GB2396360A

GB2396360A - An ignition resistant layer for upholstery fillings

Info

Publication number: GB2396360A
Application number: GB0324043A
Authority: GB
Inventors: John Stuart Uttley; Carl Rushton; John Mark Baron
Original assignee: John Cotton Group Ltd
Current assignee: John Cotton Group Ltd
Priority date: 2002-10-16
Filing date: 2003-10-14
Publication date: 2004-06-23
Anticipated expiration: 2023-10-14
Also published as: GB0324043D0; GB2396360B; GB0224006D0

Abstract

An ignition-resistant barrier layer for upholstery or bedding filling materials, comprises a material web adapted for overlying a filling material, wherein the web consists of a blend of fibres including wool and cotton, in which the wool content is from 30% to 70% by weight of the blend; and the cotton content is from 30% to 70% by weight of the blend. Up to 25% by weight of a thermoplastic textile fibre, e.g. a bi-component polyester fibre, may also be added to the blend. The barrier layer may be applied over a synthetic rich filling material so as to provide ignition resistance while maintaining the load bearing characteristics of the filling material. A method of making the web is also disclosed and comprises the steps of carding and needling the web. A product comprising the barrier layer and a filling material is also claimed.

Description

AN IGNITION RESISTANT LAYER FOR UPHOLSTERY FILLINGS

This invention concerns upholstery fillings and in particular an ignition resistant 5 barrier layer therefor.

It is desirable and in many cases a statutory requirement that upholstery filling materials have ignition resistance to small flaming ignition sources. In particular, reference is made to the ignition resistance standards defined in the UK Furniture and 10 Furnishings (Fire) (Safety) Regulations 1988 (as amended) and BS EN 597-1, BS EN 597-2, BS6807 and BS 7177, the full contents of which are hereby incorporated into the present application by reference. Resistance to ignition source 2 (BS 5852) is often adopted as a criterion for ignition resistance and fire safety.

15 It is important to distinguish between "fire resistance" or "flame resistance" per se, and "ignition resistance" as used in the context of the present invention. Fire resistance is an ill-defined term in the context of fabrics, but is generally understood to relate to postignition behaviour and rates of flame propagation, although in some contexts it may also relate to pre-ignition properties. Ignition resistance, on the other 20 hand, is well-understood in the context of fabrics (see, for example, the ignition resistance standards as defined in the UK Furniture and Furnishings (Fire) (Safety) Regulations 1988 (as amended)), and is a specific measure of resistance to ignition from a heat source. A material with a high resistance to flame propagation may have a low resistance to ignition and vice versa. In particular, a material having high 25 ignition resistance may nonetheless have a relatively low resistance to flame propagation once set alight (for example by flames in a house fire). However, UK fire safety regulations stipulate that bedding and upholstery materials must provide high resistance to ignition (both smouldering and flaming ignition), for example from a cigarette or a match or other ignition source up to "ignition source 5" as defined in 30 British Standard BS 5852.

It is known that the required ignition resistance may be achieved by incorporating wool into a blend of fibres used to manufacture filling materials. However, improved load bearing characteristics of the filling materials is achieved by incorporating a proportion of synthetic fibre into the blend, but such fibre significantly reduces the 5 ignition resistance of the filling material.

It is also known, for example from GB 1 308 097, to provide a flame retardant, bonded, non-woven fibrous product which may include wool and/or cotton (among other fibres). However, flame retardance is provided by impregnation with 10 ammonium polyphosphate.

Likewise, GB 1 054 877 discloses a self-extinguishing, bonded non-woven fabric comprising a cotton or rayon staple fibre blended with various polymers and copolymers and including antimony trioxide as a fire retardant, and US 3,629,052 15 discloses a flame retardant resin-treated cotton batting material where flame retardance is provided by impregnation with urea-phosphate complexes, berated urea formaldehyde, berated amide polyphosphate and dicyandiamide phosphoric acid derivatives. 20 The chemical fire or flame retardants outlined above tend to be environmentally unfriendly, and accordingly there is a need to provide a material having ignition resistance and without the use of chemical fire, flame or ignition retardants.

