JP5312794B2 - Flame retardant fiber blends, fire and heat insulating fabrics, and related methods - Google Patents

Abstract

A flame resistant (FR) fiber blend comprises amorphous silica fibers; and at least one fiber selected from the group consisting of FR fibers, binder fibers and mixtures thereof. A barrier fabric, manufactured from a blend of fibers comprises amorphous silica fibers; and at least one fiber selected from the group consisting of flame resistant (FR) fibers, binder fibers and mixtures thereof. A flame resistant fabric, manufactured from a blend of fibers comprises amorphous silica fibers; and at least one fiber selected from the group consisting of flame resistant (FR) fibers, binder fibers and mixtures thereof. A process for protecting materials in a product from fire and heat comprises assembling a flame resistant fabric adjacent to at least one component that comprises a material susceptible to damage due to exposure to fire and heat, occasioned by exposure to open flames.

Description

(Cross-reference to related applications)
This application is a continuation-in-part of US patent application Ser. No. 11 / 001,539 filed Nov. 30, 2004, which further includes US Provisional Patent Application No. 60 filed Mar. 11, 2005. / 660,620 claims the profit.

  The present invention relates to flame retardant fiber blends useful in making flame retardant fabrics, particularly including non-woven flame retardant materials such as barrier fabrics. The present invention further relates to a method of protecting adjacent materials in an assembly using single layer nonwovens and fire and heat shields useful for protecting articles from fire and associated heat.

  Flame retardant (FR) materials are employed in many textile products. For example, the FR material can be used as a barrier layer between furniture, duvets, pillows, and mattress outer fabric and inner stuffing. Such materials can be woven or non-woven, knitted, or laminated with other materials.

  Flame retardancy is determined by ASTM as “flame combustion is prevented, terminated, or suppressed after a flame or non-flame ignition source has been applied, with or without the removal of the ignition source. Material properties "are defined. The flame retardant material may be a polymer, fiber, or woven fabric. A retarder is defined by ASTM as “a chemical used to impart flame retardancy”.

  Flame barriers, heat barriers, and flame retardant fabrics are commonly used as protective walls for other materials in the assembly. Recent examples of the growing need for protective walls include mattresses, bedding, upholstered chairs, and futons, and in particular, the Bureau of Home Furnishings and Insulations in the California Consumer Affairs Division (Bureau of Home Furnishings and) All the regulations are promoted from the very beginning through the enthusiastic efforts of Thermal Insulation of the Department of Consumers of the State of California. California has promoted the regulation of these materials in an attempt to reduce the loss of life in fires by limiting the amount of energy released when an article is exposed to an open fire.

  In the case of mattresses and mattress sets, the proposed regulations were enacted in California on January 1, 2005, and similar country legislation is expected to follow in 2007. Based on historical market history, prices for end consumers are limited. Mattress manufacturers have shown that low-cost, high-performance barrier fabrics are needed because the associated soaring costs cannot be passed on even if the newly imposed standards are followed.

  The flame retardancy of such FR materials is typically determined by California TB 117 and TB 133 for chair drapes, NFPA 701 for curtains and thick long curtains, 1992 10 for flammability testing procedures for mattresses in public buildings. It is determined by various standard methods, such as the monthly California Test Publication 129 and the California Test Publication 603 for residential mattresses. It is desirable that the FR material does not melt in the flame or shrink away from the flame, but forms a carbide that is useful for controlling the burn and protecting the material surrounded by the fabric.

  The required protective function of the flame and heat insulating fabric is related to the other components used in the final assembly of the desired product. For example, mattresses typically include foam for cushioning and multiple layers of fiber stuffing and ticking for durable covers. Most cushion materials consist of foam and fibers that burn when exposed to an open fire. Much of the regulatory effort so far has been directed to shielding the inner cushion layer from direct fire or ignition from direct fire heat without compromising the comfort or aesthetics of the mattress.

  Other desirable properties of the FR barrier fabric include white or other neutral colors so as not to contaminate the manufacturing facility or change the appearance of the composite, and yellow the appearance of the light mattress ticking or chair drape. Such as being unaffected by UV light, soft to the touch, giving the consumer the desired feel, and being cost effective.

  Some fibers are known to have FR properties, such as halogen-containing materials, phosphorus-containing materials, and antimony-containing materials. However, these materials are heavier and have a shorter wear life than similar types of non-FR materials.

  Nevertheless, the industry is required to produce nonwoven barrier fabrics that can pass strict flammability test guidelines. Furthermore, there is a need in the industry to produce such nonwovens from materials that are relatively inexpensive and light in bat weight. In addition, other industries will benefit if flame retardant fabrics made from flame retardant fibers are available for use in place of fabrics that do not have such properties.

  For example, baghouse filters are widely used to control particulate pollutants in many industries such as food processing, cement, mineral and gravel processing, metal processing, power generation, and production of various chemicals . This type of filter cloth is ideally (1) mechanical strength that can withstand the pressure generated when used and bent multiple times, and (2) long-term irritating chemicals. (3) Characteristics not affected by high continuous operation temperature of 482 ° C. (900 ° F.), (4) Resistance to hot spark, (5) Shrinkage of less than about 1% at operating temperature, ( 6) High filtration efficiency and (7) Resistance to attack by microorganisms.

  Further, there is a need for an inexpensive flame and heat insulating fabric that protects the other components of the desired product assembly so that the assembly meets all customer and regulatory requirements.

(Summary of Invention)
Overall, the present invention provides a flame retardant (FR) fiber blend comprising amorphous silica fibers and at least one fiber selected from the group consisting of FR fibers, binder fibers, and mixtures thereof.

  The present invention further provides a barrier fabric made from a blend of fibers comprising amorphous silica fibers and at least one fiber selected from the group consisting of FR fibers, binder fibers, and mixtures thereof.

  The present invention further provides a flame retardant fabric produced from a blend of fiber fibers comprising amorphous silica and at least one fiber selected from the group consisting of FR fibers, binder fibers, and mixtures thereof. .

  The method of protecting the material in the product from fire and heat is flame retardant adjacent to at least one component containing material susceptible to damage from exposure to fire and heat due to exposure to open fire Including assembling the fabric.

  Conveniently, it has been discovered that forming nonwovens with fiber blends containing amorphous silica exhibits improved carbonization strength compared to nonwovens without amorphous silica. The carbonization strength to weight ratio of nonwoven fabrics containing amorphous silica is also improved when compared to nonwoven fabrics containing other fibers conventionally used to improve carbonization strength, such as para-aramid fibers and melamine fibers. It was.

(Detailed explanation)
The practice of the present invention comprises two types of fiber blends: a first fiber blend comprising amorphous silica fibers and at least one type of FR fibers, and amorphous silica fibers and at least one type of binder fibers. Including a second fiber blend. As described in more detail herein, fiber blends can be used to form both nonwoven and woven fabrics for a variety of applications.

In general, amorphous silica fibers that improve carbonization strength when added to fiber blends can be used. The term “silica” refers to naturally occurring silicon dioxide in various crystalline and amorphous forms. Silica is considered crystalline when the basic structure of the molecule (a silicon tetrahedron arranged so that each oxygen atom is shared by two tetrahedrons) is repeated and symmetric. Silica is considered amorphous when the molecule lacks a crystalline structure. The SiO ₂ molecules are linked randomly and do not form a repeating pattern. Crystalline silica is not preferred because it has a brittle crystal structure and breaks down into pieces that are inhaled by breathing, affecting health.

Amorphous silica fibers are high content silica fibers having a silica (SiO ₂ ) content of at least about 90% by weight, based on the total weight of the high silica fibers. In one or more embodiments, the high silica fibers have a silica content of at least 95% by weight, and in other embodiments the high silica fibers have a silica content of at least 98% by weight. For example, high silica fibers can include about 98% silica by weight, with a balance primarily including alumina. In some embodiments, the amount of halogen in the high silica fiber is as low as 120 ppm by weight.

  As mentioned above, the silica fibers are substantially amorphous. Although the fibers may contain some crystalline material, a significant amount of crystallinity is undesirable. Suitable silica fibers are commercially available, for example, from the company Polotsk-Steklovokno, Republic of Belarus.

In one embodiment, the high silica fiber starting material composition comprises about 72 to about 77% SiO ₂ , about 2.5 to about 3.5% Al ₂ O ₃ , about 20 to about 25% Na ₂ O. About 0.01 to about 1.0% CoO, and about 0.01 to about 0.5% SO ₃ , all expressed in weight percent based on the total weight of the composition. This composition can be melted at about 1480 ± 10 ° C. to form continuous fibers. The fibers can then be leached using hot sulfuric acid at a concentration of 2N, with a temperature of about 98 ± 2 ° C. and a residence time of about 60 minutes. The fiber can then be rinsed with tap water to bring the pH to about 3-5. In this embodiment, the resulting fiber has a SiO ₂ content of about 95 to about 99 ± 1 wt%, with the balance being predominantly Al ₂ O ₃ .

  High silica glass compositions and methods for making high silica fibers are described in Russian Patent 2,165,393 (the '393 patent), the disclosure of which is incorporated herein by reference. . The '393 patent high-silica fiber is described as having a low coefficient of variation in strength of the basic filaments, which stabilizes the resulting fiber's strength properties, especially when exposed to high temperatures. There is a possibility to make it. The following description of high silica fibers is taken from the '393 patent for purposes of illustration and should not be construed as limiting the invention.

