JP2007530805A - Layered bulky flame resistant batting, articles containing said batting, and process for producing the same - Google Patents

Abstract

  The present invention relates to a bulky flame resistant batting and an article such as a mattress containing such a batting, the batting comprising a base layer and an elastic layer, the base layer having a heat resistance of 10 to 30 parts by weight. Including 35 to 55 parts by weight of cellulose fiber and 15 to 25 parts by weight of binder material that maintains at least 10 percent of the fiber weight when heated in air to 700 ° C at a rate of 20 ° C per minute; And the elastic layer comprises 0 to 50 parts by weight of modacrylic fiber, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material. Based on the total weight of these two layers, the base layer constitutes 20 to 70 parts by weight of the batting, the elastic layer constitutes 80 to 30 parts by weight, and the total thickness of the batting is 1.25 cm (0.5 inch) or more.

Description

  The present invention provides a layered high loft flame resistant batting for use in fire-blocking an article such as a mattress, and a process for producing the batting, and fire-proofing the article. Regarding the method. When combusted, a mattress set using the bulky flame resistant batting of the present invention is tested within 200 minutes when tested according to the California Bulletin 603 as revised in July 2003. It has a peak heat release rate of less than kilowatts and a total heat release of less than 25 megajoules within 10 minutes.

  California is leading a movement to regulate and reduce the flammability of mattresses and mattress sets in an attempt to reduce the number of fatalities lost to home, hotel, and facility fires. In particular, the California Consumer Affairs Bureau furniture and insulation section (The Bureau of Home Furnishings and Thermal Insulation of the Department of Consumer Affiliate of the Calif.) Patent Document 1 was issued.

  The mattress typically contains a cushioning material coated with an outer fabric ticking or a mattress core coated by batting. Most cushioning materials or batting are made from foam or fiber material that burns when exposed to an open flame. One useful method of fire-protecting foam cushions, especially airplane seats, is disclosed in US Pat. No. 6,099,037 to Blaustein et al., Where 3-7 layers of flame resistant fabric are used to wrap the foam. Used under the seat covering fabric. To the extent necessary for each aircraft seat flammability test method, these fired cushions will withstand the flame jet impinging on the cushion, and the entire cushion will be swallowed by the flame or burned after the flame jet is removed Prevent from continuing to do. When applied to a mattress, the use of multiple fire layers under the ticking may add rigidity or limit the resilience of the mattress core, affecting overall comfort. Even a single layer of fire retardant fabric can constrain the batting material and affect the cushioning of the mattress. Therefore, what is desirable is a solution that does not require the incorporation of an additional fire protection layer. Particularly desirable is a batting material that can also function as a fire blocker for mattress or upholstered articles.

  While fibers such as para-aramid fibers are very useful in flame retardant fabrics, these fibers have a natural golden color that is present in fabrics made from significant amounts of those fibers. It is undesirable for the natural gold color of the para-aramid fabric to be seen through the mattress's outer ticking, which is usually white or pale or off-white, or through the furniture's upholstery-coated fabric. Therefore, what is needed is a bulky flame resistant batting incorporating heat resistant fibers where the color of the heat resistant fiber is masked by other fibers in the bulky flame resistant batting and still meets important flame resistance requirements.

  U.S. Patent No. 6,099,077 discloses a non-woven bulky flame barrier for use in furniture with mattresses and upholstery. These barriers have a very low density of 5-50 kilograms per cubic meter, most preferably 7.5 kilograms per cubic meter. A preferred nonwoven bulky flame barrier comprises a blend of fibers that are inherently fire resistant and resistant to direct flame shrinkage, and fibers from polymers made with halogenated monomers. .

  U.S. Patent Nos. 5,099,049 and 5,037,459 disclose fabric blends of inherently flame resistant fibers, and cellulose fibers having increased flame resistance, the fabric being an additive in a dyeing process, for example. Additional flame retardants added as can be included. Due to the low content of inorganic materials, the flame resistant cellulosic fibers disclosed in these references do not maintain an appropriate percentage of their weight when exposed to high temperatures.

  U.S. Patent Nos. 6,099,066 and 5,037,086 disclose high temperature insulating materials made from non-thermoplastic fibers and thermoplastic binder materials having a density of 0.1 to 3.0 pounds / cubic foot. The binder material is completely melted, and the liquefied thermoplastic material, possibly under the influence of surface tension, collects at the point where the non-thermoplastic fibers come together and forms nodes when cooled, In contrast to sheath-core binder fibers, where some fibers can be bonded to the binder fibers along their length and maintain the core of the thermoplastic material after heating.

  U.S. Patent No. 6,057,031 discloses a well blended blend of 80-98 percent polyester fiber fill and 2-20 percent synthetic organic filament material. The organic filament material can be poly (p-phenylene terephthalamide) or flame retardant rayon.

