechanically interlocking the fibers of a web.
  • the mechanical interlocking can be achieved through a needlepunch operation. Needlepunch methods of preparing non-woven fabric are known in the art.
  • the nonwoven fabric sometimes called a bart, may be constructed as follows: the fiber blend may be weighed and then dry laid/air laid onto a moving conveyor belt The speed of the conveyor belt can be adjusted to provide the desired batt weight. Multiple layers of batts are fed trough a needle loom where barbed needles are driven through the layers to provide entanglement.
  • nonwoven fabrics There are several other known methods for producing nonwoven fabrics including hydroentanglement (spunlace), thermal bonding (calendering and/or though-air), latex bonding or adhesive bonding processes.
  • the spunlace method is similar to needlepunch except waterjets are used to entangle the fibers instead of needles.
  • Thermal bonding requires either some type if thermoplastic fiber or powder to act as a binder. It is to be appreciated that all forms of nonwovens can be made with the FR fiber blends of the present invention to produce barrier fabrics having FR properties. Accordingly, reference to nonwoven fabrics herein includes all forms of manufacture.
  • Suitable non-woven fabrics have a batt weight greater than 76.29 grams per square meter (g/m 2 ). In one embodiment, the batt weight ranges from 76.29 (g/m 2 ) to 678.12 (g/m 2 ) In another embodiment the batt weight is 118.87 (g/m 2 ), In one embodiment, the fibers are carded. Then the conveyor belt moves to an area where spray-on material may optionally be added to the nonwoven batt. For example, the FR resin may be sprayed onto the nonwoven batt as a latex. In one embodiment, the conveyor belt is foraminous, and the excess latex spray material drips through the belt and may be collected for reuse later. After the optional spraying, the fiber blend is transported to a dryer or oven. The fibers may be transported by conveyer belt to the needlepunch loom where the fibers of the batt are mechanically oriented and interlocked to form a non-woven fabric.
  • the non-woven FR fabric is useful as a barrier fabric for bedding materials and bed clothing.
  • the fabric is also useful in upholstery and drapery applications where flame resistance is desired. Another use for such fabrics is as hot gas filtration fabrics. Additionally, fabrics other than non-wovens can be made from the fibers where an FR fabric is desired.
  • the samples were prepared on a miniature card and needleloom.
  • the fiber was first hand-opened and layered on the card feed apron.
  • the carded sample was run back through the card a second time to assure intimate blending of fibers.
  • the carded web, layered around the wind-up roll, was cut transversely and removed from the card. Then it was fed into the needlepunch line for needling. A second pass was performed to accomplish needling from the opposite side.
  • Standard tensile strength testers were modified to measure the char strength of the barrier fabric. More specifically, the fabric stiffness test typically used with pocket coil material was modified to measure the amount of force, measured and reported in pounds, required to push a fabric sample through a hole with a plunger. To force the material to break, a template was fabricated so that the fabric could be sandwiched between the template and the existing test plate.
  • Example Nos. 4-15 Specimens of the barrier fabric were cut into 10.16 cm by 20.32 cm (4" by 8") samples and weighed. The samples were placed in a charring frame and charred by using a Bunsen burner. The frame was then mounted into the modified stiffness tester and the char strength of the sample was measured. Table 6 summarizes the results for Example Nos. 4-15. As a standard, a blend comprising 40% modacrylic and 60% Visil was selected (Ex. No. 4). The following types of fiber were used: Basofil® (abbreviated Bas); modacrylic fiber KANECARON PBX; VISIL® (abbreviated Vis); polyethylene terephthalate (abbreviated PET); and amorphous silica (abbreviated Sil).
  • Examples 5-11 and 13-14 are comparative examples of fabric prepared from various fiber blends as indicated.
  • Examples 5 and 6 contained 10% Basofil fibers as a replacement for equal amounts of modacrylic fiber or Visil fiber;
  • Examples 7 and 8 contained 10% and 20% PET fibers as a replacement for equal amounts of Visil fiber;
  • Example 9 comprised a blend 10% Basofil fibers with PET fibers, modacrylic fiber and Visil fiber;
  • Examples 10 and 11 contained 10% and 15% PET fibers as a replacement for varying amounts of modacrylic fiber and Visil fiber;
  • Examples 13 and 14 contained 10% Basofil fibers as a replacement for varying amounts of modacrylic fiber and Visil fiber;
  • Examples 12 and 15 were prepared from fiber blends containing amorphous silica fibers.