In one or more embodiments, the glass precursor composition _can include in SiO 2, _Al 2 _{O 3,} and Na ₂ O as well, in the following proportions to CoO and SO ₃ (percent by weight).
Al ₂ O _3: 2.5~3.5
Na ₂ O: 20~25
CoO: 0.01 to 1.0
SO _3: 0.01~1.0
SiO ₂ : The remaining glass can further contain at least one oxide of the group consisting of CaO, MgO, ZrO ₂ , TiO ₂ , Fe ₂ O ₃ in the following amount (percent mass).
CaO: 0.01 to 0.5
MgO: 0.01 to 0.5
TiO _2: 0.01~0.1
Fe ₂ O _3: 0.01~0.5
ZrO ₂ : 0.01 to 0.5
The resulting high temperature silica fiber from the glass composition then contains SiO ₂ and Al ₂ O ₃ but further contains Na ₂ O, CoO and SO ₃ in the following proportions (percent mass).
SiO _2: 94~96
Al ₂ O ₃ : 3-4
Na ₂ O: 0.01~1.0
CoO: 0.01 to 1.0
SO _3: 0.01~1.0
The silica fiber can further contain at least one oxide of the group consisting of CaO, MgO, TiO ₂ , Fe ₂ O ₃ , ZrO ₂ in the following amount (percent mass).
CaO: 0.01 to 0.5
MgO: 0.01 to 0.5
TiO _2: 0.01~0.1
Fe ₂ O _3: 0.01~0.5
ZrO ₂ : 0.01 to 0.5
In one embodiment, the silica fiber is substantially free of a metal oxide coating.

  The diameter of the silica fibers can range from about 5.6 microns to about 12.6 microns, and in one embodiment, the diameter is about 8 microns. The length of the silica fibers can range from about 50 millimeters to about 125 millimeters, and in one embodiment the length is about 75 millimeters (shorter and longer fibers are also It can be used by adjusting the cutting length, but is not practical for needle punch fabric applications).

As described in Example 1 below, one method of preparing silica fibers according to the aforementioned Russian Patent No. 2,165,393 can be performed as follows. In order to produce continuous long fibers of the proposed composition (percent mass) SiO ₂ : 72.39, Al ₂ O ₃ : 2.5, Na ₂ O: 25, CoO: 0.01, SO ₃ : A container containing 0.1 can be made. The vessel can be loaded into a furnace and the composition can be melted at a temperature of about 1480 ± 10 ° C. From the molten glass mass, continuous glass fibers having a diameter of 6-9 microns can be formed at a temperature of about 1260 ± 50 ° C. using 400-hole glass molded aggregates. The resulting fiber has been shown to have a strength of about 1030 Mpa and a surface tension of about 0.318 H / m.

  The continuous glass fiber leaching can then be performed using a hot sulfuric acid solution at a concentration of about 2N (about 10%) at a temperature of about 98 ± 2 ° C. The contact time of the fibers in the solution is 60 minutes. The leaching solution, reaction product, and sizing residue are then washed from the leached fiber with tap water to a pH of about 3-5. The final wash of the fiber is done by deionized water and simultaneous dehydration.

  The preparation, processing and leaching of the glass compositions of Examples 2 and 3 below are similar to those described for Example 1 above, but with different starting material amounts. Table 1 summarizes the amount of material relative to the resulting silica composition, along with the starting amount of glass. Table 2 summarizes the properties of the molten product, the processing properties, and the properties of the glass and silica fibers. Table 3 summarizes the strength properties of the silica material after exposure to 1000 ° C.

Tables 1 to 3 also show that when cobalt and SO ₃ are introduced into the glass composition, the inhomogeneity of the glass lump increases, the surface tension decreases, and the brittleness of the fiber during processing decreases. Data confirming that the stability of the technical properties of the fiber-based silica fibers and the resulting material is increased.

Tables 4 and 5 show various glass fiber compositions from which silica fibers taught by Russian Patent No. 2,165,393 are used in all other glasses due to the presence of trace amounts of CoO and SO _3. It can be seen that it is different from the fiber type.

  Having described the amorphous silica component of the present invention, the additive fibers will now be described. As pointed out above, the present invention includes two embodiments, one using flame retardant (FR) fibers and the other using binder fibers. In the following description, the term “silica fiber” is understood to mean a fiber comprising amorphous (as opposed to crystalline) silica.

  Starting from the first type of additive fiber, ie FR fiber, the amount of silica fiber in the fiber blend may vary depending on the other fibers used. In one embodiment, the amount of silica fibers in the blend is from about 5 to about 65 weight percent, based on the total weight of the blend. In other embodiments, the amount of silica fibers in the blend is from about 15 to about 50 weight percent. In other embodiments, the amount of silica fibers in the blend is from about 20 to about 30 weight percent. The remaining fiber in the blend contains the amount of non-amorphous fiber, or FR fiber, required to equal 100% by weight.

  A variety of FR fibers are known in the art. The FR fibers used in the fabric of the present invention can be intrinsically flame retardant fibers or fibers (natural or synthetic) that are coded with FR resin. Intrinsically flame retardant fibers have an FR component that is not coated but is incorporated into the structural chemistry of the fiber. The term FR fiber as used herein includes fibers that are not inherently flame retardant but are coated with an FR resin, as well as intrinsic flame retardant fibers. Thus, for example, polypropylene fibers coated with FR resin would be FR polypropylene fibers.

Suitable intrinsically flame retardant fibers include polymer fibers having phosphorus-containing groups, amines, modified aluminosilicates, or halogen-containing groups. Examples of intrinsically flame retardant fibers are melamine, meta-aramid, para-aramid, polybenzimidazole, polyimide, polyamideimide, partially oxidized polyacrylonitrile, novoloid, poly (p-phenylenebenzobisoxazole), poly (p -Phenylene benzothiazole), polyphenylene sulfide, slow flame retardant viscose rayon (for example, viscose rayon based fiber containing 30% aluminosilicate modified silica, SiO ₂ + Al ₂ O ₃ ), polyetheretherketone, Including polyketones, polyetherimides, and combinations thereof.

  Melamines include those sold under the trademark Basofil by McKinnon-Land-Moran LLC. Meta-aramid is a poly (m-phenylene isophthalamide) such as E.I. I. Du Pont de Nemours and Co. Sold under the trademark NOMEX (registered trademark) by the company, sold under the trademarks TEIJINCONEX (registered trademark) and CONEX (registered trademark) by Teijin Limited, and FENYLENE (registered trademark) by the Russian State Complex Including those sold under the trademark. Para-aramid is a poly (p-phenylene terephthalamide), such as E.I. I. Du Pont de Nemours and Co. Sold under the trademark KEVLAR (R) by the company and poly (diphenyl ether para-aramid), for example the trademark TECHNORA (R) from Teijin Limited, and the trademark TWARON (R) by Acordis And FENYLENE ST® (Russian State Complex).

  Polybenzimidazole is sold under the trademark PBI by Hoechst Celanese Acetate LLC. Polyimides are sold under the trademark P-84 (registered trademark) by Inspec Fibers, and E.I. I. Du Pont de Nemours and Co. Including products sold by the company under the trademark KAPTON (registered trademark). Polyamideimides include, for example, those sold under the trademark KERMEL (registered trademark) by Rhone-Poulenc. Partially oxidized polyacrylonitrile can be obtained, for example, from Fortafil Fibers Inc. Sold by the company under the trademark FORTAFIL OPF (registered trademark), Textron Inc. Sold by the company under the trademark AVOX (registered trademark), Zoltek Corp. Sold by the company under the trademark PYRON (registered trademark), sold by SGL Technic under the trademark PANOX (registered trademark), sold by American Fibers and Fabrics under the trademark THORNEL (registered trademark) And Toho Rayon Corp. And those sold under the trademark PYROMEX (registered trademark) by the company.

  Novoloid is available from Gun Ei Chemical Industry Co., for example. Phenol formaldehyde novolak, such as that sold by the company under the trademark KYNOL®. Poly (p-phenylenebenzobisoxazole) (PBO) is available from Toyobo Co. It is sold by the company under the trademark ZYLON (registered trademark). Poly (p-phenylenebenzothiazole) is also called PBT. Polyphenylene sulfide (PPS) is commercially available from American Fibers and Fabrics under the trademark RYTON®, Toray Industries Inc. Sold by the company under the trademark TORAY PPS (registered trademark), Kureha Chemical Industry Co. Sold under the trademark FORTRON (registered trademark) by Toyobo Co., Ltd. And those sold under the trademark PROCON (registered trademark) by the company.

  Delayed flame viscose rayon is, for example, Lenzing A.M. G. And those sold under the trademark LENZING FR (registered trademark) by the company and those sold under the trademark VISIL (registered trademark) by Sateri Oy Finland. Polyether ether ketone (PEEK) includes, for example, those sold under the trademark ZYEX (registered trademark) by Zyex Ltd. The polyketone (PEK) includes, for example, those sold under the trademark ULTRAPEK (registered trademark) by BASF. Polyetherimide (PEI) is available from General Electric Co., for example. Including those sold by the company under the trademark ULTEM (registered trademark).

  Modacrylic fibers are made from copolymers of acrylonitrile and other materials such as vinyl chloride, vinylidene chloride, or vinyl bromide. A retarding flame retardant such as antimony oxide can be added to further enhance flame retardancy. Modacrylic fibers used in the present invention are manufactured by Kaneka under the product names KANECARON PBX and PROTEX-M, PROTEX-G, PROTEX-S, and PROTEX-PBX. The latter product contains at least 75% acrylonitrile vinylidene chloride copolymer. Solutia's SEF PLUS is a modacrylic fiber that also has slow flame retardancy.