GB 885,006, CN 1281915, JP 2001-316963 and GB 1 109 641 disclose various non 25 woven fibre blends including cotton and wool, but these disclosures are silent as to

ignition resistance and do not disclose a ratio range of cotton to wool that is specifically claimed in the present application.

GB 2 245 606 discloses a flame resistant interliner comprising a nonwoven fibrous 30 web made of wool, acrylic, PVC aramide, polyamide, polybenzimidazole or viscose fibres blended with binder fibres. The interliner is not made of a cotton/wool blend.

Furthermore, this disclosure requires a web with a Limiting Oxygen Index (LOI)

greater than 25%.

Embodiments of the present invention seek to retain the load bearing and other 5 characteristics of a filling material whilst achieving the necessary ignition resistance properties in order to comply with UK legislation.

According to a first aspect of the present invention, there is provided an ignition resistant barrier layer for upholstery or bedding filling materials, comprising a 10 material web adapted for overlying a filling material, the web consisting of a blend of fibres including wool and cotton; characterized in that the wool content is from 30% to 70% by weight of the blend; and in that the cotton content is from 30% to 70% by weight of the blend, and in that the barrier layer is not treated with or include any chemical fire retardants or the like.

According to a second aspect of the present invention, there is provided a method of manufacturing an ignition-resistant barrier layer for upholstery or bedding filling materials, wherein a blend of fibres including wool and cotton, the wool content being from 30% to 70% by weight of the blend and the cotton content being from 20 30% to 70% by weight of the blend, is subjected to a carding process to form a web, and wherein the blend is not treated with any additional chemical fire retardants or the like.

According to a third aspect of the present invention, there is provided an ignition-

25 resistant filled upholstery or bedding product, comprising a filling material and an ignition-resistant barrier layer overlaying or bonded to the filling material, wherein the barrier layer is as defined in the first aspect of the present invention.

According to a fourth aspect of the present invention, there is provided a method of 30 manufacturing an ignition-resistant upholstery or bedding product, comprising the

steps of providing a barrier layer as defined in the first aspect of the present invention, and overlaying or bonding the barrier layer to a web of a filling material.

Embodiments of the present invention have been tested and found to meet the 5 requirements of schedule 2 part 1 of the UK Furniture and Furnishings (Fire) (Safety) Regulations 1988 (as amended). Embodiments of the present invention may also provide a fire resistant layer capable of providing ignition resistance to a composite fillings assembly when tested according to schedule 2 part 4 of the Regulations.

These tests use a standard cover fabric (as specified in schedule 1 part 1 of the 10 Regulations) and use ignition source 2 (as specified in BS 5852).

The blend may include a thermoplastic textile fibre, for example a bicomponent polyester fibre or other polymeric fibre, up to 15% or even 25% by weight of the blend. It is to be appreciated that the fibre blend of the present invention incorporates cotton (having an LOI of 18%), wool (LOI of 25%) and thermoplastic textile fibre, such as polyester (LOI of 21%). Accordingly, the fibre blend as a whole has an LOI significantly less than 25%.

Preferably, the wool and cotton contents of the blend are substantially equal.

The layer is preferably formed by subjecting the blended fibres to a carding process to form them into a web which is passed through a needle loom to provide partial 25 bonding.

Preferably, the web has a weight of 200 to 1000 grams per square metro.

The barrier layer may have a density range of 30 to 100kg/m3.

The barrier layer may be bonded, or used as an overlay on, a heavier weight synthetic-rich thermally bonded filling material having a weight range of 1000 to 3000 grams per square metre, for example 1650 grams per square metro.

5 The filling material may have a thickness at or in the region of 55mm, and the ignition resistant barrier layer may occupy some 5mm of the overall thickness An embodiment of the invention will now be described, by way of example only.

to In accordance with one embodiment of the invention a filing material for upholstery comprises, for example, an unbended web consisting of recycled textile fibres, for example acrylics, cotton, polyester, wool, and others which are carded and formed into a web having some 55mm thickness and a weight of approximately 1650 grams per square metre. If required, a bi-component polyester occupying some 15% to 25% 15 by weight of the filling material, may be incorporated to assist in bonding the fibres.

