EP3052689A1 - Fire resistant panel and methods of fire blocking an article - Google Patents

Fire resistant panel and methods of fire blocking an article

Info

Publication number
EP3052689A1
EP3052689A1 EP14780966.9A EP14780966A EP3052689A1 EP 3052689 A1 EP3052689 A1 EP 3052689A1 EP 14780966 A EP14780966 A EP 14780966A EP 3052689 A1 EP3052689 A1 EP 3052689A1
Authority
EP
European Patent Office
Prior art keywords
fibers
flame retardant
vertically oriented
fire
substantially vertically
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Withdrawn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
EP14780966.9A
Other languages
German (de)
English (en)
French (fr)
Inventor
Michael S. Defranks
Sheri L. Mcguire
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.)
Dreamwell Ltd
Original Assignee
Dreamwell Ltd
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 Dreamwell Ltd filed Critical Dreamwell Ltd
Publication of EP3052689A1 publication Critical patent/EP3052689A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • 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
    • D04H1/02—Cotton wool; Wadding
    • 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
    • D04H1/4258—Regenerated 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • 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
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B11/00—Machines for sewing quilts or mattresses
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24669—Aligned or parallel nonplanarities
    • Y10T428/24686—Pleats or otherwise parallel adjacent folds

Definitions

  • the present disclosure generally relates to fire resistant panels including fire retardant treated fibers, and more particularly, to fire resistant panels including vertically oriented fire retardant treated fibers. Also disclosed are methods of fire blocking an article fire resistant panel.
  • the binder is a bi-component material having a core with a higher melting point than a surround encapsulating the core such that during thermal processing the surround is heated to a temperature greater than melting point of the surround but less than the melting point of the core to effect softening and/or melting of the surround, which functions to bind the fibers.
  • Prior art Figure 1 provides a cross sectional view depicting a non- woven batting 10 including horizontally oriented fibers webs 12.
  • Other commercially available fire resistant batting manufacturers employ the use of needles that penetrate the horizontally oriented fiber layered web through the web layers to effect fiber entanglement as a means to mechanically hold the web together.
  • the resulting cross sectional structure can generally be defined as primarily composed of horizontally oriented fiber webs. Regardless of the method of manufacturer, typically, the fire resistant battings are of a relatively low loft and also of low resilience following compression such as may occur during use.
  • a fire resistant batting material comprises a layer having a top surface and a bottom surface, the layer comprising a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface; and a binder material.
  • a method of fire blocking an article comprises combining a layer of a fabric ticking or upholstery, a layer of batting material, and an optional stitch backing layer, wherein the layer of batting material comprises a top surface, a bottom surface, a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface and a binder material; sewing the layers together to form a composite; and incorporating the composite into the article.
  • Prior Art Figure 1 illustrates a cross-sectional view of a non-woven batting material with carded and horizontally cross lapped fibers.
  • Figure 2A illustrates a cross-sectional view of a non- woven batting material with vertically oriented flame retardant treated pleated fibers in accordance with the disclosure.
  • Figure 2B illustrates an enlarged cross-sectional view of the non-woven batting material with vertically oriented flame retardant treated fibers of Figure 2Ain accordance with the disclosure.
  • Figure 3 illustrates a cross-sectional view of a non-woven batting material with vertically oriented flame retardant treated fibers in accordance with the disclosure.
  • Figure 4A-D depicts cross sectional images depicting moisture absorption profile for different fibers.
  • Figure 5 graphically illustrates moisture absorption as a function of time for fire retardant treated fibers and untreated fibers.
  • the flame resistant panels for use in cushioning articles.
  • the flame resistant panels can be employed in mattresses as a batting material, wherein the fibers are substantially vertically oriented and at least a portion are flame retardant treated fibers.
  • treated it is meant that a fire retardant is applied to the fiber, wherein the fibers by themselves may have varying degrees of flame retardancy depending on the composition.
  • Applicants have discovered that orienting the fire retardant treated fibers in a substantially vertical direction increases resiliency and the product's ability to recover due primarily to the change in fiber orientation from horizontal to vertical. The increase in resiliency has been found to translate into higher levels of comfort and product durability.
  • the mattress 100 includes a central core layer 102 between pleated middle upholstery layers 104 (also referred to herein as a fiber batting material), and a quilt layer 106 provided on the outer face of the pleated middle upholstery layers 104.