  Other examples of essential FR fibers suitable for use in the blends of the present invention are such as those sold by KoSa under the trademark TRIVERA CS® fibers or AVORA® PLUS FIBER. Contains phosphalane-containing polyester.

  Further used is Rhovy S. et al. A. Are sold under the trademark THERMOVYL (registered trademark) L9S & ZCS, FIRBRAVYL (registered trademark) L9F, RETRACYL (registered trademark) L9R, ISOVYL (registered trademark) MPS, Kureh Chemical Industry Co., Ltd. Sold by the company under the trademarks PIVIACID (registered trademark), Thuringingche, VICRON (registered trademark), Teijin Ltd. Sold by the company under the trademark TEVIRON (registered trademark), Toyo Chemical Co. Sold by the company under the trademark ENVILON (registered trademark), sold by the company Pittsfield Weaving under the trademark VICRON (registered trademark), and SARAN (registered trademark), Kureha Chemical Industry Co., Ltd. Sold by the company under the trademark KREHALON (registered trademark), Fibrasomni, S. A. de C. V. Chlorinated polymer fibers such as those sold by the company under the trademark OMNI-SARAN (registered trademark), and combinations thereof. Polytetrafluoroethylene (PTFE), poly (ethylene chlorotrifluoroethylene (E-CTFE)), polyvinylidene fluoride (PVDF), polyperfluoroalkoxy (PFA), polyfluorinated ethylene propylene (FEP), and combinations thereof, etc. These fluoropolymer fibers can also be used.

  Natural or synthetic fibers coated with FR resin can also be used in the fiber blends of the present invention. Suitable fibers coated with FR resin are: resin, phosphorus, phosphorus compound, red phosphorus, phosphorus ester, and phosphorus complex, amine compound, boric acid, bromide, urea-formaldehyde compound, phosphate-urea compound, ammonium sulfate Or those containing one or more of halogen-based compounds. Non-resin coatings such as metal coatings are not commonly used in the present invention because they tend to delaminate after continuous use of the product. Suitable commercially available FR resins are sold under the trademarks GUARDEX FR® and FFR® by Glotex Chemicals of Spartanburg, South Carolina.

  There is no particular limitation on the method in which the resin is coated on the fiber. In one embodiment, the FR resin is a liquid product that can be applied as a propellant. In other embodiments, the FR resin is a solid that can be applied to the fiber as a hot melt product, or a solid powder that subsequently melts into a fiber. In one embodiment, the FR resin is applied to the fiber in an amount from about 6 to about 25 weight percent, based on the total weight of the coated fiber.

  The amount of coated FR fiber in the blend can vary, but is from about 35 to about 95 weight percent, based on the total weight of the blend. In one embodiment, the amount of coated FR fibers in the blend is from about 40 to about 90 weight percent. In other embodiments, the amount of coated FR fibers in the blend is from about 45 to about 85 weight percent.

  The denier of the FR fiber is from about 1.5 to about 15 dpf (denier / long fiber). The listing of FR fibers should not be construed as limiting the practical invention, but instead, known FR fibers are used with amorphous silica fibers to practice the present invention. It should be interpreted as indicating the fact that it can be used. As such, fiber types include multifilament and monofilament yarns, which have various cross-sections and shapes and have fibrillated yarns, typically slit films or tapes Manufactured from.

  The fiber blend of the present invention can further comprise one or more non-FR fibers. The non-FR fiber may be a synthetic fiber or a natural fiber. Suitable non-FR synthetic fibers include polyesters such as polyethylene terephthalate (PET), cellulose derivatives such as rayon and / or lyocell, polyolefins such as nylon, polypropylene fibers, acrylic, melamine and combinations thereof. Lyocell fibers are a general class of solvent-spun cellulose derivative fibers. These fibers are commercially available under the name TENCEL®. Natural fibers include flax, kenaf, hemp, cotton, and wool. In one embodiment, non-FR fibers are used to enhance several properties such as loft, elasticity or elasticity, tensile strength, and heat retention.

  The fiber blend includes amorphous silica fibers and at least one type of FR fiber. Thus, the present invention is embodied by a fiber blend comprising amorphous silica fibers, FR fibers, optionally added FR fibers, and any one or more non-FR fibers. In one embodiment, the fiber blend comprises modacrylic fiber, cellulose fiber, lyocell, and amorphous silica fiber.

  In other embodiments, the fiber blend further includes multiple types of FR fibers. In other embodiments, the fiber blend comprises amorphous silica fibers, modacrylic fibers, and VISIL. In still other embodiments, the fiber blend includes modacrylic fibers, FR rayon fibers, and amorphous silica fibers.

  In other embodiments, the fiber blend comprises modacrylic fibers, VISIL (FR viscose rayon) fibers, amorphous silica fibers, and FR polypropylene fibers. The amount of each component can vary, but a convenient carbonization strength is that the needle punched fabric is about 40 weight percent modacrylic, about 40 weight percent VISIL, about 15 weight percent amorphous silica, and about Made from a blend containing 5 weight percent FR polypropylene fiber.

  The fibers of the present invention can be used to make fabrics, where FR properties may be desirable or useful. Essentially any type of fabric made from fibers, such as non-woven fabrics, coarse and tightly woven fabrics, knitted fabrics, and various laminates, are made using the fibers of the present invention. be able to. The manufacture of such fabrics is not limited to a particular method or apparatus. In the case of a woven fabric, it is possible to use amorphous silica fibers in the flow direction or cross flow direction to alternate with one or more of the FR fibers. Alternatively, the fibers can be alternated in the flow direction and woven with either amorphous or FR fibers in the cross flow direction. The woven fabric according to the present invention may comprise a certain proportion of the composition described above for a blend of amorphous and FR fibers.

  The nonwoven fabric of the present invention can be produced by mechanically engaging web fibers. Mechanical engagement can be achieved by a needle punching operation. Needle punch methods for making nonwoven fabrics are known in the art. In one embodiment, a non-woven fabric, also referred to as a vat, can be formed by first weighing the fiber blend and then dry laid / airlaid on a moving conveyor belt. The speed of the conveyor belt can be adjusted to obtain the desired bat weight. Multiple layers of bats are fed into a needle loom where barbed needles are passed through the layers to create an entanglement.

  There are several other known methods of producing nonwoven fabrics that include hydroentanglement (spun lace) processing, thermal bonding (calendering and / or aeration) processing, latex bonding processing, or adhesive bonding processing. The spunlace method is similar to a needle punch except that a water jet is used instead of a needle to entangle the fibers. Thermal bonding requires certain things like powders that function as thermoplastic fibers or adhesives. It will be understood that any nonwoven form can be made with the FR fiber blend of the present invention to produce a barrier fabric having FR properties. Thus, references herein to nonwoven fabrics include all manufacturing forms.

  Preferred nonwoven fabrics of the present invention have a butt weight of about 2.25 oz. / Sq. yd. Greater than (osy). In one embodiment, the bat weight ranges from about 2.25 osy to about 20 osy. In other embodiments, the bat weight is about 3.5 osy. In one embodiment, the fibers are combed. The conveyor belt then moves to the area where spray material is optionally applied to the nonwoven bat. For example, the FR resin can be sprayed onto the nonwoven bat as a latex. In one embodiment, the conveyor belt is perforated and excess latex spray material drip through the belt, which can be collected and reused at a later time. After any spraying, the fiber blend is transferred to a dryer or oven. The fibers can be transferred by a conveyor belt to a needle punch loom where the bat fibers are mechanically oriented and engaged to form a nonwoven.

  Nonwoven FR fabric is used as a bedding material and a barrier fabric for bedding. Fabrics are further used in chair drapes and thick long curtain applications where it is desirable to be flame retardant. Another use of such a fabric is as a hot gas filter cloth. Furthermore, woven fabrics other than non-woven fabrics can be made from the fibers of the present invention, in which case FR woven fabrics are desirable.

(General experiment)
In order to demonstrate the effect of various fiber blends as FR materials, a number of samples were made and tested as described below. These examples are provided to illustrate the practice of the invention and should not be construed as limiting the invention or its practice.

(Example)
(Example Nos. 4 to 15)
Samples were made on miniature cards and needle looms. The fibers were first opened by hand and placed in layers on a card feeding apron. The sown sample was returned twice through the card to ensure that the fiber was completely blended. The rolled web laminated around the take-up roll was cut transversely and removed from the card. This was then fed into the needle punch line for needling. In the second pass, needling was performed from the opposite side.

  The standard tensile strength test apparatus was modified to measure the carbonization strength of the barrier fabric of the present invention. More specifically, the force stiffness measurement, typically measured and reported in pounds, required to modify the fabric stiffness test used with pocket coil materials and push the fabric sample through the hole with the plunger. The amount was measured. In order to force the material to break, the template was processed so that the fabric was sandwiched between the template and the existing test plate.