  • the fabric formed from fiber blends containing amorphous silica show a strength to weight ratio of from 0.08 to 0.10.
  • Examples 16-45 were prepared and tested as for Examples 4-15, except that different blends of fiber were used, as summarized in Table 7. Strength of each fabric is reported in pounds, as discussed hereinabove. The fabrics have been reported in six groups of four blends and two groups of three blends. Examples 19, 23, 27, 31, 34, 38, 41, and 45 report a base fabric and the examples immediately preceding report the addition of various types of FR fiber. Char strength, in pounds, was measured and the results have been reported by decreasing values for each group.
  • FR rayon and modacrylic fibers were used to prepare Example 19, denoted FR Rayon/Modacrylic Base Fabric.
  • Examples 16-18 are variations of this base fabric, because in each case one other type of FR fiber was added: para-aramid fibers were added to Example 16, melamine fibers were added to Example 17, and amorphous silica fibers were added to Example 18, according to the present invention.
  • Example 23 was prepared from FR rayon fibers and is denoted FR Rayon Base Fabric, while Examples 20-22 were variations of this base fabric: para-aramid fibers were added to Example 20, melamine fibers were added to Example 21, and amorphous silica fibers were added to Example 22.
  • Example 27 is a rayon/modacrylic base fabric, and Examples 24-26 were variations of this base fabric: melamine fibers were added to Example 24, para-aramid fibers were added to Example 25, and amorphous silica fibers were added to Example 26.
  • Example 31 is a lyocell/modacrylic base fabric, and Examples 28-30 were variations of this base fabric: para-aramid fibers were added to Example 28, melamine fibers were added to Example 29, and amorphous silica fibers were added to Example 30.
  • Example 34 is the Visil/modacrylic base fabric, and Examples 32, 33 and 35 were variations of this base fabric: para-aramid fibers were added to Example 32, amorphous silica fibers were added to Example 33; and melamine fibers were added to Example 35.
  • Example 38 is a Visil base fabric, while Examples 36-37 were variations of this base fabric: melamine fibers were added to Example 36, and amorphous silica fibers were added to Example 37.
  • Example 41 is a rayon base fabric, while Example 39 contains rayon and melamine, and Example 40 contains rayon and amorphous silica.
  • Example 45 is a lyocell base fabric, while Example 42 contains para aramid, Example 43 contains lyocell and melamine, and Example 44 contains lyocell and amorphous silica.
  • Examples 46-53 were prepared by using a needlepunch line including a 12 inch card, a crosslapper, and a 60.96 cm (24 inch) Dilo OD-1 needle loom.
  • Example No. 46 was the base blend 271.25 (g/m 2 ) comprising 40 % modacrylic and 60 % Visil) and in the Examples following, various materials or FR fibers were employed.
  • Example 47 comprised a blend of the base blend (79 %) and leno weave carpet backing, 71.20 (g/m 2 ) (21%).
  • Example 48 comprised a blend of the base blend (89 %) and Conwed scrim. 33.91 (g/m 2 ), (11 %).
  • Example 49 comprised a blend of the base blend (85 %) and Basofil (melamine) (15 %).
  • Example 50 comprised a blend of the base blend (85 %) and Conex (15 %).
  • Conex is a meta-aramid.
  • Example 51 comprised a blend of the base blend(85 %) and amorphous silica (15 %).
  • Example 62 comprised a blend of the base blend(85 %) and Kynol (phenol-formaldehyde novolac) (15 %).
  • Example 53 comprised a blend of amorphous silica (15 %), modacrylic fiber (40 %) and Visil fiber (45 %).
  • Example No. 53 represents a fabric.
  • a tuft button simulation was designed to expose the charred fabric to stresses that it might see in an actual mattress burn, and gives a pass/fail indication of fabric strength.
  • a small test rig was constructed out of wood. Components were assembled shown in the drawing figure to form tuft button test apparatus 10.