An ignition resistant barrier layer comprising a partially bonded web of wool, cotton and bi-component polyester is laminated onto the surface of the synthetic-rich filling material to afford the necessary fire resistance to ignition source 2 (BS 5852).

In one example, the barrier layer comprises a blend of 42.5% by weight of wool, 42.5% by weight of cotton and 15% by weight of bi-component polymer. In another example, the barrier layer comprises a blend of 37.5% by weight of wool, 37.5% by weight of cotton and 25% by weight of bi- component polymer. The blend is carded 25 and formed into a web which is passed through a needle loom to provide partial bonding. This web has a weight of in the region of 200 grams per square metro. The bi-component polymer has a low melting point i.e. around 110 C and acts as a binder. Instead of a bi-component polymer (e.g. polyester), other thermoplastic textile fibres may be used.

The lightweight wool/cotton/bi-component polymer web thus produced is laid onto the surface of an unbended heavyweight web of a filling material comprising acrylics, cotton, polyester, and wool and a proportion of bi-component polyester (up to 25%), the filling material thus having a weight of approximately 1650 grams per 5 square metro.

The ignition resistant web and the unbended heavyweight web are laminated and bonded by passing the combined web through a hot air circulating oven at a temperature of 150 to 200 C, for example around 160 C. The low melting point 10 polyester content of both webs serves to assist the lamination and bonding of the two webs. The resultant product has a thickness in the region of 55mm comprising 50mm of the heavyweight synthetic-rich layer and 5mm of the ignition resistant layer.

The product is a cost-effective filling material suitable for use in futons, bed mattresses and upholstered furniture and provides an ignition resistance to ignition source 2 (BS5852) or equivalent, and meets the requirements of schedule 2 parts 1, 2 and 4 of the Regulations. In its application to a futon, for example, the ignition 20 resistant layer is provided on the opposed faces of the heavyweight layer and, if required, can also be applied around the intermediate edges thereof. Alternatively, an envelope of the ignition resistant material may be produced, into which the heavyweight filling material may be inserted.

25 The ignition resistant material ensures that small flaming ignition sources cannot ignite the inner synthetic-rich heavyweight filling material whilst the latter provides the required load-bearing performance.

The preferred features of the invention are applicable to all aspects of the invention 30 and may be used in any possible combination.

Throughout the description and claims of this specification, the words "comprise"

and "contain" and variations of the words, for example "comprising" and' "comprises", mean "including but not limited to", and are not intended to (and do not) exclude other components, integers, moieties, additives or steps.

Claims

CLAIMS:

. 1. An ignition resistant barrier layer for upholstery or bedding filling materials, comprising a material web adapted for overlying a filling material, the web consisting 5 of a blend of fibres including wool and cotton; characterised in that the wool content is from 30% to 70% by weight of the blend; and in that the cotton content is from 30% to 70% by weight of the blend, and in that the barrier layer is not treated with or include any chemical fire retardants or the like.

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2. A barrier layer as claimed in claim l, wherein the blend farther includes a thermoplastic textile fibre up to 25% by weight of the blend.
3. A barrier layer as claimed in claim 1, wherein the blend further includes a thermoplastic textile fibre up to 15% by weight of the blend.
4. A barrier layer as claimed in any preceding claim, wherein the thermoplastic textile fibre is a polyester fibre.
5. A barrier layer as claimed in claim 5, wherein the thermoplastic textile fibre is 20 a bi-component polyester fibre.
6. A barrier layer as claimed in any preceding claim, wherein the weight percentages of the wool and cotton contents of the blend are substantially equal.