Barrier fabric specimens were cut into 4 ″ × 8 ″ (10 × 16 cm) samples and weighed. The sample was placed in a carbonization frame and carbonized using a Bunsen burner. The frame was then placed in a modified stiffness test apparatus and the carbonization strength of the sample was measured. Table 6 shows Example No. The results of 4 to 15 are summarized. As a reference, a blend containing 40% modacrylic and 60% Visil was selected (Example No. 4). The types of fibers used were Basofil (registered trademark) (abbreviated as Bas), modacrylic fiber KANECARON PBX, VISIL (registered trademark) (abbreviated as Vis), polyethylene terephthalate (abbreviated as PET), and amorphous silica (Sil Abbreviated). Examples 5-11 and 13-14 are comparative examples of fabrics made from various fiber blends as shown. Examples 5 and 6 contain 10% Basofil fiber as an alternative to an equal amount of Modacrylic or Visil fiber, and Examples 7 and 8 replace 10% and 20% of PET fiber as an equivalent amount of Visil fiber. Example 9 includes a blend of 10% Basofil fiber and PET fiber, modacrylic fiber, and Visil fiber, and Examples 10 and 11 include 10% and 15% PET fiber in various amounts of modacrylic fiber and As an alternative to Visil fiber, Examples 13 and 14 include 10% Basofil fiber as an alternative to various amounts of Modacrylic fiber and Visil fiber, and Examples 12 and 15 are amorphous silica fibers according to the present invention. Made from a fiber blend containing

  Where the carbonization strength of the fabric correlates with the weight of the sample, the fabric formed from fiber blends containing amorphous silica (Examples Nos. 12 and 15) has a strength to weight of 0.08 to about 0.10. It can be seen that the ratio is shown.

(Example Nos. 16 to 45)
Examples 16-45 were made and tested as in Examples 4-15, except that the fiber blends used were different as summarized in Table 7. The strength of each fabric is reported in pounds, as explained above. Textiles have been reported in 6 groups of 4 blends and 2 groups of 3 blends. Examples 19, 23, 27, 31, 34, 38, 41, and 45 report base fabrics and the previous examples report the addition of various types of FR fibers. Carbonization strength in pounds was measured and the results are reported in order of decreasing value for each group.

  For example, FR rayon and modacrylic fibers were used to make Example 19, indicated as FR rayon / modacrylic base fabric. Examples 16-18 are modifications of this basic fabric because in each case one other type of FR fiber was added, and according to the present invention, para-aramid fibers were added to Example 16 and melamine fibers Was added to Example 17 and amorphous silica fiber was added to Example 18.

  Similarly, Example 23 is made from FR rayon fiber and is designated as FR rayon base fabric, but Examples 20-22 are variations of this base fabric, and para-aramid fiber according to the present invention. Was added to Example 20, melamine fibers were added to Example 21, and amorphous silica fibers were added to Example 22.

  Similarly, Example 27 is a rayon / modacrylic base fabric, Examples 24-26 are variations of this base fabric, and according to the invention, melamine fibers are added to Example 24 and para-aramid fibers are Example 25. In addition, amorphous silica fibers were added to Example 26.

  Example 31 is a lyocell / modacryl base fabric, Examples 28-30 are variations of this base fabric, and para-aramid fibers are added to Example 28 and melamine fibers are added to Example 29 according to the present invention. Amorphous silica fiber was added to Example 30.

  In the next series, Example 34 is a Visil / Modacryl base fabric, Examples 32, 33, and 35 are variations of this base fabric, and para-aramid fibers are added to Example 32 according to the present invention, and non- Crystalline silica fibers were added to Example 33 and melamine fibers were added to Example 35.

  Example 38 is a Visil base fabric, but Examples 36-37 are variations of this base fabric, and according to the present invention, melamine fibers are added to Example 36 and amorphous silica fibers in Example 37. Added.

  In accordance with the present invention, Example 41 is a rayon base fabric, while Example 39 includes rayon and melamine, and Example 40 includes rayon and amorphous silica.

According to the present invention, Example 45 is a lyocell base fabric, while Example 42 contains para-aramid, Example 43 contains lyocell and melamine, and Example 44 contains lyocell and amorphous silica.

  From the data in Table 7, for example, Example No. 18 and Example No. When compared to 19, it can be seen that the fabric containing 10 weight percent amorphous silica has improved carbonization strength compared to the same base fabric without amorphous silica. The use of other FR materials, i.e., para-aramid and melamine, with base fabrics generally provides greater strength compared to blends containing amorphous silica, but the two materials are much more expensive than silica. Note that there are. In addition, aramid gives the fabric a bright yellow color, while melamine gives it an off-white color. Amorphous silica does not add any color, so the resulting fabric is white without the addition of pigments. Finally, the carbonization strength of fabrics containing amorphous silica is more suitable for bedding, clothing, furniture, thick curtains, and related purposes.

(Example Nos. 46 to 53)
Examples 46-53 were made by using a needle punch line including a 12 inch card, a cross wrapper, and a 24 inch Dilo OD-1 needle loom. Example No. 46 is a basic blend (8 osy) containing 40% modacrylic and 60% Visil, and various materials or FR fibers are used in the following examples. Example 47 included a base blend (79%) and a leno weave carpet backing 2.1 osy (21%) blend. Example 48 included a basic blend (89%) and a blended scrim 1osy (11%) blend. Conweed is a very lightweight polypropylene material that, at the apex, “warp” and “weft” single fibers are “welded” into a single piece, giving it an “entangled type” appearance. Example 49 included a basic blend (85%) and a Basofil (melamine) (15%) blend. Example 50 included a basic blend (85%) and a Conex (15%) blend. Conex is meta-aramid. Example 51 included a blend of basic blend (85%) and amorphous silica (15%). Example 52 included a basic blend (85%) and a blend of Kynol (phenol formaldehyde novolac) (15%). Example 53 included a blend of amorphous silica (15%), modacrylic fiber (40%), and Visil fiber (45%). Example 53 represents a fabric of the present invention.

  The tuft button simulation is designed to expose the carbonized fabric to the stress seen when the mattress is actually burned, and provides an indication of the success or failure of the fabric strength. A small test device was made from wood. The tuft button test apparatus 10 was formed by assembling the components shown in the figure. A mattress comprising a 4 inch foam 12, two 1 inch extra soft foams 14, 16, a barrier fabric 18 that is 0.5 oz (osf) per square foot, a PET fiber filler 20, and a PET ticking fabric 22. The components were assembled as described below and then baked under tension.

  The components were assembled on the upper plate 24. Foam components 12, 14, and 16 were compressed and the barrier fabric 18, fiber filler 20, and ticking 22 were wrapped around the upper plate 24. The lower plate 26 was disposed so that the fabrics 18, 20, and 22 were sandwiched between the upper plate 24 and the lower plate 26. Tuft button simulator 28 was welded to threaded rod 30 and rod 30 was pushed through all mattress components and through alignment holes 32, 34 in upper and lower plates 24,26. The wing nut 36 was tightened to the rod 30, tension was applied to the assembly, and the tuft button simulator 28 was pulled down into the foam.

The TB 603 upper burner 28 was placed in the center of the tuft button simulator 10 and ignited and burned for 70 seconds. The results are summarized in Table 8.

  In some previous full mattress combustions of various constructions, 60% Visil / 40% Modacrylic 8 osy needle punched fabric passes the standards specified in California Test Bulletin 603. Only in structures where the barrier is subjected to tension after carbonization, the fabric is not successful. As a control, an 8 osy fabric was used to compare this bench test with fabric performance known in full scale tests (Example No. 46). The sample was pyrolyzed within the area around the tuft button within 30 seconds and the entire assembly was completely burned within 40 seconds. This is the desired performance because it accurately indicates the performance of this fabric at full scale combustion. Example No. In 47, an 8 osy fabric was used in a composite with a 2.1 osy leash secondary carpet lining fabric. Similarly, it was pyrolyzed within 20 seconds and removed as a solution. Similarly, Example No. In 48, a very light (about 1 osy) polypropylene scrim in wt units with a “lean weave appearance” was used. Although not a woven fabric, the vertices of single fibers of “warp” and “weft” were fused into one. This sample further pyrolyzed well in less than 1 minute.

  The remaining samples made were not composites, but fiber needle stitching was performed on a pilot line card / cross wrapper / needle loom assembly. These samples were also produced at low weight to gain economic benefits. The first fabric evaluated, Example No. 49 was a 6 osy fabric consisting of 85% “basic blend” of 15% melamine, 60/40 Visil / Modacryl. The fabric pyrolyzed within 30 seconds and combustion was uncontrollable. This was eliminated as a candidate for this use. Example No. A 6osy fabric consisting of 50% 15% meta-aramid and 60/40 Visil / Modacrylic 85% “basic blend” also pyrolyzed and burn was uncontrollable within 25 seconds. Example No. 51, 6osy fabric consisting of 15% amorphous silica and 85% “basic blend” of 60/40 Visil / Modacryl, did not pyrolyze and the entire assembly self-extinguished within 8 minutes after ignition. Similarly, Example No. 52, 6osy fabric consisting of 85% “basic blend” of 15% novoloid and 60/40 Visil / Modacryl, did not pyrolyze and self-extinguished within 11.5 minutes. Many other fibers were considered for this demonstration, but some fibers were expensive and were not considered economical. As an additional verification of these tests, the fabric according to the invention, Example No. 53, a 5 osy fabric consisting of 15% amorphous silica, 40% modacrylic, and 45% Visil was assembled in a tuft button simulator device, but it also did not pyrolyze, and in fact it was self-assembled within about 13 minutes. The fire was extinguished.

  Since the use of amorphous silica fibers with FR fibers has proven to be very effective in realizing FR fabrics, a second embodiment is described next.