  • Mattress component including 10.16 cm (4 inch) foam 12, two 1 inch super-soft foams 14,16, barrier fabric 18, which was 152.57 (g/m 2 ), PET fiber fill 20, and a PET ticking fabric 22 were assembled as described below, and then burned under tension.
  • the components were assembled on top of upper plate 24.
  • the foam components 12, 14 and 16 were compressed and the barrier fabric 18, fiber fill 20, and ticking 22 were wrapped around all sides of upper plate 24.
  • Lower plate 26 was positioned to sandwich fabrics 18, 20, 22 between upper plate 24 and lower plate 26.
  • a tuft button simulatur 28 was welded threaded rod 30, and rod 30 was pushed through all of the mattress components, and through aligned holes 32, 34 in upper and lower plates 24, 26.
  • Wing nut 36 was fastened to rod 30 to apply tension to the assembly and draw tuft button simulator 28 down into the foam.
  • Ex No 48 used the 271.25 (g/m 2 ) fabric In a composite with a 71.20 (g/m 2 ) leno weave secondary carpet backing fabric. Likewise, it cracked within 20 seconds, and was withdrawn as a possible solution.
  • Ex No 48 used a polypropylene scrim, very light in wt 33.91 (g/m 2 ) that had a "leno-weave look" to it Though it was not a woven fabrics, the vertices of the "warp" and "fill” monofilaments were fused together. This sample also cracked well under 1 minute.
  • the remaining samples prepared were not composites, but needled blends of fibers performed on a pilot line card/crosslapper/needleloom assembly. These samples were also produced at lower weights to gain economic advantages.
  • the first fabric evaluated, Ex No.49, was a 203.43 (g/m 2 ) fabric consisting of 15% melamine, and 85% "base blend" of 60/40 Visil/modacrylic. This fabric cracked within 30 seconds and flamed out of control. It was eliminated as a candidate for this application.
  • a 203.43 (g/m 2 ) fabric consisting of 15% meta aramid; and 86% "base blend" of 60/40 Visil/modacrylic also cracked and burned out of control within 25 seconds.
  • a single layer nonwoven fabric useful in protecting items from fire and the related heat is disclosed and a process for protecting adjacent materials in an assembly using the fire and heat barrier fabric as well.
  • the nonwoven barrier is of at least 15.28 (g/m 2 ) of an amorphous silica fiber and at least 15.26 (g/m 2 ) of a binder fiber; the single layer nonwoven fabric having a basis weight of at least 101.72 (g/m 2 ).
  • the fiber blend by weight of the nonwoven fabric comprises 15 to 80 percent by weight amorphous silica fiber, 15 to 85 percent by weight binder fiber and may, but not necessarily, contain up to 70 percent by weight of complimentary fibers with a reduction of the other two fibers to total 100 percent by weight without falling below the minimum amounts.
  • the amorphous silica fiber is always present in the nonwoven fabric composition and comprises at least 15 percent by weight of the fiber blend, but no more than 80 percent. In one embodiment the amorphous silica fiber comprises between 35 and 50 percent by weight of the fiber blend. As the blend percentage by weight of the silica fiber is reduced, the effectiveness of the single layer nonwoven to shield open flames and heat diminishes. Although the individual amorphous silica fibers continue to resist burning and melting at levels lower than 15 percent by weight in the nonwoven, at least this level must be maintained to offer adequate structure and integrity within the nonwoven fabric construction during and after exposure to an open flame. At least 15 percent by weight of the amorphous fibers by weight are required in the nonwoven to maintain any acceptable level of char strength.
  • the blend percentage by weight of the amorphous silica is limited to no more than 80 percent by weight in the described nonwoven to preserve the functional characteristics required of a fire and heat barrier fabric.
  • the fiber-to-fiber cohesion of the amorphous silica is such that at least 20 percent by weight of more cohesive fibers are required for sufficient fiber web strength and fiber entanglement in the nonwoven. It is this entanglement combined with the thermal bond that makes this single layer nonwoven unique.