  U.S. Pat. No. 6,089,077 discloses a refractory material comprising a fiber fill bat and at least one refractory layer of aramid fibers.

US Pat. No. 4,750,443 International Publication No. 03/023108 Pamphlet US Pat. No. 6,132,476 US Pat. No. 6,547,835 US Pat. No. 5,609,950 US Pat. No. 6,579,396 US Pat. No. 6,383,623 US Pat. No. 4,199,642 US Pat. No. 5,578,368 Technical Bulletin 603 “Requirements and Tests for Resistance of a Residential Mattress / Box Spring Set-to-Let Spring-Piece-Spring-Letter-Spring-Letter-Spring-Strip-Gap

  The present invention relates to a bulky flame resistant batting and an article such as a mattress containing such a batting, the batting comprising a base layer and an elastic layer, the base layer having a heat resistance of 10 to 30 parts by weight. Including 35 to 55 parts by weight of cellulose fiber and 15 to 25 parts by weight of binder material that maintains at least 10 percent of the fiber weight when heated in air to 700 ° C at a rate of 20 ° C per minute; And the elastic layer comprises 0 to 50 parts by weight of modacrylic fiber, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material. Based on the total weight of these two layers, the base layer constitutes 20 to 70 parts by weight of the batting, the elastic layer constitutes 80 to 30 parts by weight, and the total thickness of the batting is 1.25 cm (0.5 inch) or more.

The present invention is also a method for producing a bulky flame resistant batting comprising:
(A) 10 to 30 parts by weight of heat resistant fiber, 35 to 55 parts by weight of cellulose fiber that maintains at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute, and Forming a base layer fiber mixture comprising 15 to 25 parts by weight of binder fibers;
(B) forming an elastic layer fiber mixture comprising 0 to 50 parts by weight of modacrylic fiber, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder fiber;
c) forming a layered bat having a total thickness of at least 1.25 centimeters (0.5 inch), one layer containing the base layer fiber mixture and another layer of the elastic layer fiber mixture Containing a step;
d) heating the layered bat to activate the binder fibers to form a bulky batting.
Optionally, a portion of the bulky batting can be recycled into the base layer fiber mixture.

The present invention further provides a fireproof quilt incorporating a layered bulky flame resistant batting, as well as a method of fireproofing articles,
a) combining a fabric ticking or upholstery layer, a bulky batting, and optionally a stitching backing layer, wherein the bulking batting comprises:
10 to 30 parts by weight of heat resistant fiber,
A base comprising 35-55 parts by weight of cellulose fibers that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute, and 15-25 parts by weight binder material Layers,
0 to 50 parts by weight of modacrylic fiber,
A resilient layer comprising 50 to 85 parts by weight of polyester fibers and 15 to 25 parts by weight of a binder material,
Based on the total weight of these two layers, the base layer comprises 20-70 parts by weight of the batting, the elastic layer comprises 80-30 parts by weight, and the total thickness of the batting is at least 1.25 cm A process that is meters (0.5 inches);
b) stitching the layers together to form a fireproof quilt fabric or upholstery;
c) incorporating a fireproof quilt fabric or chair upholstery into the article.

  The present invention relates to layered bulky flame resistant batting and articles such as mattresses containing such batting. The batting comprises a base layer and a resilient layer that work together to form a fire protection material. The base layer comprises 10 to 30 parts by weight of heat resistant fibers and 35 to 55 parts by weight of cellulose fibers that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute. And 15 to 25 parts by weight of a binder material, and the elastic layer comprises 0 to 50 parts by weight of modacrylic fiber, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material. Comprising. In the layered bulky batting, the base layer is present in an amount of 20 to 70 parts by weight and the resilient layer is present in an amount of 80 to 30 parts by weight, based on the total weight of the base layer and the elastic layer.

  The bulky layered batting of the present invention has a total thickness of 1.25 centimeters (0.5 inches) or greater. There is no actual limit on how thick the batting can be, but for many typical applications, the bulky batting thickness need not be higher than 7.6 cm (3 in) and for many mattress applications Less than 5 cm (2 in) is very useful. The layered batting of the present invention also has a preferred basis weight in the range of 8-12 ounces per square yard. The batting also has a preferred composite density of 5.3 to 32 kilograms per cubic meter (0.33 to 2.0 pounds per cubic foot) based on the total weight and thickness of the combined layers . Higher density batting generally does not have the elasticity desired for use as a cushioning in mattresses and other articles. It is believed that batting thinner or less dense than the desired range does not provide the amount of cushioning desired.