  As pointed out above, the present invention is further directed to a method of protecting adjacent materials in an assembly using single layer nonwovens and fire insulation fabrics useful for protecting articles from fire and associated heat. To do. The nonwoven barrier fabric is comprised of at least about 0.45 ounces / square yard of amorphous silica fibers and at least about 0.45 ounces / square yard of binder fibers, and the single layer nonwoven is at least about 3.0 ounces / square. Has a yard basis weight. The fiber blend by weight of the nonwoven comprises about 15 to about 80 weight percent amorphous silica fibers, about 15 to about 85 weight percent binder fibers, but is not required, up to about 70 weight percent complementary fibers And the other two fibers can be reduced to a total of 100 weight percent without dropping below the minimum amount.

  As already mentioned, the amorphous silica fibers are always present in the nonwoven composition and represent at least about 15 weight percent and not more than about 80 weight percent of the fiber blend weight. In one embodiment, the amorphous silica fibers comprise from about 35 to about 50 weight percent of the fiber blend weight. As the blend ratio by weight of silica fiber is reduced, the effectiveness of single layer nonwovens to shield direct fire and heat decreases. Individual amorphous silica fibers resist combustion and melting even at levels below about 15 percent by weight in the nonwoven, but at least this level is adequate in the nonwoven structure during and after exposure to an open flame. Must be maintained to achieve the correct structure and integrity. At least about 15 weight percent of amorphous fibers are required in the nonwoven to maintain an acceptable level of carbonization strength.

The blend ratio by weight of amorphous silica is limited to about 80 weight percent or less in the described nonwoven fabric to retain the necessary functional properties of the fire and heat shield fabric. An interfiber cohesion of at least 20 weight percent amorphous silica of the more cohesive fibers is necessary for sufficient fiber web strength and fiber entanglement in the nonwoven. It is this entanglement combined with thermal bonding that makes this single layer nonwoven fabric unique. Combining mechanical and thermal bonding results in a nonwoven structure, which, in at least one embodiment, can do at least one of the following without limiting the ability to shield against fire and heat, and others In this embodiment, the majority of the following can be done without limiting the ability to shield the flame and heat, and in other embodiments, all of the following can be done without restricting the ability to shield the flame and heat be able to.
i) Needle stitches can be retained in the sewing assembly without the support of an additional fabric layer as required for support and reinforcement of conventional thermobonded nonwovens ii) Conventional thermobonded nonwovens Without the support of an additional fabric layer as required for support and reinforcement, thermal stitches can be retained in the ultrasonic weld assembly iii) Required as support and reinforcement for conventional heat bonded nonwovens Can retain thermal stitches in the thermal weld assembly without the support of an additional fabric layer, such as iv) Excessive wear along the exposed surface, especially as compared to materials utilizing FR surface coatings Can preserve the integrity of the nonwoven structure as a surface layer of the assembly without waking up v) Aesthetically unpleasant contrast within the assembly of different materials Can be mixed with colors that are common to many conventional flame retardant materials (natural color is white, mixed hue is achieved by blending binder fibers or other additional fibers )
vi) Can be used in moving and / or contact assemblies without generating excessive noise associated with nonwoven structures vii) Sufficient loft, low density, and large thickness are possible and needle stitching assembly Satisfactory quilted seam depth that is considered aesthetically pleasing within (conventional needle punch construction is not)
viii) sufficient loft, low density, and large thickness are possible, resulting in a satisfactory quilted seam depth that is considered aesthetically pleasing within the ultrasonic welding assembly (conventional needle punch structures are Not)
ix) sufficient loft, low density, and large thickness are possible, resulting in a satisfactory quilted seam depth that is considered aesthetically pleasing within the thermal welding assembly (the conventional needle punch construction is Not)
x) Flameproof and heat shield efficiency can be maintained after exposure to moisture (not a performance-based aqueous solution that can be washed away)
xi) It can provide sufficient rigidity as a means to prevent the occurrence of wrinkles around the cut surface and / or wrinkles on the cut surface, which is often a problem with soft structures.

  In addition to amorphous silica fibers, binder fibers are always present in the nonwoven composition and account for at least 15 weight percent of the fiber blend weight. In one embodiment, the amorphous silica fibers represent 50 to 65 weight percent of the fiber blend weight. Binder fibers are necessary for the thermal bonding required for nonwoven barrier fabrics, but multicomponent binder fibers can also be mechanically and thermally involved in nonwoven structures. In mechanical terms, the at least one fiber provides sufficient inter-fiber cohesion to maintain the integrity of the fiber web and sufficient structure to maintain fiber entanglement between the amorphous silica fibers. Must be secured after thermal bonding. This agglomerated fiber is a component of the binder fiber (in the case of a multicomponent binder fiber) that remains intact after thermal bonding, or one or more fibers added to the amorphous silica and binder fiber during blending It can be.

  The binder fiber may be a single component low melting fiber that acts strictly as an adhesive for thermal bonding required in the nonwoven. Exemplary single component fibers are low melting point polyethylene terephthalate, polypropylene, polyethylene, low density polyethylene, linear low density polyethylene, polylactic acid, polytrimethylene terephthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6 , 6, nylon 11, nylon 12, polymethylpentene, and other thermoplastic polymers with intrinsic or modified sufficiently low melting points. “Sufficiently low” means that such thermoplastic fibers have the lowest melting point of all the component fibers present. Some polymers inherently have the lowest melting point, while other polymers, such as polyesters, use appropriate additives to obtain a lower melting point than the intrinsic polymer has. It may be necessary to denature.

  Single component binder fibers comprise at least 15 weight percent of the fiber blend in the nonwoven. In the context of the present invention, when single component binder fibers are used, it is necessary to add at least 15 weight percent highly cohesive fibers for mechanical fiber engagement after thermal bonding. The melting temperature of the single component binder fiber must be 107 ° C. or higher, but the melting temperature cannot exceed 10 ° C. lower than the lowest melting temperature of other structural fibers in the nonwoven fiber blend.

  At the highest melting temperature of single component binder fibers, the binder fibers can be melted and flowed so that these fibers are along and between the structural fibers when placed at a temperature below the melting point. Forming an adhesive matrix. The minimum temperature depends on the end use application of the nonwoven flame retardant thermal insulation fabric and is based on a temperature higher than the maximum exposure temperature of the nonwoven barrier fabric within the subsequent assembly process and daily operational use and environment. Preferably, the melting temperature of the single component binder fiber is minimized within a range that reduces the energy and time required to heat bond the nonwoven barrier fabric.

  The diameter of the single component binder fiber ranges from about 20 microns to about 60 microns, and in one embodiment is about 31 microns. The length of single component fibers ranges from about 50 millimeters to about 125 millimeters, and in one embodiment is about 75 millimeters for needle punch applications. Single component binder fibers should not act as an incentive fuel source for open flames.

  The binder fiber may be a multi-component low-melting fiber that acts strictly as an adhesive for thermal bonding required in the nonwoven fabric. Exemplary multicomponent fibers are polyethylene terephthalate, polypropylene, polyethylene, low density polyethylene, chained low density polyethylene, polylactic acid, polytrimethylene terephthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, Co-extruded polymer fibers in a combination comprising at least two of Nylon 11, Nylon 12, polymethylpentene, and other thermoplastic polymers with inherently or modified sufficiently low melting points. The term “sufficiently low” has the same meaning as described above for single component fibers. Similar to single component fibers, multicomponent fibers provide two polymers that melt to provide thermal bonding.

  This multi-component thermally bonded fiber comprises at least about 15 weight percent of the fiber blend in the nonwoven. In the context of the present invention, if the multi-component binder fiber acts only as a thermal adhesive, at least about 15 weight percent and no more than about 70 weight percent highly cohesive fiber is required to mechanically engage the fibers after thermal bonding. It is necessary to add. The melting temperature of the multi-component thermally bonded fiber must be 107 ° C. or higher, but the melting temperature cannot exceed a value that is 10 ° C. lower than the lowest melting temperature of other structural fibers in the nonwoven fiber blend.

  At the highest melting temperature of the multi-component thermally bonded fibers, the binder fibers can be melted and flowed, along and between the structural fibers when these fibers are placed at a temperature below the melting point, Form an adhesive matrix. The minimum temperature depends on the end use application of the nonwoven flame retardant thermal insulation fabric and is based on a temperature higher than the maximum exposure temperature of the nonwoven barrier fabric within the subsequent assembly process and daily operational use and environment. Preferably, the melting temperature of the multi-component bonded fibers is minimized within a range that reduces the energy and time required to thermally bond the nonwoven barrier fabric.

  The diameter of the multi-component binder fiber ranges from about 20 microns to about 60 microns, and in one embodiment is about 31 microns. The length of single component fibers ranges from about 50 millimeters to about 125 millimeters, and in one embodiment is about 75 millimeters for needle punch applications. Multi-component binder fibers should not act as an incentive fuel source for open flames.

  Binder fibers act as adhesives for the necessary thermal bonding within the nonwoven and as a mechanical agent with sufficient inter-fiber cohesion to maintain the entanglement of the nonwoven fiber matrix (multicomponent multi-bonding) Mechanical and thermal bonding function) Low melting point fiber. Exemplary multi-component multi-adhesive component fibers are polyethylene terephthalate, polypropylene, polyethylene, low density polyethylene, chain low density polyethylene, polylactic acid, polytrimethylene terephthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6 , 6, nylon 11, nylon 12, polymethylpentene, and a combination co-extruded polymer fiber comprising at least two of inherently or modified sufficiently low melting point other thermoplastic polymers. The term “sufficiently low” has the same meaning as described above for single component fibers. Similar to single component fibers, multi-component, multi-bonded fibers provide a polymer that melts to provide thermal bonding, while the second polymer does not melt and provides a mechanical function of fiber entanglement. This latter difference is the difference between multicomponent fibers and multicomponent multibond fibers.