  • the combination of the mechanical and thermal bond results in a nonwoven construction, in at least one embodiment, capable of at least one of the following without limiting its ability to shield flames and heat, in another embodiment, capable of a majority of the following without limiting its ability to shield flames and heat and, in another embodiment, capable of all of the following without limiting its ability to shield flames and heat:
  • a binder fiber is always present in the nonwoven fabric composition and comprises at least 15 percent by weight of the fiber blend. In one embodiment, the amorphous silica fiber comprises between 50 and 65 percent by weight of the fiber blend.
  • the binder fiber is necessary for the required thermal bonding of the nonwoven barrier fabric, but a multi-component binder fiber may also serve both a mechanical and a thermal role in the nonwoven fabric construction. Mechanically, at least one fiber must offer sufficient fiber-to-fiber cohesion to maintain the integrity of the fiber web and sufficient structure after thermal bonding to maintain entanglement of the fibers among the amorphous silica fibers.
  • This cohesive fiber may be a component of the binder fiber (in the case of a multi-component binder fiber) that remains intact after thermal bonding, or it may be a fiber, or fibers, additive to the amorphous silica and binder fiber in the blend.
  • the binder fiber may be a single component, low melting point fiber that strictly acts as a binding agent for the thermal bond necessary in the nonwoven.
  • Exemplary single component fibers include low-melt polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low-density polyethylene, polylactic acid, polytrimethylene terepthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified.
  • sufficiently low is meant that such thermoplastic fibers will have the lowest melting point of all the component fibers present. Some polymers will inherently have the lowest melting point while others, such as the polyesters, may need to be modified with an appropriate additive to yield a lower melting point than inherently possessed by the unmodified polymer.
  • the single-component binder fiber comprises at least 15 percent by weight of the fiber blend in the nonwoven. Any instance where a single-component binder fiber is used requires the addition of at least 15 percent by weight of a higher cohesion fiber for mechanical fiber interlock after thermal bonding.
  • the single-component binder fiber must have a melting temperature no less than 107° C, but the melting temperature cannot exceed a value 10° C less than the lowest melting temperature of any other structural fiber in the fiber blend of the nonwoven.
  • the maximum melt temperature of the single-component binder fiber allows for the binder fiber to melt and flow, forming a binding matrix along and between structural fibers as these fibers are left intact at a temperature lower than their melting point.
  • the minimum temperature varies by end-use application of the nonwoven fire/heat barrier and is based on a temperature higher than the maximum temperature exposure of the nonwoven barrier in subsequent assembly processes and day-to-day operational use and environs.
  • the melt temperature of the single-component binder fiber is minimized within the range to reduce the energy and time required to thermally bond the nonwoven barrier fabric.
  • Diameter of the single-component binder fiber ranges from 20 microns to 60 microns and in one embodiment, it is 31 microns. Length of the single-component fiber ranges from 50 millimeters to 125 millimeters and in one embodiment, it is 75 millimeters, for needlepunch applications.
  • the single-component binder fiber should not act as a contributory fuel source for an open flame.
  • the binder fiber may be a multiple component, low melting point fiber that acts strictly as a binding agent for the thermal bond necessary in the nonwoven.
  • exemplary multiple component fibers include those fibers of co-extruded polymers in combinations containing at least two of the following polymers: polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low-density polyethylene, polylactic acid, polytrimethylene terpthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified.
  • the term "sufficiently low” has the same meaning as set forth above for the single-component fibers. Similar to the single-component fibers, the multi-component fibers provide two polymers that melt to provide thermal bonding.
  • This multi-component thermal binding fiber comprises at least 15 percent by weight of the fiber blend in the nonwoven. Any case where a multi-component binder fiber acts only as a thermal binding agent, its use requires the addition of at least 15 percent by weight of a higher cohesion fiber, but no more than 70 percent by weight, for mechanical fiber interlock after thermal bonding.
  • This multi-component thermal binding fiber must have a melting temperature no less than 107° C, but the melting temperature cannot exceed a value 10° C less than the lowest melting temperature of any other structural fiber in the fiber blend of the nonwoven.
  • the maximum melt temperature of the multi-component thermal binding fiber allows for the binder fiber to melt and flow, forming a binding matrix along and between structural fibers as these fibers are left intact at a temperature lower than their melting point.
  • the minimum temperature varies by end-use application of the nonwoven fire/heat barrier and is based on a temperature higher than the maximum temperature exposure of the nonwoven barrier in subsequent assembly processes and day-to-day operational use and environs.