  The base layer of the layered bulky batting consists of 10-30 parts by weight of heat resistant fibers and cellulose fibers 35 that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C at a rate of 20 ° C per minute. -55 parts by weight and 15-25 parts by weight of binder material. Preferably, the heat resistant fiber is present in an amount of 20-30 parts by weight and the cellulose fiber is present in an amount of 40-50 parts by weight. The base layer provides a dense structure that forms charcoal and maintains integrity in the flame.

  By “heat resistant fiber” is meant that the fiber preferably maintains 90 percent of its fiber weight when heated in air to 500 ° C. at a rate of 20 ° C. per minute. Such fibers are usually flame resistant, meaning that the fiber, or fabric made from the fiber, has a limiting oxygen index (LOI) such that the fiber or fabric does not support a flame in the air, A preferred LOI range is about 26 or greater. Preferred fibers do not shrink excessively when exposed to a flame, i.e., the length of the fiber is not significantly shortened when exposed to a flame. Fabrics containing organic fibers that maintain 90 percent of the fiber weight when heated in air to 500 ° C. at a rate of 20 ° C. per minute have limited amounts of cracks when burned by impinging flames. And tend to have openings, which is important for the performance of the fabric as a fire protection body.

  Heat resistant stable fibers useful in the nonwoven fire retardant fabric of the present invention include fibers made from para-aramid polymers, polybenzazole polymers, polybenzimidazole polymers, and polyimide polymers. Preferred heat resistant fibers are made from aramid polymers, especially para-aramid polymers.

  As used herein, “aramid” means a polyamide in which at least 85% of the amide (—CONH—) linkages are directly attached to two aromatic rings. “Para-aramid” means that two rings or radicals are para-oriented to each other along a molecular chain. Additives can be used with aramids. In fact, up to 10 weight percent of other polymeric materials can be blended with aramid, or 10 percent of other diamines can be replaced with diamines of aramids or 10 percent of other diacid chlorides can be diacidified of aramids. It has been found that copolymers substituted with products can be used. In the practice of the present invention, the preferred para-aramid is poly (paraphenylene terephthalamide). Methods for producing para-aramid fibers useful in the present invention are generally described, for example, in US Pat. No. 3,869,430, US Pat. No. 3,869,429, and US Pat. , 767,756. Such aromatic polyamide organic fibers, and various forms of these fibers, are available under the trademark Kevlar® fibers from the DuPont Company, Wilmington, Delaware, DuPont Company, Wilmington, Delaware. is there.

  Commercially available polybenzazole fibers useful in the present invention include Zylon® PBO-AS (poly (p-phenylene-2,6-benzobis), available from Toyobo, Japan, Japan. Oxazole) fibers, Zylon® PBO-HM (poly (p-phenylene-2,6-benzobisoxazole)) fibers, and commercially available polybenzimidazole fibers useful in the present invention include Celanese acetate. PBI® fibers available from LLC (Celanese Acetate LLC) include commercially available polyimide fibers useful in the present invention, P-84® available from LaPlace Chemical. Fiber.

  The base layer of the layered bulky batting also contains 35 to 55 parts by weight of cellulose fibers that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute. These fibers are said to be char forming. The cellulose fibers used in the composite of the present invention are preferably regenerated cellulose fibers in which 10 percent inorganic compounds are incorporated into the fibers. Such fibers and methods for producing such fibers are generally disclosed in US Pat. No. 3,565,749 and British Patent No. 1,064,271. A preferred char-forming regenerated cellulose fiber for the present invention is a viscose fiber containing silicon dioxide in the form of polysilicate with aluminum silicate sites. Such fibers and methods for producing such fibers are generally disclosed in US Pat. No. 5,417,752 and WO 92217629. Viscose fibers containing silicic acid and having about 31 (± 3) percent inorganic material are sold under the trademark Visil® by the Sateri Oy Company of Finland, Finland Has been.

  The base layer of the layered bulky batting also contains 15 to 25 parts by weight of binder material. Preferred binder materials are binder fibers that are activated by the application of heat. Such binder fibers are typically made from a thermoplastic material that flows at a lower temperature (ie, has a lower softening point) than any of the other staple fibers in the fiber blend. Sheath / core bicomponent fibers, especially polyester homopolymers such as those commonly available from Unitika Co., Japan (eg sold under the trademark MELTY®) A composite binder fiber having a core and a sheath of a copolyester as a binder material is preferred as the binder fiber. Useful types of binder fibers include those made from polypropylene, polyethylene, or polyester polymers or copolymers, fibers containing only the polymers or copolymers, or fibers containing side-by-side or sheath / core composite fibers Can be mentioned.