  • the quilt layer 106 can extend around the sides of the mattress, where it is shown partially cut away to reveal layers behind quilt layer 106.
  • Other layers such as an insulator layer or the like (not shown) may also be included as may be desired for different applications.
  • FIG. 2B illustrates an enlarged view of the mattress 100 corresponding with the circle indicated in Figure 2A.
  • the core layer 102 may comprise one or more foam layers, a coil spring layer, and combinations thereof.
  • the quilt layer 106 is a composite layer of the mattress and can be made of foam or a cross-laid non-woven web of fibers stitched to the underside of a protective fabric cover, e.g., ticking layer, which provides a soft surface texture to the mattress.
  • a protective fabric cover e.g., ticking layer
  • the pleated middle upholstery layers 104 comprise a pleated (vertically lapped) web of cross-laid fibers.
  • the pleats are formed from a cross-laid non-woven web of fibers as will be described in greater detail below
  • the non-woven fiber batting material for the middle upholstery layer 104' can include a plurality of individual flame retardant treated fibers 102 substantially oriented in a vertical direction, i.e., generally transverse (y-direction) to a horizontal plane (x-direction) of the batting material.
  • non- woven as used herein in connection with fabrics, fibrous compositions, textiles, materials, products and similar items means a structure that is produced by attaching, bonding and/or interlocking two or more of the same or different components, such as filaments, microfibers, fibers, fibrous compositions, threads or yarns, together, generally by loosely bonding them together, and using one or more of a variety of techniques that generally does not involve weaving or interlacing, but employs mechanical, chemical, thermal and/or solvent means, for example, using known needle punching, melt-blowing, spun bonding, wet-forming and various bonded carded web processes.
  • Non-woven materials may be manufactured using fusing or chemical bonding techniques (with the use of binding agents, such as PVA or polyester) or similar techniques, which are known by those of skill in the art. This term generally does not include fabrics, textiles, fibrous compositions or materials that are woven, knitted, tufted, or those made using wool or other felting processes.
  • the upholstery layer i.e., batting material, including the flame retardant treated fiber in the substantially vertically oriented orientation of the present disclosure is also cost effective, soft, yet durable and suitable for various cushioning articles including, but not limited to a mattress component, mattress covers, comforters, bedspreads, quilts, coverlets, duvets, pillows, pillow covers, cushions, in addition to other home uses, protective apparel applications, and industrial end-use applications.
  • the fibers employed in the vertically oriented flame retardant treated fiber batting material are not intended to be limited so long as a fire retardant can be applied and retained in an amount effective to provide the panel with a fire resistance that meets or exceeds 16 C.F.R. Part 1633.
  • the fibers can be natural fibers and/or synthetic fibers. The use of natural fibers in bedding components is desirable due to the softness and durability associated with these fibers as well as the absorption properties of most natural cellulosic fibers.
  • Suitable fibers include, without limitation, polyester, polyolefins such as a polypropylene and polyethylene, cellulosic fibers, cotton, rayon, wool, silk, acetate, nylon, lyocell, flax, ramie, jute, angora, kenaf, and the like, and mixtures thereof.
  • the fibers may have varying diameter and denier, be hollow or solid, or may be crimped. Blending different types of fibers may further contribute to resiliency of the batting material. The amounts will vary generally depending on the fiber composition, and flame retardant employed.
  • the flame retardant treated fiber is lyocell, which is a regenerated cellulose fiber made from dissolving pulp (bleached wood pulp) and is commercially available as fibers under the brand name Tencel from Lenzing AG.
  • lyocell is a regenerated cellulose fiber made from dissolving pulp (bleached wood pulp) and is commercially available as fibers under the brand name Tencel from Lenzing AG.
  • the US Federal Trade commission defines lyocell as "a cellulose fiber that is obtained by an organic solvent spinning process” and classifies the lyocell fiber as a sub-category of rayon.
  • Some main characteristics of lyocell fibers are that they are soft, absorbent, very strong when wet or dry, and resistant to wrinkles; all of which are generally desirable for a batting material.
  • the moisture absorption properties provide improved moisture wicking, which is highly desirable for mattress applications.
  • Figures 4A-4D depict cross sections of various cellulosic fibers after immersion in dyed water, wherein lighter regions indicate minimal moisture absorption and darker regions indicate maximum moisture absorption.