  • the melt temperature of the multi-component binding fiber is minimized within the range to reduce the energy and time required to thermally bond the nonwoven barrier fabric.
  • Diameter of the multi-component binder fiber ranges from 20 microns to 60 microns and in one embodiment, it is 31 microns.
  • Length of the single-component fiber ranges from 50 millimeters to 125 millimeters and in one embodiment, it is 75 millimeters, for needlepunch applications.
  • the multi-component binder fiber should not act as a contributory fuel source for an open flame.
  • the binder fiber may be a multiple component, multi-binding (both mechanical and thermal binding functions) low melting point fiber that acts as a binding agent for the thermal bond necessary in the nonwoven and as a mechanical actor that has fiber-to-fiber cohesion sufficient to maintain entanglement of the nonwoven fiber matrix.
  • Exemplary multiple component, multi-binding component fibers include those fibers of co-extruded polymers in combinations containing at least two of the following polymers: polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low-density polyethylene, polylactic acid, polytrimethylene terpthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified.
  • the term "sufficiently low” has the same meaning as set forth above for the single-component fibers.
  • the multi-component, multi-binding fibers provide a polymer that melts to provide thermal bonding; however, the second polymer does not melt and provides the mechanical function for fiber entanglement. This latter difference is a distinction between the multi-component fibers and the multi-component multi-binding fibers.
  • the multi-component multi-binding fibers must contain at least one component comprised of a lower-melt binding agent and a higher melt point component that remains intact after exposure to heat in the thermal bonding stage. This latter difference is a distinction between the multi-component fibers and the multi-component, multi-binding fibers.
  • the multi-component multi-binding fiber comprises at least 15 percent by weight of the fiber blend in the nonwoven. Any case where a multi-component multi-binding fiber is used does not necessarily require the addition of another higher cohesion fiber for mechanical fiber interlock after thermal bonding provided all described criteria are met.
  • Diameter of the multi-component multi-binding fiber ranges from 20 microns to 60 microns and in one embodiment, it is 31 microns.
  • Length of the single-component fiber ranges from 50 millimeters to 125 millimeters and in one embodiment, it is 75 millimeters, for needlepunch applications.
  • the multi-component multi-binding fiber should not act as a contributory fuel source for an open flame and may, in fact, be flame resistant.
  • the multi-component, multi-binding fibers may be any of several different fiber configurations (e.g. concentric sheath/core, eccentric sheath/core, side-by-side or bilateral, pie wedge, hollow pie wedge, islands-in-the-sea or matrix, and the like.), but it must retain core fibers of near original length after thermal bonding. These remaining core fibers must have strength sufficient to maintain mechanical entanglement under stress and must not act as a contributory fuel source to an open flame.
  • a minimum of 10 percent, but no more than 90 percent, by weight of the individual fiber acts as the thermal binding agent and must have a melting temperature no less than 107° C, but no more than 150° C. In another embodiment the melting temperature is 110° C.
  • the previously described core fiber comprises a minimum of 10 percent, but no more than 90 percent, by weight of the individual fiber and must have a melting temperature no less than 115° C.
  • a useful binder fiber is a core/sheath bi-component configuration comprised of a polyethylene terephthalate (PET) core and a lower melt temperature PET sheath wherein the sheath is 60 percent by weight of the individual fiber and the core is the remaining 40 percent.
  • the sheath acts as the thermal binding agent forming the outer surface of the binder fiber and has a melting temperature of 110° C and the core has a melting temperature of 130° C.
  • PET polyethylene terephthalate
  • core has a melting temperature of 110° C
  • the core has a melting temperature of 130° C.
  • core/sheath bi-component binder fiber comprises between 50 and 65 percent by weight of the fiber blend in the nonwoven barrier.
  • multi-component multi-binding fibers that may also be employed include those fibers of co-extruded polymers in combinations containing at least two of the following polymers: polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low-density polyethylene, polylactic acid, polytrimethylene terepthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified, or any natural cellulosic fibers (cotton, flax, ramie, jute, kenaf, hemp, and the like) or protein fibers (wool, cashmere, camel hair, mohair, other animal hair, silk, and the like) coated or joined together with any of the aforementioned thermoplastic polymers.