  The elastic layer of the layered bulky batting contains 0 to 50 parts by weight of modacrylic fiber, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material. The resilient layer preferably functions as the outer layer of the layered bulky batting and is sacrificially melted in the flame and optionally off-gas to provide a resilient structure to suppress the flame. The resilient layer is typically white or light in color and preferably shields any coloration of the base layer.

  The elastic layer contains 50 to 85 parts by weight of polyester fiber in order to provide elasticity to the layered batting. If more than 85 parts by weight of polyester fiber is used, it is believed that the batting is too flammable to be used in the fire protection body. Polyester fibers are well known in the art and can be obtained from a number of sources. Preferred polyester fibers are made from poly (ethylene terephthalate) (PET) polymer. However, homopolymers; poly (propylene terephthalate, poly (butylene terephthalate), poly (1,4-cyclohexylene-dimethylene terephthalate) monomers and copolymers and mixtures thereof with polyester polymers, terpolymers, blends, etc. One type of PET fiber useful in the present invention is available from Invista, Inc. of Wilmington, Delaware, with a cut length of Trademark DACRON® type 808 in one hole, with a linear density of 7.2 dtex / filament (6.5 denier / filament), 3.8 cm (1.5 in) It is commercially available as a single hole hollow fiber.

  The resilient layer also contains 15 to 25 parts by weight of binder material. As in the base layer, preferred binder materials are binder fibers that are activated by the application of heat. In general, the same binder can be used for both the resilient layer and the base layer, but this is not a requirement.

  The elastic layer optionally also contains 0 to 50 parts by weight of modacrylic fiber. Modacrylic fiber is useful for this outer layer of batting because it emits a flame-suppressing halogen-containing gas when burned. Modacrylic fiber means acrylic synthetic fiber made from a polymer comprising acrylonitrile. Preferably, the polymer is a copolymer comprising 30 to 70 weight percent acrylonitrile and 70 to 30 weight percent halogen-containing vinyl monomer. The halogen-containing vinyl monomer is at least one monomer selected from, for example, vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, and the like. Examples of copolymerizable vinyl monomers are acrylic acid, methacrylic acid, salts or esters of such acids, acrylamide, methyl acrylamide, vinyl acetate and the like.

  The preferred modacrylic fiber used in the present invention is a copolymer of acrylonitrile combined with vinylidene chloride, which copolymer further comprises one or more antimony oxides for improved flame retardancy. Such useful modacrylic fibers include those disclosed in U.S. Pat. No. 3,193,602 having an amount of antimony trioxide of 2 weight percent, an amount of at least 2 weight percent, preferably no more than 8 weight percent. US Pat. No. 5,208,105 having fibers disclosed in US Pat. No. 3,748,302, and 8 to 40 weight percent of antimony compound, made with various antimony oxides present in And the fibers disclosed in US Pat. No. 5,506,042, but are not limited thereto. A preferred modacrylic fiber is commercially available Protex C from Kaneka Corporation, Japan, which is said to contain 10-15 weights of antimony oxide, but not more than 6 weight percent Fibers with less antimony oxide within the range can also be used.

  In the layered bulky batting, the base layer is present in an amount of 20 to 70 parts by weight and the resilient layer is present in an amount of 80 to 30 parts by weight, based on the total weight of the base layer and the elastic layer. Preferably, the base layer is present in an amount of 40 to 55 parts by weight and the resilient layer is present in an amount of 60 to 45 parts by weight.

The present invention is also a process for producing a bulky flame resistant batting comprising:
(A) 10 to 30 parts by weight of heat resistant fiber, 35 to 55 parts by weight of cellulose fiber that maintains at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute, and Forming a base layer fiber mixture comprising 15 to 25 parts by weight of binder fibers;
(B) forming an elastic layer fiber mixture comprising 0 to 50 parts by weight of modacrylic fiber, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder fiber;
c) forming a layered bat having a total thickness of at least 1.25 centimeters (0.5 inches), one layer containing the base layer fiber mixture and another layer of the elastic layer fiber mixture Containing a process,
d) heating the layered bat to activate the binder fibers and forming a bulky batting.

  The fiber mixture and layered bat can be formed by any method that can produce a low density web. For example, a mass of crimped staple fibers and binder fibers obtained from fiber bales can be opened by a device such as a picker. Preferably, these fibers have a linear density of about 0.55 to about 110 dtex per filament (0.5 to 100 denier per filament), preferably 0.88 to 56 dtex / filament (0.8 to 50 denier). Staple filaments, most preferably in the linear density range of about 1-33 dtex / filament (0.9-30 denier / filament). The fibers generally have a cut length of about 1.3 cm to 10.2 cm (0.5 to 4 inches) and a preferred crimp frequency of about 2.4 to 5.9 crimps per cm (6 to about 15). Of crimp / inch).