  In other words, the multi-component multi-bonded fiber must contain at least one component consisting of a low melting point adhesive and a high melting point component that remains intact after being exposed to heat in the thermal bonding stage. This latter difference is the difference between multicomponent fibers and multicomponent multibond fibers.

  The multi-component multi-bonded fibers comprise at least 15 weight percent of the fiber blend in the nonwoven. In the context of the present invention, when multi-component, multi-bonded fibers are used, other highly cohesive fibers for mechanical fiber engagement after thermal bonding if all the described criteria are met Is not necessarily added.

  The diameter of the multi-component, multi-bonded fibers ranges from about 20 microns to about 60 microns, and in one embodiment is about 31 microns. The length of single component fibers ranges from about 50 millimeters to about 125 millimeters, and in one embodiment is about 75 millimeters for needle punch applications. The multi-component multi-bonded fibers should not act as an incentive fuel source for direct fire and may be flame retardant in nature.

  Multi-component, multi-bonded fibers can take several different fiber configurations (eg, concentric sheath / core, eccentric sheath / core, side-by-side or side-by-side, sector, hollow sector, sea-island structure or matrix, etc.). After the thermal bonding, the core fiber having a length close to the original length must be retained. These remaining core fibers must be strong enough to retain the mechanical entanglement under stress and must not act as an incentive fuel source for direct fire. In one embodiment, a minimum of about 10 weight percent of the individual fibers, but not more than about 90 weight percent, acts as a thermal adhesive and the melting temperature should be about 107 ° C. or higher and about 150 ° C. or lower. In other embodiments, the melting temperature is about 110 ° C. The core fibers already mentioned account for a minimum of about 10 weight percent of the individual fibers, but no more than about 90 weight percent, and the melting temperature should be about 115 ° C or higher.

  A useful binder fiber is a core / sheath bicomponent construction consisting of a polyethylene terephthalate (PET) core and a low melt temperature PET sheath, where the sheath is about 60 weight percent of the individual fibers and the core is the remaining 40 weight Percent. The sheath forms the outer surface of the binder fiber and acts as a thermal adhesive, with a melting temperature of about 110 ° C. and a core melting temperature of about 130 ° C. Such core / sheath bicomponent binder fibers are available from Huvis Corporation of Korea. In one embodiment, the core / sheath bicomponent binder fibers comprise 50 to 65 weight percent of the fiber blend in the nonwoven barrier fabric.

  Other multi-component, multi-bonded fibers that can be used are polyethylene terephthalate, polypropylene, polyethylene, low density polyethylene, chain low density polyethylene, polylactic acid, polytrimethylene terephthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethylpentene, and other thermoplastic polymers with inherently or modified sufficiently low melting points, or natural cellulosic fibers (cotton, flax, ramie, jute, kenaf, hemp, etc.) ) Or a co-pressing combination comprising at least two of the protein fibers (wool, cashmere, camel hair, mohair, other animal hair, silk, etc.) coated or bonded with any of the aforementioned thermoplastic polymers Issues, including the molded polymer fibers. The term “sufficiently low” has the same meaning as described above for single component fibers.

  These multi-component multi-bonded fibers, like the multi-component multi-bonded fibers described above, are a plurality of low melting point adhesives and high melting point components that remain intact after exposure to heat in the thermal bonding stage. Must contain the ingredients. The adhesive can be any synthetic fiber having a melting temperature within the aforementioned range that acts as an incentive fuel source for direct fire. The remaining core portion may be synthetic or natural fiber with a melting temperature of 115 ° C. or higher, does not act as an incentive fuel source for open fire, maintains fiber web integrity after needling, and entangles the fibers. Sufficient inter-fiber cohesion to hold.

For the purposes of the present invention, the fiber's minimum limiting oxygen index (LOI) must be at least about 21 to be considered a non-incentive fuel source. LOI is a relative measure of flammability determined by igniting a sample in an oxygen / nitrogen atmosphere and then adjusting the oxygen content to the minimum amount necessary to sustain steady combustion. The higher the value, the lower the flammability of the material. The limiting oxygen index (LOI), also called the critical oxygen index (COI) or oxygen index (OD), is

Defined as
[O ₂ (conc)] and [N ₂ ] are the minimum oxygen concentration in the inflow gas and the nitrogen concentration in the inflow gas, respectively, necessary to pass the “minimum combustion length” criterion. If the incoming gas is maintained at a constant pressure, the denominator of the equation is constant because the decrease in oxygen partial pressure (concentration) balances with the corresponding increase in nitrogen partial pressure (concentration). The limiting oxygen index is usually reported as a percentage rather than a fraction.

Since air contains about 20.95% oxygen by volume, materials whose critical oxygen index is less than this value will easily burn in air. Conversely, the combustion behavior and flame propagation tendency for polymers with a limiting oxygen index above 20.95 will be low or zero after removal of the ignition source. Self-combustion is not possible when LOI> 100, and such values are not physically meaningful. Examples of LOI for various compounds are summarized in Table 9 below.

  Some examples of commercially available binder fibers for practicing the present invention include special single polymer fibers, which are PETG binder fibers (unstretched) (T-135), PETG binder fibers ( Fiber Innovations, Johnson City, Tennessee, including Stretch) (T-137), PCT (T-180), FR (Flame Retardant) PET (T-190), and FR PET (T-191) for spinning. Sold by Technology (FIT), product codes are shown in parentheses. Other examples of binder fibers include concentric sheath / core bicomponent fibers, which are 110 ° C. “melted” CoPET / PET (T-201), 185 ° C. molten CoPET / PET (T-202), T- 201 Dawn Gray version (T-203), T-202 Black version (T-204), 130 ° C. melted CoPET / PET (T-207), 150 ° C. melt high crystallinity CoPET / PET (T-215), Black version of T-215 (T-225), PCT / PP (T-230), PCT / PET (T-231), PETG / PET (T-235), 185 ° C., high Tg coPET / PET (T- 236), HDPE / PET (T-250), HDPE / PP (FDA food contact) (T-251), LLDPE / PET (T-25) 2), PP / PET (T-260), Nylon 6 / Nylon 6,6 (T-270), Black version of T-270 (T-271), which are also available from FIT The product code is shown in parentheses. Polyethylene terephthalate (PET) is particularly useful in practicing the present invention, but there are various types of binder fibers.

  Still other binder fibers available from FIT are PET (polyester), coPET, Tm = 110 ° C., coPET, Tm = 125 ° C., coPET, Tm = 180 ° C., coPET, Tm = 200 ° C., PLA (polylactic acid) , Tm = 130 ° C., PLA, Tm = 150 ° C., PLA, Tm = 170 ° C., PTT (polytrimethylene terephthalate), PCT (polycyclohexanediol terephthalate), PETG (PET) sold under the trademark Cortera ™ Glycol), HDPE (high density polyethylene), LLDPE linear low density polyethylene, PP (polypropylene), PE / PP copolymer, PMP (polymethylpentene), nylon 6, nylon 6,6, nylon 11, and nylon 12 including.

  In addition to the above, polyester binder fibers can optionally be used. Examples of polyester binder fibers are available from Wellman, Inc. of Fort Mill, South Carolina. Including those sold by the company under various model names such as 209, H1305, H1295, H1432, M1440, M1429, M1427, M1425, M1428, and M1431.

  In addition to the required amorphous silica fibers and the required binder fibers, the nonwoven composition can include up to 70% by weight of other fibers, i.e., complementary fibers, considered non-incentive fuel sources. In the context of the present invention, an embodiment consisting of a heat-only binder fiber, such as a single component binder fiber, comprising a low melting point polymer is a cohesive fiber of at least 15 weight percent to mechanically engage the fiber after thermal bonding. Need to be added. One embodiment of the present invention includes a core / sheath binary binder in which about 35 to 50 weight percent amorphous silica, 50 to 65 weight percent core is polyethylene terephthalate (PET) and the sheath is low melt temperature PET. Fibers and 5 to 10 weight percent complementary fibers such as solution dyed (pigmented) PET fibers to color single layer nonwoven flameproof thermal insulation fabrics.

  Also, up to about 15 weight percent, in one embodiment up to about 10 weight percent, and in other embodiments up to about 5 weight percent are considered to be “non-triggered” fuel sources (as defined above). It is possible to include complementary fibers that are not, ie, have a LOI of less than 21. However, such fibers used have limited application to the production of flame retardant fabrics or flame and heat shield fabrics.

  The present invention further reduces the slight mechanical entanglement of the web of fibers and the physical property directional bias, maintains a more complete length of the individual fibers, encapsulates the individual fibers, It also relates to methods of producing single layer nonwovens through other thermal bonds that reduce the density per area of the nonwoven without significantly reducing the.

A nonwoven fabric can be produced as follows. Various combinations of fibers that can be used in the present invention can be weighed and formed dry or wet into a fibrous web. The web can be formed in any of several different ways:
1. Web formation by the dry laying, carding method.
The bails of each fiber type are sent to a process where the fiber masses and bundles are separated (opened). Each type of open fiber is weighed during the process and fed together into a blended web laydown calculated at the total percent fiber type weight. This web laydown is then fed into the card where a rotating cylinder with fine teeth is used to bring the fibers into a parallel array. The carded web can then be transferred directly to the gluing process or cross-wrapped onto a perpendicularly moving conveyor to increase the web width, web weight, and / or cross-direction strength with carded web layering. Can be transferred to the gluing process.
2) Web formation by air laying method.
The bails of each fiber type are sent to a process where the fiber masses and bundles are separated (opened). Each type of open fiber is weighed during the process and fed together into a blended web laydown calculated at the total percent fiber type weight. This web laydown is formed by suspending the fibers in the air and then collecting them as bats on a screen and separating the fibers from the air. This web can then be transferred directly to the gluing process or cross-wrapped on a conveyor moving at right angles to increase the web width and / or web weight with carded web layering and then transferred to the gluing process. it can. In the context of the present invention, a useful method of web formation is the dry card method.