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7. A barrier layer as claimed in any preceding claim, wherein the web has a weight of 200 to 1000 grams per square metro.
8. A barrier layer as claimed in any preceding claim, having a density range of 30 to lOOkg/m3.
9. A barrier layer as claimed in claim 2 or 3 or any claim depending therefrom, wherein the thermoplastic textile fibre has a melting point of around 110 C.
10. A barrier layer as claimed in any preceding claim, bonded or provided as an overlay on a filling material.
11. An ignition-resistant filled upholstery or bedding product, comprising a filling material and an ignition-resistant barrier layer overlaying or bonded to the filling material, wherein the barrier layer is as claimed in any one of claims 1 to 10.
12. A product as claimed in claim 11, wherein the filling material is a synthetic-

rich filling material.
13. A product as claimed in claim 11 or 12, wherein the filling material 15 comprises a web of textile fibres with a weight range of 1000 to 3000 grams per square metre.
14. A product as claimed in any one of claims 11 to 13, wherein the filling material further includes a thermoplastic textile fibre up to 25% by weight of the 20 filling material as a binder fibre.
15. A product as claimed in any one of claims 11 to 13, wherein the filling material further includes a thermoplastic textile fibre up to 15% by weight of the filling material as a binder fibre.
16. A product as claimed in claim 14 or 15, wherein the thermoplastic textile fibre is a polyester fibre.
17. A product as claimed in claim 16, wherein the thermoplastic textile fibre is a 30 bi-component polyester fibre.
18. A product as claimed in any one of claims 11 to 17, wherein the filling material is provided as a web having top and bottom surfaces and side surfaces, and wherein the barrier layer is provided on the top or bottom surface only of the web of filling material.
19. A product as claimed in any one of claims 11 to 17, wherein the filling material is provided as a web having top and bottom surfaces and side surfaces, and wherein the barrier layer is provided on both the top and bottom surface of the web of filling material.
20. A product as claimed in claim 18 or 19, wherein the barrier layer is additionally provided on one or more of the side surfaces of the web of filling material. 15
21. A product as claimed in any one of claims 11 to 20, wherein the barrier layer is bonded to the filling material.
22. A product as claimed in any one of claims 11 to 20, wherein the barrier layer is laminated to the filling material.
23. A product as claimed in any one of claims 11 to 20, wherein the barrier layer is not bonded to the filling material.
24. A product as claimed in any one of claims 11 to 17, wherein the barrier layer 25 is configured as an envelope containing the filling material.
25. A method of manufacturing an ignition-resistant barrier layer for upholstery or bedding filling materials, wherein a blend of fibres including wool and cotton, the wool content being from 30% to 70% by weight of the blend and the cotton content 30 being from 30% to 70% by weight of the blend, is subjected to a carding process to

form a web, and wherein the blend is not treated with any additional chemical fire retardants or the like.
26. A method according to claim 25, wherein the web is passed through a needle 5 loom to provide partial bonding.
27. A method according to claim 25 or 26, wherein a thermoplastic textile fibre is incorporated in the blend to a proportion of up to 25% by weight of the blend.

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28. A method according to claim 25 or 26, wherein a thermoplastic textile fibre is incorporated in the blend to a proportion of up to 15% by weight of the blend.
29. A method according to claim 27 or 28, wherein the thermoplastic textile fibre is a polyester fibre.
30. A method according to claim 27 or 28, wherein the thermoplastic textile fibre is a bi-component polyester fibre.
31. A method according to any one of claims 25 to 30, wherein the weight 20 percentages of the wool and cotton contents of the blend are substantially equal.
32. A method of manufacturing an ignition-resistant upholstery or bedding product, comprising the steps of providing a barrier layer as claimed in any one of claims 1 to 10, and overlaying or bonding the barrier layer to a web of a filling 25 material.
33. A method according to claim 32, wherein the barrier layer is laminated to the web of filling material.

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34. A method according to claim 32 or 33, wherein the barrier layer is laminated to the web of filling material in a hot air circulating oven.
35. A method according to claim 34, wherein the oven is operated at a temperature of 150 to 200 C.

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36. An ignition-resistant barrier layer for upholstery or bedding filling materials, substantially as hereinbefore described.
37. An ignition-resistant filled upholstery or bedding product, substantially as hereinbefore described.
38. A method of manufacturing an ignition-resistant barrier layer for upholstery or bedding filling materials, substantially as hereinbefore described.
39. A method of manufacturing an ignition-resistant upholstery or bedding 15 product, substantially as hereinbefore described.