  • the various cellulosic fibers included cotton, a rayon commercially available under the trademark VISCOSE from the Lenzing Group, a modified rayon commercially available under the trademark MODAL from the Lenzing Group; and lyocell commercially available under the trademark TENCEL from the Lenzing Group. As shown, lyocell exhibited the greatest and most uniform moisture absorption as evidenced by the uniform dark color throughout the cross section.
  • Man-made fibers can be produced to any desired cut length, which is generally deteimined by the equipment and product performance.
  • the fibers to be fire retardant treated generally have a length of 0.25 to 4 inches; in other examples, a length of 0.5 to 3 inches, and in still other examples, a length of 1.5 to 3 inches.
  • the cut lengths for carding are generally between
  • the fiber length can generally vary from 0.5 to 1.
  • the non- woven fiber batting material when vertically oriented can also have a total thickness or loft of 0.5 inches (1.25 centimeters) or greater. While there is no real limitation on how thick the batting can be, for many typical applications, the thickness of the high loft batting need not be higher than 3 inches (7.6 cm), and for many mattress applications less than 2 inches (5 cm) is useful.
  • the batting material can also generally have a basis weight of about 5 to 18 ounces per square yard (169 to 610 grams per square meter) and are preferably 8 to 11 ounces per square yard (271 to 373 grams per square meter). The total density of the batting material is generally aligned with the basis weights described above.
  • Denser battings generally do not have the resiliency desired for use as cushioning in mattresses and other articles. As for battings that are less dense, the batting materials are oftentimes bulky to handle during fabrication and are generally compressed into the preferred density range when incorporated into a quilted composite. Thinner and denser battings also do not provide the desired softness, aesthetics, and may lack durability in application and with FR protection.
  • the fire retardant treated fibers may be chemically, thermally or mechanically bonded to improve structural integrity.
  • Chemical binders can generally be applied to the flame retardant treated fibers by impregnating, coating and/or spraying.
  • Exemplary chemical binders include, without limitation, acrylate polymers, styrene-butadiene copolymers, and vinyl acetate polymers.
  • Thermally bonded fibers generally include the addition of low melting polymeric materials, e.g., low molecular weight polyester fibers, to the flame retardant treated fibers, wherein further processing to form the web results in melting and/or partial melting of the low molecular weight binder so as to form bonds under controlled heating between the fibers of the batting material.
  • a web of fibers including the flame retardant treated fibers can be processed to increase fiber entanglement.
  • mechanical bonding There are generally two types of mechanical bonding: needle punching and hydro -entanglement. Needle punching can be used on most fiber types and generally includes the use of specially designed needles that are pushed and pulled through the web to entangle the fibers. Webs of different characteristics can be needled together to produce a gradation of properties difficult to achieve by other means.
  • Hydro- entanglement employs water jets to effect entanglement.
  • the flame resistant panels made using treated fire retardant fibers are comprised of a blend in an amount that meets and/or exceeds the flammability standards set forth in 16 CFR 1633.
  • Flame resistance generally depends on the fiber composition, flame retardant chemical that is applied, and the flame retardant loadings. In most embodiments, at least 50% of the fibers are fire retardant treated fibers. In other embodiments, at least 60% of the fibers are fire retardant treated fibers; and in still other embodiments, at least 80% of the fibers are fire retardant treated fibers.
  • the remaining fibers in the panel composition can comprise untreated fibers, binder fibers, and the like.
  • multiple layers of vertically oriented fibers are stackedly arranged to provide a desired thickness for the batting material application.
  • the stacked layers may be subjected to chemical, thermal and/or mechanical bonding to provide the desired amount of structural integrity between layers.
  • a binder such as a low molecular weight polyester and/or adhesive may be used intermediate the layers to provide structural integrity or the stacked arrangement may be needle punched to effect fiber entanglement.
  • an ammonium polyphosphate fire retardant treated lyocell fiber batting material at a density of 0.8 ounces per square foot also met and/or exceeded the product safety standard codified in 16 C.F.R Part 1633 required, which represents a significant and unexpected result compared to prior art batting materials.
  • the prior art batting materials generally needed 80% fire retardant treated fibers at a density of 1 ounce per square foot to meet this codified standard whereas the data provided in Table 2 below indicates that only 70% of substantially vertically oriented fire retardant fibers at density of 0.8 ounce per square foot was needed to meet the product safety standard.
