MXPA06010724A - Layered high loft flame resistant batting, articles containing said batting, and processes for making same - Google Patents

Abstract

This invention relates to a high loft flame resistant batting, and an article such as a mattress containing such batting;the batting comprising a base layer and a resilient layer, the base layer comprising 10 to 30 parts by weight heat resistant fibers, 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air to 700 C at a rate of 20 degrees C per minute, and 15 to 25 parts by weight binder material;the resilient layer comprising 0 to 50 parts by weight modacrylic fibers, 50 to 85 parts by weight polyester fiber, and 15 to 25 parts by weight binder material. The base layer comprises 20 to 70 parts by weight and the resilient layer comprises 80 to 30 parts by weight of the batting, based on the total weight of those two layers, and the batting has a total thickness of 1.25 centimeters (0.5 inches) or greater.

Description

MATTRESS OF FIBERS IN LAYERS THAT HAVE ELEVATED SPONJOSITY, AND WHICH IS RESISTANT TO THE FLAME, ARTICLES THAT CONTAIN THE SAME, AND PROCESSES TO MANUFACTURE IT FIELD OF THE INVENTION This invention relates to a mattress of multi-layer, flame resistant and high fluffed fibers, for use in a fire-blocking article such as a mattress and processes for manufacturing the fiber mattress and article methods. that block fire. When burning mattress sets utilizing the high-flux flame resistant fiber mattress of this invention they have a peak heat release rate of less than 200 kilowatts within 30 minutes and a total heat release of less than 25 megajoules within 10 minutes. minutes when tested in accordance with Technical Bulletin 603 of the State of California, as revised in July 2003.

BACKGROUND OF THE INVENTION The State of California has led the action of regulating and reducing the inflammability of mattresses and mattress sets in an attempt to reduce the number of lives lost in homes, hotels, and institutional fires. In particular, the Office of Home Furnishings and Thermal Insulation of the Events Department of Ref .: 175299 Consumer of the State of California published Technical Bulletin 603"Test Requirements and Procedure for Resistance of a Residential Mattress / Box Game to Flame - Open Long "to quantify the performance of the inflammability of mattress sets. Mattresses usually contain a mattress core covered by cushioning material or fiber mattress which in turn is covered with an outer fabric cuticle. Most of the cushioning material or fiber mattress is made of foam or fiber materials that will burn when exposed to an open flame. A useful method of fire-blocking foam cushions, particularly airplane seats, is described in U.S. Patent No. 4,75O, 443 of Blaustein, et al., Wherein three to seven layers of flame-resistant fabrics are used. underneath the seat cover fabric to coat the foam. To the degree required by the flammability test method of the airplane seat, these fire-blocking cushions withstand a jet of flame striking the cushion and prevent the entire cushion from being absorbed by the flame or continuing to burn after the jet. of flame is removed. When applied to mattresses, the use of multiple fire blocking layers - beneath the cutie can add stiffness to restrict the elasticity of the mattress core, affecting overall comfort. Even individual layers of fire blocking fabrics can restrict the fiber mattress materials and affect the cushioning of the mattresses. Therefore, what is desired is a solution that does not require incorporating a layer that blocks additional fire. In particular, what is desired is a fiber mattress material that can also function as a fire blocker for mattresses or upholstery article. Fibers such as para-aramid fibers are very useful in flame retardant fabrics however these fibers have a natural gold color which is present in the fabrics manufactured from substantial quantities of those fibers. It is undesirable for the natural gold color of the para-aramid fabric to completely show the outer skin of the mattresses, which are normally a light color or white-cream, or completely show the fabric covering the outer upholstery of the furniture. Therefore, what is needed is a high high flame resistant fiber mattress incorporating a heat resistant fiber where the color of that heat resistant fiber is masked with other fibers in the mattress of high high flame resistant fibers , while still meeting the resistant requirements. a major flame. PCT publication WO 03/023108 describes a high non-woven high flame barrier for use in mattresses and upholstered furniture. These barriers have very low density, in the range from 5 to 50 kilograms per cubic meter, more preferably 7.5 grams per cubic meter. The preferred high nonwoven high flame barrier comprises a blend of fibers including fibers that are inherently fire resistant and resistant to direct flame shrinkage, and polymer fibers made of halogenated monomers. U.S. Patents Nos. 6,132,476; 6,547,835, and 5,609,950 disclose fabric blends of inherently flame resistant fibers and cellulosic fibers having increased flame resistance; the fabric may contain an additional fire retardant which is added, for example, as an additive in a dyeing step. Due to the low content of inorganic material the flame resistant cellulose fiber described in these references does not retain an adequate percentage of its weight when exposed to high temperatures. U.S. Patent Nos. 6,579,396 and 6,383,623 describe a high temperature insulating material having a density from 1.6 to 48.06 kg / cubic meter (0.1 to 3.0 pounds / cubic foot) made of non-thermoplastic fibers and thermoplastic binder materials. The binder materials are completely melted, and the melted thermoplastic material, presumably under the influence of surface tension, collects non-thermoplastic fibers at the points, forming nodes when cooled, in contrast to the core-shell binding fibers that can agglutinate a number of fibers to the binder fiber along its length and which retains a core of thermoplastic material after heating. U.S. Patent No. 4,199,642 describes an intimate blend of 80 to 98 pnt synthetic polyester down and 2 to 20 pnt synthetic organic filamentous material. The organic filamentous material can be poly (p-phenylene terephthalamide) or flame retardant rayon. U.S. Patent No. 5,578,368 discloses a fire resistant material comprising a mattress of synthetic down fibers and at least one fire resistant layer of aramid fibers.