  The loosened fiber mixture can then be blended by any available method such as pneumatic conveying to form a more uniform mixture. Alternatively, the fibers can be blended to form a uniform mixture before picker fiber unraveling. The fiber blend can then be converted to a fiber web by use of a device such as a card, although other methods such as fiber airlay can be used. Next, the fibrous web is sent by conveyor to a device such as a cross wrapper, and the individual webs are layered on top of each other in a zig-zig structure. Bulky cross-wrapped structures can be made. The rate of fiber unwinding and cross-wrapping is controlled to create a bulky cross-wrap structure of the desired height. Exemplary processes useful for achieving a cross-wrap structure are well known in the art, including a process for cross-wrapping a web that is airlaid or otherwise formed on a belt or apron. Generally, U.S. Pat. No. 3,558,029 to Manns, U.S. Pat. No. 3,877,628 to Asselin et al., Granted to Freund. U.S. Pat. No. 4,984,772, issued to Jourde et al., U.S. Pat. No. 6,195,844, and British Patent No. 1, granted to Jowett. No. 527,230.

  In order to make the multilayer bulky batting of the present invention, two or more bulky structures having different configurations, preferably the base layer and elastic layer configurations described above, are manufactured simultaneously or sequentially and then a conveyor or belt Above, one can be placed on top of the other. The layered bulky web batting is then cured to activate the binder material, preferably by the use of a heated oven and preferably by application of heat without compression of the batting. The bulky batting is then cooled to cure the binder material.

  In a preferred process, the edge of the layered bulky batting is then trimmed to provide a batting having a uniform width. The trimmed bulky batting portion is then recycled back into the process, preferably by treating the material with a picker that separates the trimmed edges into individual fibers. This recycled portion contains fibers from both the base layer and the resilient layer, and therefore, the recycled portion is preferably added to the base layer to maintain the color consistency of the resilient layer. However, since the base layer provides integrity to the layered batting in the flame and the recycled material contains flammable fibers, the amount of recycled material added to the base layer must be limited. Preferably, the total amount recycled to the base sheet is less than about 25 parts by weight of the total weight of the base sheet. Preferably, by this recycling process, the base layer may further contain polyester fibers in an amount up to 15 parts by weight and modacrylic fibers in an amount up to 5 parts by weight of the base layer.

  The present invention also includes a fire-protected article comprising the layered bulky batting described herein. Preferably, the article is a mattress comprising a quilt panel incorporating the bulky web batting of the present invention. The mattress quilt panel is used on the layer of the ticking fabric, one or more layers of the layered bulk batting of the present invention, optionally foam, and if necessary, the side of the mattress quilt facing the interior of the mattress Can be formed by combining scrim backings.

Ticking fabrics are typically very durable, woven or knitted fabrics using any number of weaves, ranging from 2 to 8 ounces per square yard (68 to 271 grams per square meter). There is a tendency to have an inner basis weight. Typical ticking fabrics can contain, but are not limited to, cotton, polyester fibers, or rayon fibers. The foam is typically a polyurethane foam. A scrim backing is generally a layer of non-woven fabric (generally spunbond) of 0.5-1 oz / yd ² . The layers of mattress quilt panels can be firmly bonded together by stitching lines with yarn.

  The layered bulky batting of the present invention can be incorporated into mattresses, foundations, and / or box springs as a flame blocking layer. For example, mattress, foundation, and / or box spring panels and borders can use the mattress panel quilt described above, or any other variation that incorporates the layered bulky batting of the present invention as a component. Stitching can be sewn with non-flame retardant yarns, but flame retardant yarns such as those made from Kevlar® aramid fibers can be stitched, especially mattresses, foundations, and / or boxes. Preferred for spring border stitching.

The present invention further provides a method for fireproofing an article, comprising:
a) Combining a layer of fabric ticking or upholstery and a bulky batting and optionally a stitching backing layer, the bulking batting being 10-30 parts by weight heat resistant fiber, 20 ° C. per minute A base layer comprising 35 to 55 parts by weight of cellulose fibers and 15 to 25 parts by weight binder material that maintains at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of An elastic layer comprising 50 parts by weight modacrylic fiber, 50 to 85 parts by weight polyester fiber, and 15 to 25 parts by weight binder material, based on the total weight of the two layers, The base layer constitutes 20 to 70 parts by weight of batting, the elastic layer constitutes 80 to 30 parts by weight, A step total thickness of at least 1.25 centimeters (0.5 in) of,
b) stitching the layers together to form a fireproof quilt fabric or upholstery;
c) incorporating a fireproof quilt fabric or chair upholstery into the article.