  • At least a portion of the fibers are treated with flame retardant chemistry, which may be provided as a durable or a non-durable finish.
  • Durable flame retardant finishes are not removed by exposure to water or handling.
  • Exemplar ⁇ ? fire retardatits include, without limitation, chlorinated flame retardant compounds, such as chlorinated hydrocarbons, chlorinated phosphate esters, chlorinated polyphosphates, chlorinated organic phosphonates, chloroalkyl phosphates, polychlorinated biphenyls, polychlorinated dibenzo-p-dioxins and dibenzofurans are molecules containing a high concentration of chlorine that generally act chemically in the gas phase.
  • chlorinated compounds include: (a) chlorinated paraffins; (b) chlorinated alkyl phosphates; and (c) chlorinated cyclo aliphatic compounds.
  • chlorinated compounds include dodecachlorodimethanodibe- nzocyclooctane, tris(2-chloroethyl)phosphate, tris(2-chloro-l-methylethyl)phosphate, tris(2- chloro- 1 -(chloromethyl)ethyl)p-hosphate(TDPP), tris(chloropropyl)phosphate, tris (dichloropropyl)phosphat-e, tris(2-chloroethyl)phosphite, ammonium chloride, chlorendic acid, chlorendic anhydride, tris(dichlorobropropyl)phosphite,
  • Brominated fire retardant compounds such as brominated organic compounds and brominated hydrocarbons, exhibit fire retardant efficiency in many materials.
  • the three main families of brominated fire retardants include: (a) aliphatic brominated compounds; (b) aromatic brominated compounds; and (c) brominated epoxy fire retardants.
  • Aliphatic brominated compounds include, for example, trisbromoneopentylphosphate, trisbromoneopentyl alcohol, dibromoneopentyl glycol, hexabromocyclohexane, hexabromocyclododecane, tetrabromo cyclopentane, hexabromo cyclohexane, hexabromo cyclooctane, hexabromo cyclodecane and hexabromo cyclododecane.
  • Aromatic brominated compounds include, for example, hexabromo benzene, decabromobiphenyl, octabromodiphenyl oxide, hexabromobenzene, tris (tribromophenyl)triazine, tetrabromobisphenolA bis (2,3 dibromo propyl ether), dibromoneopentyl glycol, poly(pentabromobenzyl acrylate), pentabromodiphenyl ether, octabromodiphenyl oxide, octabromodiphenyl ether, decabromodiphenyl, decabromodiphenyl ethane, decabromodiphenyl oxide, decabromodiphenyl ether, tetrabromobisphenol A and brominated trimethylphenyl indan.
  • Brominated epoxy fire retardants include brominated epoxy oligomers and polymers.
  • brominated fire retardant compounds include brominated diphenyl ethers, polybrominated diphenyl ethers, dimethyl-3 -(hydro xymethy-lamino)-3-oxopropyl phosphonate, pentabromo toluene, tetrabromo chlorotoluene, pentabromo phenol, tribromo aniline, dibromobenzoic acid, pentabromotoluene, decabromodiphenyl oxide, tribromophenol, hexabromocyclododecane, brominated phosphorous, ammonium bromide, decabromobiphenyl oxide, pentabromobiphenyl oxide, decabromobiphenyl ether, 2,3-dibromopropanol, octabromobiphenyl ether, octabromodiphenyl oxide, tetrabromobiphenyl ether, hexabro
  • Phosphorous-based fire retardants are compounds that include phosphorous, such as halogenated phosphates (chlorinated phosphates, brominated phosphates and the like), non-halo genated phosphates, triphenyl phosphates, phosphate esters, polyols, phosphonium derivatives, phosphonates, phosphoric acid esters and phosphate esters, which are the largest class of phosphorous flame retardant compounds.
  • Phosphorous-based fire retardants are usually composed of a phosphate core to which is bonded alkyl (generally straight chain) or aryl (aromatic ring) groups. Halogenated phosphate compounds are often introduced to decrease total halogen concentration.