  Useful fabric formation is mechanical fibers by needle punching the web and then heat bonding with heat applied above the melting temperature of the binder and below the melting temperature of the structural fibers that mechanically bond the fabric through entanglement. It is intertwined.

  It is also possible to hydroentangle the fibers using a high-pressure water jet, but the water jet tends to cause more damage to the delicate amorphous silica fiber than the needle punch.

  One embodiment is a nonwoven fabric in which mechanically entangled fibers are further thermally bonded, although it is also possible to blend the fibers in a woven fabric configuration and then thermally bond. In the case of woven fabrics, it is possible to use amorphous silica fibers in the flow direction or cross flow direction to alternate with one or more of the FR fibers or binder fibers. Alternatively, the fibers can be arranged alternately in the flow direction and woven with either amorphous or FR fibers or binder fibers in the cross flow direction. The woven fabric according to the present invention may contain the above-described proportion of composition for blending amorphous silica and binder fibers as well as amorphous silica and FR fibers. The particular weave structure of the coarsely woven fabric is not a limitation of the present invention and thus includes the full range of final counts in both the flow direction and the cross flow direction.

Weaving of woven fabrics is possible through various yarn structures (“type” = fiber type of blend):
1) Single yarn:
a) A plurality of types of staple fibers are blended before spinning into a continuous yarn.
b) A plurality of types of long fibers are blended before being twisted or entangled into a continuous yarn.
2) Double yarn / Cord yarn:
a) Twist two or more single yarns of different types into a double yarn.
b) Twist two or more different types of twin yarns into cord yarns.
3) Core-spun / wrap yarn:
a) A central core of continuous or long fibers, in which other types of fibers are wrapped or twisted, resulting in a continuous yarn containing one fiber type as the core and the other type constituting the outer layer.

Weaving of woven fabrics is further possible through the weaving structure of yarns of different fiber types:
1) One type of warp and one type of weft can be used.
2) Yarns of different fiber types can be combined into warp yarns at certain intervals.
3) Yarns of different fiber types can be combined with wefts at certain intervals.
4) Yarns of different fiber types can be combined in both warp and weft directions.

  The present invention relates to fabrics useful for protecting articles, or products such as mattresses, from fire and related heat, methods for producing woven fabrics, and methods for protecting materials in products by using fire and heat shield fabrics. To do. One such method of protecting materials in a product using fire and heat insulation is by direct ultrasonic bonding or ultrasonic welding of the barrier fabric to at least one component also present in the product. It is. Such components include materials that are vulnerable to fire and heat damage caused by exposure to an open fire and therefore require barrier protection. While ultrasonic bonding is well known in the art, it is novel to incorporate fire and heat insulation functions directly into the subassembly. In ultrasonic bonding, ultrasonic energy is used to bond layers of thermoplastic material. We weld between thermoplastics and fuse materials with high-speed ultrasonic vibration. This fusion or welding requires a similar thermoplastic material to form a bond.

  For example, many conventional mattress structures are covered by a high-loft fiber bat surface assembly between an outer layer of a ticking fabric and an inner layer of a lightweight fabric (typically spunbond), quilted with needles and threads. Holds reverse stitching. The quilted assembly forms a soft and prominent surface due to the raised quilting pattern. High loft fiber bats are traditionally PET and both outer ticking layer and inner structural layer are available in PET or mostly mixed PET, so these and similar assemblies or products such as furniture, Occasionally seats and surfaces of transport means, futons, etc. are quilted by means of ultrasonic bonding rather than quilting with traditional needle and thread.

  The use of ultrasonic bonding to produce quilted assemblies typically allows for higher processing speeds, requires less raw material (no yarn required), and less mechanical wear (needle) Has less advantages than the stitching method and can form a bond between layers comparable to or better than conventional quilting seams.

  Many materials and material blends that can form a suitable flame and heat shield are not thermoplastic and are significantly different from other thermoplastic components used in the final product. Thus, as the need for products to meet new open flame requirements increases, the possibility of quilting using ultrasonic bonding is lost.

  The blends and resulting fabrics of the present invention are such as to allow ultrasonic adhesive quilting of assemblies that include a flame and thermal barrier fabric. Within the described range of blends, blends comprising at least 40 weight percent PET, or other suitable thermoplastic, are ultrasonically bonded to other materials containing the same or similar minimum 40 percent thermoplastic. It is suitable for doing. One embodiment is a flame and thermal barrier fabric that includes a minimum of 50 weight percent PET, and the other layers of the assembly include at least 50 weight percent PET or similar thermoplastic.

The mattress structure assembly can be produced in many configurations (no inner layer required):
1. The flameproof thermal insulation fabric can be ultrasonically bonded to the outer ticking layer over the entire width of the assembly and at several locations along the entire length.
2. The flameproof thermal insulation fabric can be ultrasonically bonded to the outer ticking layer at several locations only along the edges of the assembly.
3. To add flexibility or depth to the quilted pattern along the plane, a layer of high loft bat called “pop” in the mattress industry is added between the flameproof thermal insulation fabric and ticking From the above, it can be bonded as described in 1 above.
4). To add flexibility along the plane, the layer (s) of high loft bat can be added between the flameproof thermal insulation fabric and the ticking and then bonded as described in 2 above.
5. In the configuration outlined in items 2 and 4, the main body of the barrier cloth does not include an adhesion point, so that the flameproof and heat shield function can be improved. The nature of ultrasonic bonding requires the application of pressure between the horn and the anvil. For this reason, the layers are compressed at their respective points of adhesion, and compression as a result of these points typically results in greater heat transfer through the material, and in some cases, when the material is exposed to an open flame. Carbonization strength is weakened. Where a smooth surface resulting from assembly configurations 2 and 4 is not desired, a high loft vat or other loft fabric is used here where the flameproof thermal insulation fabric is then superposed at some points along the edges of the assembly as an inner layer. Before being sonic bonded, it is taught that it can be ultrasonically bonded directly to the outer ticking layer in the manner described in 1 and 3.
6). A variation of configuration 3 that provides the same or similar effect is possible by layering the flameproof thermal insulation fabric directly onto the ticking layer, and is high before ultrasonic bonding as described in 1 above. The loft bat is stratified on the inside.
7). A variation of configuration 4 that provides the same or similar effect is possible by layering the flame and heat shield fabric directly onto the ticking layer, and is high before ultrasonic bonding as described in 2 above. The loft bat is stratified on the inside.

  Other products used in mattress construction are boundary fabrics, or side fabric materials. For example, satisfactory boundary assemblies for mattresses and / or box springs can be produced in any of the above configurations using good material for rolls of full width up to about 120 inches wide (theoretically, this The width is unlimited: ultrasonic horns and anvils are unlimited because they can be arranged in a modular fashion, but in practice this width is currently available for roll ticking and high loft batts Limited to width as well as currently available support devices). The body quilt pattern is ultrasonically bonded using a series of wide horns applied across the width of the patterned cylinder anvil. Typical widths of the boundary assembly range from about 9 inches to about 14 inches (or more). These individual widths can be ultrasonically slit, and the edges are ultrasonically sealed with a stitch pattern (or other pattern) using a series of in-line or offline horns and slitter / sealing anvils. be able to.

  The fabrics of the present invention are particularly useful because there is no need for comfort at the mattress boundary, which incorporates the padding to provide panel flexibility and loft, the top and bottom of the mattress, i.e. within the panel. In. Thus, at the boundary, the FR fabric is easily incorporated into the ticking, such as by ultrasonic welding, to form its product, which is considered a mattress subassembly that is a complete product.

  An exemplary process setup for an ultrasonic seal uses a 1.1 kW power supply for a 9 inch horn between the width of the cylinder anvil patterned into the desired quilting design within the body of the assembly. After the layer is fed from this part of the process and unwound and placed in this part, if necessary, before flowing through a series of 1 inch diameter horns spaced at the desired width of the boundary assembly Additional layers can be introduced, using a 1.1 kW power supply for each horn, and simultaneously slit and sealed (if necessary). Process variables such as pressure, speed, amplitude, power booster and load vary depending on the type and mass of material used.

  In order to demonstrate the effectiveness of the fabric according to the present invention, a number of fabric samples were exposed to an open fire and tested to determine their respective resistance to fire and related heat, and then the protective ability to the article. Testing of protected articles is often specific to the end use application of the protected article, and testing includes testing the entire article, not as a test of the individual components that make up the article Will be understood. Testing fabrics as components to predict or correlate results in the final article typically varies among article manufacturers. Preliminary tests were performed using various barrier fabrics containing various amorphous silica to binder fiber ratios. As a result of this screening, for use in mattresses, a 40 percent amorphous silica content was determined to be a useful amount because it balances cost with the necessary barrier protection. However, since it is acceptable in terms of cost to produce the fabric, it is also effective to adjust the amount of amorphous silica in other environments (products) with different barrier property requirements. Other such uses are described below.