  • the term "sufficiently low” has the same meaning as set forth above for the single-component fibers
  • the binding agent may be any synthetic fiber with a melting temperature within the aforementioned range that does act as a contributory fuel source for an open flame.
  • the remaining core portion may be any synthetic or natural fiber with a melting temperature no less than 115° C, does not act as a contributory fuel source for an open flame, and has fiber-to-fiber cohesion sufficient to maintain fiber web integrity and hold entanglement among fibers after needling.
  • a fiber must have a minimum Limiting Oxygen Index (LOI) of at least 21 to be considered a non-contributory fuel source.
  • LOI Limiting Oxygen Index
  • LOI is a relative measure of flammability that is determined by igniting a sample in an oxygen/nitrogen atmosphere and then adjusting the oxygen content to the minimum amount required to sustain steady burning. The higher the value, the less flammable a material is considered.
  • LOI limiting oxygen index
  • COI critical oxygen index
  • OI oxygen index
  • LOI O 2 conc O 2 conc + N 2
  • [O 2 (conc)] and [N 2 ] are the minimum oxygen concentration in the inflow gases required to pass the "minimum burning length"' criterion and the nitrogen concentration in the inflow gases respectively. If the inflow gases are maintained at constant pressure then the denominator of the equation is constant since any reduction in the partial pressure (concentration) of oxygen is balanced by a corresponding increase in the partial pressure (concentration) of nitrogen. Limiting oxygen index is more commonly reported as a percentage rather than fraction.
  • binder fibers commercially available include the following specialty single polymer fibers, all of which are available from Fiber Innovations Technology (FIT) of Johnson City, Tennessee, the product code of each being provided in parentheses: PETG binder fiber (undrawn) (T-135), PETG binder fiber (drawn) (T-137), PCT (T-180), FR (flame resistant) PET (T-190) and FR PET for yarn spinning (T-191).
  • FIT Fiber Innovations Technology
  • binder fibers include the following concentric sheath/core bi-component fibers, also available from FIT and having the product code set forth in parentheses: 110°C "melt" CoPET/PET (T-201), 185°C melt CoPET/PET (T-202), Dawn Grey version of T-201 (T-203), Black version of T-202 (T-204), 130°C melt CoPET/PET (T-207), 150°C melt high crystallinity CoPET/PET (T-215), Black version of T-215 (T-225), PCT/PP (T-230), PCT/PET (T-231), PETG/PET (T-235), 185°C, high Tg coPET/PET (T-236), HDPE/PET (T-250), HDPE/PP (FDA food contact) (T-251), LLDPE/PET (T-252), PP/PET (T-260), Nylon 6/ nylon 6,6 (T-270), and Black version of T
  • polyester binder fibers may be used in some instances.
  • polyester binder fibers include those available from Wellman, Inc. of Fort Mill, South Carolina, under various type names such as 209, H1305, H1295, H1432, M1440, M1429, M1427, M1425, M1428, and M1431.
  • the nonwoven fabric composition may comprise up to 70 percent by weight of other fibers, i.e. , complimentary fibers, considered to be a non-contributory fuel source.
  • a thermal-only binder fiber such as a single component binder fiber containing a low melt polymer, requires the addition of at least 15 percent by weight of a higher cohesion fiber to provide mechanical fiber interlock after thermal bonding.
  • One embodiment comprises between 35 and 50 percent by weight of the amorphous silica, between 50 and 65 percent by weight of the binder fiber, wherein the binder fibers is of a core/sheath bi-component configuration comprised of a polyethylene terephthalate (PET) core and a lower melt temperature PET sheath, and between 5 and 10 percent by weight of a complimentary fiber such as a solution dyed (pigmented) PET fiber for color in the single layer nonwoven fire and heat barrier fabric.
  • PET polyethylene terephthalate
  • a complimentary fiber such as a solution dyed (pigmented) PET fiber for color in the single layer nonwoven fire and heat barrier fabric.
  • any such fibers employed will have limited application in the production of flame resistant fabrics or fabrics resistant to fire and heat.