BRIEF DESCRIPTION OF THE INVENTION This invention relates to a high high flame resistant fiber mattress and an article such as a mattress containing such a fiber mattress; the fiber mattress comprising a base layer and an elastic material, the base layer comprising 10 to 30 parts by weight of heat resistant fibers, 35 to 55 parts by weight of a cellulose fiber that retains at least 10 pnt of its fiber weight when heated in air to 700 C at a rate of 20 degrees C per minute, and 15 to 25 parts by weight of the binder material; the elastic layer comprising 0 to 50 parts by weight of modacrylic fibers, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material. The base layer comprises 20 to 70 parts by weight and the elastic layer comprises 80 to 30 parts by weight of the fiber mattress, based on the total weight of those two layers, and the fiber mattress has a total thickness of 1.25 centimeters. (0.5 inches) or greater. This invention also relates to a process for manufacturing a high high flame resistant fiber mattress, comprising the steps of: a) forming a basecoat fiber blend comprising 10 to 30 parts by weight of heat resistant fibers, 55 parts by weight of a cellulose fiber that retains at least 10 pnt of its fiber weight when heated in air to 700aC at a rate of 20 degrees C per minute, and 15 to 25 parts by weight of binder fibers; (b) forming a fiber blend of elastic layer comprising 0 to 50 parts by weight of. modacrylic fibers, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder fibers; (c) forming a multi-layer fiber mattress having a total thickness of at least 1.25 centimeters (0.5 inches) where one layer contains the base layer fiber mixture and another layer contains the elastic layer fiber mixture; and (d) heating the multi-layer fiber mattress to activate the binder fibers and form a high-fluff fiber mattress. Optionally, a portion of the mattress, of high fluff fibers can be recycled into the layer fiber mixture. base. This invention is further related to a fire-blocking padding incorporating a high-flame-resistant fiber mattress and a method of blocking fire to an article comprising the steps of: a) combining a layer of a. fabric cuticle or upholstery, a mattress made of high fluff fibers > and optionally a stitched backing layer, the high-fluff fiber mattress comprising a base layer comprising 10 to 3O parts by weight of heat-resistant fibers, 35 to 55 parts by weight of a cellulose fiber that retains at least 10% by weight. pnt of its fiber weight when heated in air to 700SC at a rate of 20 degrees C per minute, and 15 to 25 parts by weight of binder material; and an elastic layer comprising 0 to 50 parts by weight of modacrylic fibers, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material; the base layer comprising 20 to 70 parts by weight and the elastic layer comprising 80 to 30 parts by weight of the fiber mattress, based on the total weight of those two layers, the fiber mattress having a total thickness of at least 1.25 centimeters (0.5 inches), b) sew the layers together to form a quilting that blocks fire or upholstery fabric, and c) incorporate the quilting -which blocks fire or upholstery fabric in the article.