Test Method Thermogravimetric Analysis (Thermo Gravametric Analysis)
The fibers used in the present invention maintain some of their fiber weight when heated to high temperatures at a specific heating rate. This fiber weight was measured using a Model 2950 Thermogravimetric Analyzer (A Division of Waters Corporation), TA Instruments, Newark, Delaware (Thermogravimetric Analyzer). Was measured using. TGA gives a scan of sample weight loss vs. elevated temperature. The percent weight loss can be measured at any recording temperature using the TA Universal Analysis program. The program profile equilibrates the sample at 50 ° C., raises the temperature from 10 or 20 ° C. per minute to 50 to 1000 ° C., uses air as the gas supplied at 10 ml / min, and a 500 microliter ceramic cup. (PN 952018.910) consisting of using a sample container.

  The test procedure is as follows. The TGA was programmed using a TGA screen on a TA Systems 2900 controller (Controller). A sample ID was entered and a planned temperature rise program of 20 degrees per minute was selected. An empty sample cup was tared using the instrument's tare function. The fiber sample was cut to a length of about 1/16 inch (0.16 cm) and the sample pan was loosely filled with the sample. Sample weight should be in the range of 10-50 mg. The TGA has a balance, so there is no need to predetermine the exact weight. None of the samples should be outside the pan. The filled sample pan was loaded onto a balance wire to make sure that the thermocouple was close to the top edge of the pan but not touching it. Raise the oven over the pan and start the TGA. Once the program is complete, the TGA automatically lowers the furnace, removes the sample pan, and enters a cooling mode. The TA Systems 2900 universal analysis program is then used to analyze and generate a TGA scan for percent weight loss over the temperature range.

Thickness The thickness of the layered batting can be measured using ASTM D5736-95 (Reapproved 2001).

Mattress Flammability California Consumer Affairs Department Furniture and Thermal Insulation (The Burning and Thermal Insulation of the Department of the Consumer Affords State 95 3485 Orange Grove Avenue, North Highlands, California 95660-5595, USA)), a tech report on Technical Bulletin 603 "Naked Fire on Technical Bulletin" February 2003 to quantify the flammability performance of mattress sets. Mattress / Box Spring Set Resistance Requirements and Test Procedures (Requirements and Test Procedures for Resistance of a Residential Matters / Box Spring Set to a Large Open-Frame) ”. This report was later revised in July 2003 with a Peak Heat Release Rate (PHRR) limit of less than 200 kilowatts and a Total Heat Release limit of 25 megajoules in 10 minutes. Needed to be less than. This protocol provides a means to determine the combustion behavior of a mattress / foundation set by measuring a specific fire test response when the mattress and foundation are exposed to a specific burning ignition source under well ventilated conditions To do. It is published by the National Institute of Standards and Technology, titled "Protocol of Testing Mattress / Foundation Using a Pair of Gas Burners" dated February 2003. Based on the National Institute of Standards and Technology Publications.

  From the point of ignition, a specific pair of gas burners until (1) all sleep set combustion stops, (2) a period of 30 minutes elapses, or (3) a test chamber flashover is inevitable Test data describing the combustion during and after the addition of. The rate of heat release (energy generated by the fire) from the burning test specimen is measured by measuring the amount of heat consumed by oxygen. A description of the principles, limitations, and required instrumentation can be found in ASTM E 1590 “Standard Test Method of Fire Testing of Mattresses”. Terminology associated with testing is defined in ASTM E 176 “Standard Terminology of Fire Standards”.

  Generally, the test protocol uses a pair of propane burners designed to mimic the heat flux level and duration imposed on the mattress and foundation by burning the bedding. The burner imposes different fluxes on the mattress top and mattress / foundation sides for different times. During and after such exposure, the time-dependent heat release rate is measured from the test specimen.

  The mattress / foundation is placed on a short bed frame located on the catch surface. During the test, rising smoke is captured by a hood instrumented to measure the rate of heat release. Test twin-size mattresses and foundations for practicality. After ignition by the burner, the specimen is allowed to burn freely under fully ventilated conditions.

  The test specimen includes a mattress placed on the foundation, and a T-shaped burner is set to burn the specimen. One burner strikes the flame on the top surface of the mattress and is set to 39 mm from the surface of the mattress. The second burner strikes the flame vertically on the side of the mattress / foundation combination and is set 42 mm from the side of the specimen. The side burner and the top burner are not set at the same location along the length of the specimen, but are offset from about 18-20 cm above another along the length. The burner is specially constructed and aligned for each test method.