  • Non-halo genated phosphate compounds include, for example, red phosphorous, inorganic phosphates, insoluble ammonium phosphate, ammonium polyphosphate, ammonium urea polyphosphate, ammonium orthophosphate, ammonium carbonate phosphate, ammonium urea phosphate, diammonium phosphate, ammonium melamine phosphate, diethylenediamine polyphosphate, dicyandiamide polyphosphate, polyphosphate, urea phosphate, melamine pyrophosphate, melamine orthophosphate, melamine salt of boron-polyphosphate, melamine salt of dimethyl methyl phosphonate, melamine salt of dimethyl hydrogen phosphite, ammonium salt of boronpolyphosphate, urea salt of dimethyl methyl phosphonate, organophosphates, phosphonates and phosphine oxide.
  • Phosphate esters include, for example, trialkyl derivatives, such as triethyl phosphate and trioctyl phosphate, triaryl derivatives, such as triphenyl phosphate, and aryl-alkyl derivatives, such as 2-ethylhexyl-diphenyl phosphate.
  • phosphorous-based fire retardants include methylamine boron-phosphate, cyanuramide phosphate, cresyl diphenyl phosphate, tris(l-chloro-2-propyl) phosphate, tris(2-chloroethyl)phosphate, tris(2,3-dibromopropyl)phosphate, triphenyl phosphate, magnesium phosphate, tricresyl phosphate, hexachlorocyclopentadiene, isopropyl triphenyl phosphate, tricresol phosphate, ethanolamine dimethyl phosphate, cyclic phosphonate ester, monoammonium phosphate and diammonium phosphate, which permit a char formation as a result of esterification of hydroxyl groups with the phosphoric acid, trialkyl phosphates and phosphonates, such as triethyl phosphate and dimethyl, aryl phosphates, such as triary
  • Metal hydroxide fire retardants include inorganic hydroxides, such as aluminum hydroxide, magnesium hydroxide, aluminum trihydroxide (ATH) and hydro xycarbonate.
  • Melamine-based fire retardants are a family of non-halogenated flame retardants that include three chemical groups: (a) melamine(2,4,6-triamino-l,3,5 triazine); (b) melamine derivatives (including salts with organic or inorganic acids, such as boric acid, cyanuric acid, phosphoric acid or pyro/poly-phosphoric acid); and (c) melamine homologues.
  • Melamine derivatives include, for example, melamine cyanurate (a salt of melamine and cyanuric acid)), melamine-mono-phosphate (a salt of melamine and phosphoric acid), melamine pyrophosphate and melamine polyphosphate.
  • Melamine homologues include melam (1 ,3,5-triazin-2,4,6-tri-amine-n-(4,6-diamino-l ,3,5-triazine-2-yl), melem (2,5,8-triamino 1,3,4,6, 7,9, 9b-heptaazaphenalene) and melon (poly[8-amino-l,3,4,6,7,9,9b- heptaazaphenalene-2,5-diyl).
  • Other melamine-based fire retardant compounds are set forth hereinabove.
  • Borate fire retardant compounds include zinc borate, borax (sodium borate), ammonium borate, and calcium borate.
  • Zinc borate is a boron-based fire retardant having the chemical composition xZnO y B 2 0 3 zH 2 0.
  • Zinc borate can be used alone, or in conjunction with other chemical compounds, such as antimony oxide, alumina trihydrate, magnesium hydroxide or red phosphorous. It acts through zinc halide or zinc oxyhalide, which accelerate the decomposition of halogen sources and promote char formation.
  • Silicon-based materials include linear and branched chain-type silicone with (hydroxy or methoxy) or without (saturated hydrocarbons) functional reactive groups.
  • Phosphonic acid derivatives include phosphonic acid, ethylenediamine salt of phosphonic acid, tetrakis hydroxymethyl phosphonium chloride and n-methyl dimethylphosphono propionamide.
  • intumescent substances include, but are not limited to, ammonium polyphosphate, boric acid, chlorinated paraffin, Dl-pentaerythritol, melamine, mono- ammonium phosphate, pentaerythritol, phosphate esters, polytetrafiuoroethylene, tributoxyethyl phosphate, triethyl phosphate, tris (2-ethylhexyl) phosphonate, urea, xylene and zinc borate.
  • powdered metal containing flame retardant substances which can be employed alone or in combination with other flame retardant substances, include, but are not limited to, magnesium oxide, magnesium chloride, talcum, alumina hydrate, zinc oxide, zinc borate, alumina trihydrate, alumina magnesium, calcium silicate, sodium silicate, zeolite, magnesium hydroxide, sodium carbonate, calcium carbonate, ammonium molybdate, iron oxide, copper oxide, zinc phosphate, zinc chloride, clay, sodium dihydrogen phosphate, tin, molybdenum and zinc.