For the development of the fire and thermal insulation fabric of the present invention for use in the mattress industry, a dedicated test from an independent testing laboratory was used to establish a performance baseline and track its progress against that baseline. The details of the test are kept confidential by an independent laboratory, but it can be clearly seen that this test is based on an open fire that contacts the surface of the fabric over a period of time. After the open flame is removed, the fabric continues to burn until it is completely extinguished. The maximum temperature is measured on the opposite side of the flame over the duration of the test. The mass of the sample is measured before and after exposure to the flame and the mass loss is calculated. The strength of the fabric at the time of exposure can be tested to see if it is retained or carbonized (depending on the application, this can be stretching, puncturing, pyrolysis testing, etc.) . The test results are reported in Table 10 below.

  Although the details of the test are exclusive, the shared results show the performance of the present invention, i.e. amorphous silica blends compared to other flameproof and thermal insulation fabrics when exposed to an open fire. Shows the performance. The “mass per unit area”, “maximum temperature”, and “percent mass loss” values are the average of six test specimens for each blend or product. Tests conducted by independent laboratories established a baseline for the performance of products currently used as fire and heat shield fabrics in the mattress industry ("Current Market Products", Examples Nos. 54-56). Although the results of this test do not directly represent that it correlates with the performance of bedding tested in accordance with the previously described TB603 California Open Fire Standard, these results indicate that the component fabric has excessive mass loss or It is an indicator that can withstand direct flame exposure without causing excessive heat transfer through the fabric.

  What is “excessive” and what is not may vary from mattress manufacturer to manufacturer, but this type of testing is a direct comparison between the candidate fabric and a confirmed component fabric that has been extensively tested on finished bedding. Can be compared. The tested fabrics include 10 examples (Nos. 54-63) of fabrics not covered by the present invention, followed by 11 examples (Nos. 64-74) of fabrics according to the present invention. . Referring to the data in Table 10, it can be seen that using a barrier fabric containing 40% amorphous silica provided an acceptable protective capability compared to the current product. Examples 66 and 67 showed a high percent mass loss, which was attributed to a lower mass per unit area (4.9 and 4.7) compared to other fabrics. Please keep in mind. Further, Example 73 shows both a high maximum temperature and a high mass loss, which is an 8 percent PP fiber, fuel source added to obtain a colored or pigmented fabric. Good, that is, there were complementary fibers that were not “non-inducing” fuel sources.

In view of the foregoing disclosure, it will be understood that possible end uses of the inventive FR fabric in various articles include:
1. Bedding—a barrier that is under the ticking or exposed at the bottom of a single-sided mattress or the top and / or bottom of a box spring. Such boundaries are also products that benefit from the presence of barriers.
2. Furniture—a barrier that is under a furniture quilt or exposed to the underside of furniture or other invisible areas.
3. Transport--a barrier that is under a seat covering or exposed to the underside of the seat or other invisible area. Barriers behind wall coverings or mounted behind or within layers of curtains or thick long curtains. Lining for engines and cargo compartments or areas that require shielding from extreme heat.
4). Futon-layered in blankets, duvets, pillows, etc.
5. Garment-Layered in personal protective clothing for flame and heat insulation. Applications include use as articles such as coats, trousers, gloves and boots in firefighters, military personnel, astronauts, industry, laboratories and the like.
6). Automotive-engine bay linings, pipe wraps, barriers in seats and behind carpets, and upholstered surfaces.
7). Architecture / household / industry-house wrap, inner wall protection layer, fire blanket, storage lining for combustibles, welding curtain, landfill lining, potentially emitting flammable gas, etc. Hot gas filtration, small carpets and carpet linings, pans, and gloves.

  Accordingly, the present invention includes any of the aforementioned products produced by the method of the present invention.

  Thus, it will be apparent that the use of amorphous silica fibers is very effective in achieving FR blends and fabrics. The present invention can be practiced by combining amorphous silica fibers with at least one other flame retardant fiber, or binder fiber, but is necessarily limited thereto. Implementation is not limited to the selection of a particular FR fiber or binder fiber, as long as one or more selected fibers are combined with amorphous silica fibers. The fiber blends of the present invention can be used to produce flame retardant fabrics for a variety of purposes including, but not limited to, barrier fabrics used in comforters, bedding, and futon applications. Furthermore, these woven fabrics are not limited to non-woven fabrics.

  Based on the foregoing disclosure, the use of the fiber blend described herein is novel and provides barrier fabrics and flame retardant fabrics as described herein. Will be clear. Accordingly, obvious modifications are within the scope of the claimed invention, and the selection of particular component elements can be determined without departing from the spirit of the invention disclosed and described herein. Will be understood. Thus, the scope of the present invention is intended to include all modifications and variations that are considered to be within the scope of the appended claims.

The drawing is an exploded view showing the assembly of the tuft button test apparatus.

Claims (19)

A flame retardant (FR) fiber blend:
_SiO 2 from 94 to 96 wt%, 3 to 4 wt% _Al 2 _O 3, from 0.01 to 1.0 wt% _Na 2 O, from 0.01 to 1.0 wt% CoO, and 0.01 To 1.0 % by weight of amorphous silica fibers containing a mixture of SO ₃ ; and
A flame retardant (FR) fiber blend comprising at least one fiber selected from the group consisting of FR fibers, binder fibers, and mixtures thereof. The FR fibers include modacrylic, phosphalane-containing polyester, melamine, meta-aramid, para-aramid, polybenzimidazole, polyimide, polyamideimide, partially oxidized polyacrylonitrile, novoloid, poly (p-phenylenebenzobisoxazole), Coated with poly (p-phenylenebenzothiazole), polyphenylene sulfide, flame retardant viscose rayon, viscose rayon containing aluminosilicate modified silica, cellulose derivative, polyetheretherketone, polyketone, polyetherimide, FR resin The fiber blend according to claim 1 selected from the group consisting of natural or synthetic fibers, and combinations thereof. The fiber blend according to claim 1, wherein the blend comprises at least 5 weight percent amorphous silica fibers based on the total weight of the fibers being blended. The fiber blend of claim 3, wherein the blend comprises 5 to 65 weight percent amorphous silica fibers and 35 to 95 weight percent FR fibers. The fiber blend according to claim 2, comprising amorphous silica fiber, modacrylic fiber, and FR rayon fiber. The fiber blend according to claim 2, comprising amorphous silica fiber, modacrylic fiber, and viscose rayon fiber. The fiber blend according to claim 2, comprising amorphous silica fiber, modacrylic fiber, and cellulosic fiber. The fiber blend according to claim 2, comprising amorphous silica fiber and FR rayon fiber. The fiber blend according to claim 2, comprising amorphous silica fiber, modacrylic fiber, viscose rayon fiber, and FR polypropylene fiber. 2. The fiber blend according to claim 1, wherein the binder fiber is selected from the group consisting of a single component fiber, a multiple component fiber, a multiple component multiple adhesive fiber, and a complementary fiber, and the fiber has a melting temperature of 107 ° C. or higher. 11. The fiber blend of claim 10, wherein the blend includes at least 15 weight percent amorphous silica fibers based on the total weight of the fibers being blended. The blend includes 15 to 80 weight percent amorphous silica fiber, 15 to 85 weight percent binder fiber, and up to 70 weight percent complementary fiber, without dropping below the minimum amount described above. The fiber blend according to claim 11, wherein the two fibers are reduced to a total of 100 weight percent. 13. The fiber blend of claim 12, wherein the blend comprises 15 to 80 weight percent amorphous silica fiber, 15 to 85 weight percent of the single component binder fiber, and at least 15 weight percent of the complementary fiber. The single component binder fibers are low melting point polyethylene terephthalate, polypropylene, polyethylene, low density polyethylene, chain low density polyethylene, polylactic acid, polytrimethylene terephthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6, The fiber blend according to claim 10, selected from the group consisting of 6, nylon 11, nylon 12, and polymethylpentene. The multi-component binder fiber is polyethylene terephthalate, polypropylene, polyethylene, low density polyethylene, chain low density polyethylene, polylactic acid, polytrimethylene terephthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11. The fiber blend of claim 10, comprising a combination coextruded polymer fiber comprising at least two polymers selected from the group consisting of 11, nylon 12, and polymethylpentene. The multi-component, multi-adhesive binder fibers can be concentric sheath / core, eccentric sheath / core, side-by-side or bilateral, pie wedge, hollow sector, sea-island structure, or matrix 11. The fiber blend according to claim 10, wherein the fiber blend is selected from the group consisting of a structure and a mixture thereof, and retains core fibers of substantially the original length after heat bonding. The multi-component multiple adhesive binder fibers are polyethylene terephthalate, polypropylene, polyethylene, low density polyethylene, chain low density polyethylene, polylactic acid, polytrimethylene terephthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6 A co-extruded polymer fiber comprising a combination of at least two polymers selected from the group consisting of nylon 11, nylon 12, and polymethylpentene, wherein the multi-component multi-bonded fiber comprises a low melting polymer and the low melting polymer 17. The fiber blend of claim 16, comprising at least one component comprising a high melting point polymer that remains intact after exposure to sufficient heat to melt. The multi-component multi-adhesive binder fiber comprises a core / sheath bicomponent configuration consisting of a polyethylene terephthalate (PET) core and a low melt temperature PET sheath, wherein the sheath is 60 weight percent individual fibers, The fiber blend according to claim 17, wherein the remaining 40 weight percent. 1 or a plurality of non-FR fibers, fiber blend according to any one of claims 1 to 18.

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