  Test specimens are conditioned for 24 hours prior to testing at ambient temperatures greater than 12 degrees Celsius (54 degrees Fahrenheit) and less than 70 percent relative humidity. Mattress and foundation test specimens are centered on each other and on the frame and catch surface. If the mattress is 1-2 cm narrower than the foundation, the mattress can be moved until the sides of the mattress and foundation are aligned vertically. Burners are aligned from the specimen and spaced from the specimen. The data recording and logging device is turned on at least 1 minute before ignition. The burners are ignited, the top burners are burned for 70 seconds, the side burners are burned for 50 seconds (if possible), and then they are removed from the area. Data collection continues until all burning and smoldering signs are complete or until 1 hour has passed.

  A two-layer bulky batting with a base layer and an elastic layer was produced and the fibers in both layers were held in place by use of copolymer PET sheath / PET core binder fibers with a melting temperature of 120 ° C. A conventional carding line / garnet machine and cross wrapper were used to loosen and blend the fibers to form separate bulky batting layers that were combined together and heat cured using a gas fire oven. Next, the bulky batting was cooled. Part of the bulky batting was recycled back to the card, and the fibers from this recycled part became part of the base layer. The base layer, excluding recycled material, is a type 970 Kevlar® aramid fiber (available from DuPont) with an individual filament denier of 2.2 dpf and an average cut length of 2 inches ), Type 33AP Visil® cellulose fibers (available from Sateri) with an individual filament denier of 3.5 dpf and an average cut length of 50 mm, and an individual filament denier of 4 dpf And contained binder fibers (available from Nan Ya) having an average cut length of 51 mm. The elastic layer consists of PET polyester fiber (available from KG) with an individual filament denier of 15 dpf and an average cut length of 64 mm, and Protex with an individual filament denier of 7 dpf and an average cut length of 51 mm (Protex) C modacrylic fiber (available from Kaneka) and the same binder fiber as the base layer.

  Test items, fiber blend ratio by weight, base layer and top layer basis weight are all shown in the table. The item had a thickness in the range of about 2.5-3.8 cm (1-1.5 in).

  The bulky batting was then tested for open flame test protocol TB 603 on single and double sided mattresses.

Four single-sided mattresses were prepared for testing. Two of the mattresses incorporated item # 1 under the ticking on the top panel, and two of the mattresses incorporated item # 3 under the ticking on the top panel. All mattress borders of 4 used a fabric composed of two spunlace layers of fabric as fire protection, one spunlace layer having a basis weight of 2.5 oz / yd ² and a kevlar ( It was composed of a 50% / 50% mixture of Aramid fiber and Vigil® cellulose fiber. The other spunlace layer had a basis weight of 4.0 oz / yd ^{2 and} was composed of a 33% / 67% mixture of Vigil® fibers and Protex C modacrylic fibers. This same fire protection was used as the foundation border. The fire protection body used on the foundation panel is one spunlace layer with a basis weight of 4.0 oz / yd ² and is 25% / 75 of Kevlar® aramid fiber and Vigil® cellulose fiber. % Mixture.

  A four sided mattress was also prepared for the test. They were prepared in the same way as single-sided mattresses except that item # 1 was incorporated into two of the mattresses and item # 4 was incorporated into two of the mattresses, and these were double-sided mattresses, so bulky layered batting Built into both panels. All other materials were the same.

  When tested, all of the mattress sets have a peak heat release rate of less than 200 kilowatts within 30 minutes when tested according to California Technical Report 603 as revised in July 2003, 10 minutes Within a total heat dissipation of less than 25 megajoules.

Claims (25)