  • the method of producing the single layer nonwoven fabric through slight mechanical entanglement of a web of the fibers and further thermal bonding to reduce physical property directional bias, maintain fuller length of individual fibers, encapsulate and contain individual fibers, and to reduce density per area of the nonwoven fabric without significantly diminishing the integrity of the fabric is also disclosed.
  • the nonwoven fabric may be constructed as follows.
  • the various combinations of fibers that can be employed may be weighed and dry or wet formed into a fiber web.
  • the web may be formed by any of several different methods:
  • a useful method of web formation is the dry-laid carded process.
  • the useful fabric formation is mechanical fiber entanglement by needlepunching the web and then thermal bonding through the application of heat above the melting temperature of the binder, but below the melting temperature of the structural fibers that mechanically bind the fabric through entanglement.
  • one embodiment is a nonwoven fabric with mechanically entangled fibers that are then heat bonded
  • woven fabrics it is possible to employ amorphous silica fibers in the machine direction or the cross machine direction, alternating with one or more of the FR or the binder fibers.
  • the fibers can be alternated in the machine direction and woven with either an amorphous or an FR or a binder fiber in the cross machine direction.
  • As a percentage can comprise the compositions stated above for the blend of amorphous silica and FR fibers as well as amorphous silica and binder fibers.
  • the particular weave construction for open weave fabrics and all ranges of end counts in both the machine and cross machine directions are included.
  • the blend in the woven is also possible through woven construction of yarns of different fiber types:
  • a fabric useful in protecting items, or products, such as mattresses, from fire and the related heat; a process for producing the fabric; and a process for protecting materials in a product by using the fire and heat barrier fabric are described.
  • One such process for protecting materials in a product using the fire and heat barrier is by ultrasonically bonding or ultrasonically welding the barrier fabric directly to at least one component that is also present in the product.
  • Such a component comprises a material that is susceptible to damage due to fire and heat, occasioned by exposure to open flames and therefore, requires barrier protection.
  • Ultrasonic bonding is well known in the art, but the ability directly incorporate a fire and heat barrier into a sub-assembly is novel. Ultrasonic bonding uses ultrasonic energy to join layers of thermoplastic materials. High speed ultrasonic vibrations result in welds between thermoplastics fusing the materials together. This fusing, or welding, requires similar thermoplastic materials to form the bond.
  • the quilted assembly forms a surface that is both soft and visually appealing due to the lofty quilted pattern.
  • the high-loft fiber batt is conventionally PET, and because both the outer ticking layer and the inner structural layer are available in PET or a majority-blend PET, these and similar assemblies, or products, e.g., furnishings, transportation seats and surfaces, bed clothing and the like, are sometimes quilted by ultrasonic bonding means, rather than by the traditional needle-and-thread sew quilting.
  • Using ultrasonic bonding for the production of quilted assemblies typically has advantages over the sewing method because of the higher throughput speeds possible, fewer raw materials (no thread) required, less mechanical wear (no needle breaks; fewer moving parts), and is capable of forming a bond between the layers comparable, or better, than the sewn seams of traditional quilting.
  • blends and resultant fabrics are such that they allow for the ultrasonically bonded quilting of an assembly containing a flame and thermal barrier.
  • those blends comprising at least 40 percent by weight PET, or other suitable thermoplastic, are suitable for ultrasonic bonding to other materials containing a minimum of 40 percent of the same or similar thermoplastic.
  • One embodiment is for the flame and thermal barrier fabric to comprise a minimum of 50 percent PET by weight, and the other layers of the assembly contain at least 50 percent by weight of PET or similar thermoplastic.
  • Assemblies for mattress construction may be produced in any number of configurations (no inner layer is necessary) such as the following:
  • border fabric Another product used in mattress construction, is the border fabric, or side fabric material.
  • satisfactory border assemblies for mattresses and/or box springs may be produced in any of the above configurations using full width roll-good materials up to approximately 120-inches in width (theoretically the width is unlimited because the ultrasonic horns and anvils may be arranged in a modular format, but practically, the width is limited to currently available widths of roll-good ticking and high-loft batt as well as currently available supporting equipment).
  • the body quilt pattern is ultrasonically bonded using a series of wide horns applied across the width of a patterned cylinder anvil.