  • fire retardant substances that can be applied to the fibers also include boric acid, boron oxide, calcium borate, alumina trihydrate (alumina hydroxide), alumina carbonate, hydrated aluminum, aluminum hydroxide, antimony oxide, antimony trioxide, antimony pentoxide, sodium antimonate, magnesium carbonate, potassium fluorotitanate, potassium fluorozirconate, zinc oxide, hunite-hydromagnesite, ammonium octamolybdate, ammonium bromide, ammonium sulfate, ammonium carbonate, ammonium oxylate, barium metaborate, molybdenum trioxide, zinc hydroxystannate, sodium tungstate, sodium antimonate, sodium stannate, sodium aluminate, sodium silicate, sodium bisulfate, ammonium borate, ammonium iodide, tin compounds, molybdic oxide, sodium antimonate, ammonium sulfamate,
  • the chemistry may be added to the fibers using application methods known to those skilled i the art.
  • the flame retardant may be singular, or in combination with other finishing chemistries like antistats, lubricants, binders, antimicrobials, color, water and oil repellents, surfactants, and other chemical auxiliaries known to the art.
  • the substrate is centrifuged and dried. Exemplary application processes are disclosed in US Pat. No. 7,736,696 to Tintoria-Piana, incorporated herein by reference in its entirety.
  • a closed-loop system and process can be used for applying fire retardant chemicals to the fibers.
  • the untreated fibers are first positioned in a vessel such as a dye machine, which circulates the fire retardant chemicals.
  • the fire retardant chemicals may be in the form of a solution, a dispersion or emulsion. In some embodiments, the fire retardant chemicals are in the form of an aqueous solution.
  • the fire retardant chemical solution, dispersions, emulsion or otherwise may be at room temperature or at an elevated temperature. In most embodiments, the fire retardant chemical solution, dispersions, emulsion or otherwise will be at a temperature from about 4°C to about 100°C; in other embodiments, from 20 to 50°C and in still other embodiments, at about ambient temperature.
  • non-absorbed fire retardant chemicals are recovered and re-used on subsequent batches of fibers.
  • the re-use of fire retardant chemicals can take place in the same vessel that is used to treat successive batches of fiber.
  • recovery can be achieved by directing the non-absorbed fire retardant composition into a second dye machine containing additional fibers, or by extracting the fire retardant composition by centrifugation or other means, or by a combination of the two processes.
  • the treated fibers may then be rinsed and dried.
  • the fire retardant may be applied to the fibers at a subsequent stage of manufacturing, e.g., after blending with the binder fibers or fomiing the non-woven web, or after the non-woven web has been pleated.
  • the fire retardant can be selected to permeate substantially throughout the cross sectional fiber structure unlike many types of fibers where the fire retardant coats exposed surfaces with minimal or no impregnation of the fire retardant into the fiber core.
  • ammonium polyphosphate can applied to the lyocell fiber and has been found to permeate substantially throughout a cross section of the lyocell fiber.
  • the batting from the treated fibers may be formed using one of several processes for converting a source of fiber into vertically oriented fibers as is generally known in the art.
  • the vertically oriented fibers can be formed as described in U.S. Pat. No. 5,702,801 , incorporated herein by reference.
  • the peaks of the vertically oriented fibers in the batting material may be brushed or needle punched to improve the entwining of individual fibers of one peak into adjacent peaks.
  • Adjacent peak s of vertically oriented fibers may be of substantially the same height, or alternatively may have different heights in a repeating pattern.
  • the vertically oriented fibers can be in the form of pleats as discussed above.
  • the pleats are formed from a cross laid non-woven web of fibers that can be less than 5 millimeters (mm) (i.e., about 0.2 inches) thick before pleating and in other embodiments, about 2 mm thick (e.g., a mattress approximately 2000 mm long can have about 500 pleats, each or two sheets).
  • mm millimeters
  • the fibers are 0.25 to 4 inches long.
  • the pleated layer can be cross-needled to provide additional structural strength.
  • the pleating can provide a pleated layer having a thickness less than about 2 inches.