(A) (i) 10 to 30 parts by weight of heat resistant fiber,
(Ii) 35-55 parts by weight of cellulose fibers that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute, and (iii) 15-25 parts by weight of binder A base layer comprising a material;
(B) (i) 0 to 50 parts by weight of modacrylic fiber,
A bulky flame resistant batting comprising (ii) 50 to 85 parts by weight of a polyester fiber, and (iii) a resilient layer comprising 15 to 25 parts by weight of a binder material,
Based on the total weight of these two layers, the base layer constitutes 20-70 parts by weight of the batting, the elastic layer constitutes 80-30 parts by weight, and the total thickness of the batting is 1.25 cm Bulky flame resistant batting that is (0.5 inch) or more.   The bulky flame resistant batting of claim 1, wherein the heat resistant fiber is an organic fiber that maintains 90 percent of the fiber weight when heated in air to 500 ° C at a rate of 20 ° C per minute.   The bulky flame resistant batting of claim 2, wherein the heat resistant fiber comprises a para-aramid polymer, a polybenzazole polymer, a polybenzimidazole polymer, or a polyimide polymer.   4. The bulky flame resistant batting according to claim 3, wherein the para-aramid is poly (paraphenylene terephthalamide).   The bulky flame resistant batting according to claim 1, wherein the cellulose fiber is a viscose fiber containing silicic acid.   The bulky flame resistant batting of claim 1 wherein the total composite density is 0.33 to 2.0 pounds per cubic foot.   The bulky flame resistant batting according to claim 1, wherein the basis weight is 8 to 12 ounces per square yard.   The bulky flame resistant batting according to claim 1, wherein the modacrylic fiber is present in the elastic layer in an amount of 20 to 50 parts by weight.   The bulky flame resistant batting according to claim 1, wherein the polyester fiber is present in the elastic layer in an amount of 30 to 60 parts by weight.   The bulky flame resistant batting according to claim 1, wherein the heat resistant fibers are present in the base layer in an amount of 20 to 30 parts by weight.   The bulky flame resistant batting according to claim 1, wherein the cellulose fibers are present in the base layer in an amount of 40 to 50 parts by weight.   The bulky flame resistant batting according to claim 1, wherein the base layer further comprises polyester fibers in an amount of up to 15 parts by weight.   The bulky flame resistant batting according to claim 1, wherein the base layer further comprises modacrylic fiber in an amount of up to 5 parts by weight.   The bulky flame resistant batting according to claim 1, wherein the binder material is a binder fiber.   An article comprising the bulky flame-resistant batting according to claim 1 as a fireproof layer.   A mattress comprising the bulky flame-resistant batting according to claim 1 as a fireproof layer. A method for producing a bulky flame resistant batting comprising:
(A) (i) 10 to 30 parts by weight of heat resistant fiber,
(Ii) 35-55 parts by weight of cellulose fibers that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute, and (iii) 15-25 parts by weight of binder Forming a base layer fiber mixture comprising fibers;
(B) (i) 0 to 50 parts by weight of modacrylic fiber,
Forming a resilient layer fiber mixture comprising (ii) 50 to 85 parts by weight of polyester fibers, and (iii) 15 to 25 parts by weight of binder fibers;
c) forming a layered bat having a total thickness of at least 1.25 centimeters (0.5 inch), one layer containing the base layer fiber mixture and another layer of the elastic layer fiber mixture Containing a step;
d) heating the layered bat to activate the binder fiber to form a bulky batting.   18. The method of claim 17, wherein the base layer fiber mixture is present in the layered bat in an amount of 20 to 70 parts by weight of the total weight of the bulky batting.   18. The method of claim 17, wherein the elastic layer fiber mixture is present in the layered bat in an amount of 80 to 30 parts by weight of the total weight of the bulky batting.   18. The method of claim 17, wherein the layered bat is formed by first forming a separate web of base layer fiber mixture and elastic layer fiber mixture and then layering the webs on top of each other.   18. The method of claim 17, comprising the additional step of recycling a portion of the bulky batting, wherein the recycled portion of fibers becomes part of the base layer fiber mixture.   The method of claim 21, wherein the recycled fibers comprise no more than 25 parts by weight of the base layer fiber mixture. A fireproof quilt comprising an outer fabric ticking layer or cover fabric layer, one or more layers of layered bulky flame resistant batting, and optionally a stitch backing layer,
Bulky batting,
(I) 10 to 30 parts by weight of heat resistant fiber,
(Ii) 35-55 parts by weight of cellulose fibers that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute, and (iii) 15-25 parts by weight of binder A base layer comprising a material;
(I) 0 to 50 parts by weight of modacrylic fiber,
(Ii) 50 to 85 parts by weight of polyester fiber, and (iii) an elastic layer comprising 15 to 25 parts by weight of a binder material,
Based on the total weight of these two layers, the base layer comprises 20-70 parts by weight of the batting, the elastic layer comprises 80-30 parts by weight, and the total thickness of the batting is at least 1.25 cm Fireproof quilt that is meters (0.5 inches). A method for fire-protecting an article,
a) combining a fabric ticking or upholstery layer, and a bulky batting, and optionally a stitch backing layer, wherein the bulking batting comprises:
(I) 10 to 30 parts by weight of heat resistant fiber,
(Ii) 35-55 parts by weight of cellulose fibers that maintain at least 10 percent of the fiber weight when heated in air to 700 ° C. at a rate of 20 ° C. per minute, and (iii) 15-25 parts by weight of binder A base layer comprising a material;
(I) 0 to 50 parts by weight of modacrylic fiber,
(Ii) 50 to 85 parts by weight of polyester fiber, and (iii) an elastic layer comprising 15 to 25 parts by weight of a binder material,
Based on the total weight of these two layers, the base layer comprises 20-70 parts by weight of the batting, the elastic layer comprises 80-30 parts by weight, and the total thickness of the batting is at least 1.25 cm A process that is meters (0.5 inches);
b) stitching the layers together to form a fireproof quilt fabric or upholstery;
c) incorporating a fireproof quilt fabric or chair upholstery into the article.   24. The method of claim 23, wherein the article is a mattress.