  • the typical width of a border assembly ranges from 22.86cm (9 inches) to 35.56cm (14 inches) (or more).
  • These individual widths may be ultrasonically slit and the edges ultrasonically sealed with a stitch pattern (or other pattern) using an in-line or off-line series of horns and slitter/sealing anvils.
  • Fabrics are particularly useful for mattress borders because the need for comfort is not present, as it is in the tops and bottoms of mattresses, the panels, which will incorporate batting to give the panel softness and loft. Accordingly, in the borders, the FR fabric is readily assembled to the ticking, as by ultrasonic welding, to form that product, which can be thought of a sub-assembly of the complete product, the mattress.
  • An example process setup for ultrasonic sealing would employ 1.1kW power supplies to 22.86 cm (9-inch) horns in series across the width of a cylinder anvil patterned to the quilting design desired in the body of the assembly. After the layers are fed from and unwound into this portion of the process, additional layers may be introduced if desired before flowing through a series of one inch diameter horns spaced at the desired widths of the border assemblies to be simultaneously slit and sealed (if desired) using a 1.1kW power supply to each horn. Process variables such as pressure, speed, amplitude, power boosters and loadings differ based on the types of materials used and the mass.
  • testing of the protected item is often times specific to the end-use application of the protected item and the test includes that item as a whole rather than testing of the individual components that make up that item.
  • Testing of the fabric as a component to predict or correlate results in the finished item usually differs between manufacturers of the item. Preliminary testing was conducted with a variety of barrier fabrics comprising a range of amorphous silica to binder fiber ratios.
  • a 40 percent amorphous silica content was a useful amount, as it balanced costs against needed barrier protection. Nonetheless, greater or lesser amounts of amorphous silica may well have use in other environments (products) where barrier property requirements may differ as will permissible costs to product the fabric. Such other uses are discussed hereinbelow.
  • test For development of the fire and thermal barrier fabrics for use in the mattress industry, a proprietary test at an independent test lab was employed to establish a performance baseline and track progress versus that baseline. Although the specifics of the test are held confidential by the independent lab, it can be revealed that the test is based on an open flame in contact with the face of the fabric for a set period of time. After the open flame is removed, the fabric is allowed to continue to burn until it fully extinguishes itself. The maximum temperature is measured on the side opposite the flame over the length of the test. The mass of the sample is measured before and after exposure to the flame to calculate mass loss.
  • the strength of the fabric at the point of exposure may be tested to determine retained strength or char strength (depending on the application, this could be tensile, puncture, inspection for cracking or other). Test results are reported in Table 10 that follows: TABLE 10 OPEN FLAME TESTING OF FR FABRICS Example No.
  • Example 73 showed both a greater maximum temperature and mass loss, which was due to the presence of the 8 percent PP fiber, a complimentary fiber which may be a fuel source, i.e., not a "non-contributory” fuel source, added to provide a colored, or pigmented, fabric.
  • amorphous silica fibers is highly effective in providing FR blends and fabrics.
  • Amorphous silica fibers with at least one other flame resistant fiber, or a binder fiber can be combined.
  • the fiber blends of the present invention can be utilized to manufacture flame resistant fabrics for a variety of purposes including, but not limited to barrier fabrics for upholstery, bedding and bed clothing applications. Moreover, the fabrics are not limited to non-woven types.

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DK1861524T3 (da) 2012-05-29
BRPI0516642B1 (pt) 2016-08-30
EP1861524A4 (en) 2010-05-19
CA2589863C (en) 2014-08-19
KR101341293B1 (ko) 2013-12-12
AU2005338024A1 (en) 2007-06-21
AU2005338024B2 (en) 2011-07-21
KR20070100262A (ko) 2007-10-10
CA2589863A1 (en) 2007-05-31
IL183618A (en) 2014-01-30
ES2385391T3 (es) 2012-07-24
ATE552368T1 (de) 2012-04-15
JP5312794B2 (ja) 2013-10-09
WO2007061423A3 (en) 2007-12-06
BRPI0516642A (pt) 2008-09-16
JP2008522056A (ja) 2008-06-26
IL183618A0 (en) 2009-02-11
EP1861524A2 (en) 2007-12-05
AU2005338024A8 (en) 2008-12-18

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