  • the non-woven web or the pleated layer can also include a binder fiber, which bonds the fibers to form a fiber mat.
  • the binder fiber can be a bi- component fiber having a standard polyester core, e.g., having a melting point of about 250°C within a low melting temperature polyester surround having a melting point of about 130°C.
  • the non-woven web can be heat treated above the melting temperature of the fiber surround but beneath the temperature of the fiber core to cause the bi-component fibers to bind the fire retardant treated fibers.
  • the non-woven web can be cross-needled to enhance its strength.
  • the pleated layer may be cut during the manufacturing process as a result of the vertically lapped arrangement of fibers.
  • Flame retardant loading generally depends of the type of flame retardant and is generally at a loading of 13 to 20% based on a total weight of the fiber and the fire retardant.
  • the vertical arrangement of the fibers in the pleated layer when a load is applied to the cushioned article, e.g., mattress, the vertical arrangement of the fibers in the layer supports the load in a spring-like manner, compressing vertically to accommodate the shape of the load without flattening in the neighboring regions.
  • the vertically oriented fibers e.g., the vertically lapped formed pleats, act as vertical springs with cross needling to effect limited attachment between pleats but without causing pleats to flatten except under load.
  • the vertically oriented fibers readily recover it shape due to the independently spring-like nature of the vertically oriented fibers.
  • the vertically oriented fibers e.g., vertically lapped formed pleats
  • have a low area density which may result in lighter products and correspondingly less expensive manufacture and transport.
  • Example 1 the fibers used to produce the vertically oriented fire retardant treated fiber batting product represented a blend of 70% ammonium polyphosphate treated lyocell with 30% low melt copolymer PET binder fiber.
  • the fire retardant treated lyocell was treated via dye bath process under temperature and pressure to consistently load the fire retardant chemistry into the lyocell fiber.
  • Example 2 a batting material layer including a plurality of substantially vertically oriented flame retardant treated lyocell fibers I was formed.
  • the flame retardant treated lyocell fibers of Example 1 were mixed low molecular weight polyester at a weight ratio of 70:30.
  • Lyocell fibers used were 3 denier per filament (dpi) x 2.5 inch cut length and were treated with ammonium polyphosphate.
  • the low melt copolymer binder fiber was 4 dpf x 2.5" cut length.
  • the batting material had a basis weight of 1 ounce per square foot and was subjected to a fire test in accordance with 16 CFR Part 1633. The results provided with three samples are shown below in Table 3.
  • the results shown above for the flame retardant treated lyocell fibers exceed the minimum requirements provided in 16 CFR Part 1633.
  • the peak heat release cannot exceed 200 kilowatts and the total energy released in the first ten minutes of the test cannot exceed 15 megajoules.
  • the peak heat release was 38-41 kilowatts, which is significantly less than 200 kilowatts; and the total energy released in the first ten minutes was 4.3 to 6.7, which is significantly less than the standard maximum of 15 megajoules.
  • Example 3 In this example, a comparison of moisture uptake was made between flame retardant treated lyocell fibers and untreated lyocell fibers.
  • the flame retardant treated lyocell fibers were treated with ammonium polyphosphate via a dye bath process, rinsed, and dried. The fibers were exposed at room temperature to 55% and 98% relative humidity. The results are graphically shown in Figure 5. As shown, there was no difference in moisture uptake between the treated and untreated lyocell fibers.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Fireproofing Substances (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Nonwoven Fabrics (AREA)
EP14780966.9A 2013-10-04 2014-09-17 Fire resistant panel and methods of fire blocking an article Withdrawn EP3052689A1 (en)

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US14/046,547 US20150096125A1 (en) 2013-10-04 2013-10-04 Fire resistant panel and methods of fire blocking an article
PCT/US2014/056038 WO2015050702A1 (en) 2013-10-04 2014-09-17 Fire resistant panel and methods of fire blocking an article

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EP (1) EP3052689A1 (enExample)
JP (1) JP2016540130A (enExample)
CN (1) CN105593422A (enExample)
AU (1) AU2014329896A1 (enExample)
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WO2015050702A1 (en) 2015-04-09
CA2865600A1 (en) 2015-04-04
US20150096125A1 (en) 2015-04-09
CN105593422A (zh) 2016-05-18
JP2016540130A (ja) 2016-12-22

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