DETAILED DESCRIPTION -D? THE INVENTION This invention relates to a high multi-layer high flame resistant fiber mattress, and an article such as a mattress containing such a fiber mattress. The fiber mattress comprises a base layer and an elastic layer that works together to form a material that blocks fire. The base layer comprises 10 to 30 parts by weight of heat resistant fibers, 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air at 700aC at a rate of 20 degrees C per minute, and 15 to 25 parts by weight of the binder material; the elastic layer comprises 0 to 50 parts by weight of modacrylic fibers, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of the binder material. In the multi-layer high fluff fiber mattress, the base layer is present in an amount of 20 to 70 parts by weight and the elastic layer is present in an amount of 80 to 30 parts by weight, based on the total weight of the base and elastic layers. The high-flux multi-layer fiber mattresses of this invention. They have a total thickness of 1.25 centimeters (0.5 inches) or greater. While there is no real limitation on how thick the fiber mattress can be, for many typical applications the thickness of the high-fluff fiber mattress does not need to be greater than 7.6 cm (3 inches), and for many smaller mattress applications than 5 cm (2 inches) - it's very useful. The multi-layer fiber mattresses of this invention also have a preferred basis weight in the range of 2.2 to 3.3 kilograms per square meter (8 to 12 ounces per square yard). Fiber mattresses also have, based on the total weight and thickness of the combined layers, a preferred composite density of 5.3 to 32 kilograms per cubic meter (0.33 to 2.0 pounds per cubic foot). More dense fiber mattresses generally do not have the desired elasticity for use as cushioning in mattresses and other items. Mattresses of fibers that are thinner or less dense than the desired ranges are not intended to provide the desired amount of cushioning. The base layer of the multi-layer high fluff fiber mattress contains 10 to 30 parts by weight of heat resistant fibers, 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when it is heated in air to 700SC at a rate of 20 degrees C per minute, and 15 to 25 parts by weight of the binder material. Preferably, the heat resistant fibers are present in the amount of 20 to 30 parts by weight, the cellulose fibers are present in the amount of 40 to 50 parts by weight. The base layer provides a dense structure that forms a burn and maintains integrity in flame. By "heat resistant fiber" it is meant that the fiber preferably retains 90 percent of its fiber weight when heated in air at 500SC at a rate of 20 degrees C per minute. Such a fiber is normally flame resistant, which means that the fiber or fabric made of the fiber has an Oxygen Limit Index (LOI) such that the fiber or fabric will not support a flame in air, the preferred LOI range being approximately 26 and higher. Preferred fibers do not shrink excessively when exposed to a flame, that is, the length of the fiber will not be shortened significantly when exposed to flame. Fabrics that contain an organic fiber that retains 90 percent of its fiber weight when heated in air to 500SC at a rate of 20 degrees C or minute tend to have limited amount of cracks and openings when burned by an incident flame, which is important for the performance of the fabric as a fire blocker. Stable and heat-resistant fibers useful in the fire-blocking non-woven fabric of this invention include fiber made from para-aramid, polybenzazole, polybenzimidazole, and polyimide polymer. Preferred heat resistant fibers are made of aramid polymer, especially para-aramid polymer. As used herein, "aramid." means a polyamide wherein at least -85% of the amide bonds (-CONH-) are directly attached to two aromatic rings. "Para-aramid" means that the two rings or radicals are for oriented with respect to each other along the molecular chain. The additives can be used with aramid. In fact, it has been found that up to as much as 10 percent, by weight, of another polymeric material can be mixed with the aramid or that copolymers can be used which have as much as 10 percent another diamine substituted for the diamine of the aramid or as much as 10 percent of another diacid chloride substituted by the diacid chloride of aramid. In the practice of this invention, the preferred para-aramid is poly (paraphenylene terephthalamide). Methods for making para-aramid fibers useful in this invention are generally described in, for example, U.S. Patent Nos. 3,869,430, 3,869,429, and 3,767,756. Such aromatic polyamide organic fibers and various forms of these fibers are available from DuPont Company, Wilmington, Delaware under the trademark fibers. Kevlar®. Available polybenzazole fibers • commercially useful in this invention include Zylon® PBO-AS fiber (Poly (p-phenylene-2,6-benzobisoxazole), Zylon® PBO-HM fiber (Poly (p-phenylene-2,6-benzobisoxazole)), available from Toyobo, Japan. Commercially available fibers, polybenzimidazole useful in This invention includes PBI® fiber available from Celanese Acétate LLC Commercially available polyimide fibers useful in this invention include P-84® fiber available from LaPlace Chemical.

The base layer of the multi-layer high fluff fiber mattress also contains 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air at 700 ° C at a rate of 20. degrees C per minute. These fibers are said to be burn-forming. The cellulose fibers used in the compound of this invention are preferably regenerated cellulose fibers having 10 percent inorganic compounds incorporated within the fibers. Such fibers, and methods for making such fibers, are generally described in U.S. Patent No. 3,565,749 and U.S. Patent No. 1,064,271. A preferred burn-regenerated cellulose fiber for this invention is a viscous fiber containing silicon dioxide in the form of a polysilicic acid with aluminum silicate sites. Such fibers, and methods for making such fibers are generally described in U.S. Patent No. 5,417,752 and PCT Patent Application WO 9217629. The viscous fiber containing silicic acid and having approximately 31 (+/- 3) percent of material Inorganic is sold under the trademark Visil® by Sateri € > and Company of Finland. The base layer of the multi-layer high fluff fiber mattress also contains 15 to 25 parts by weight of the binder material. The preferred binder material is a binder fiber which is activated by the application of heat. Such binder fibers are typically manufactured from thermoplastic material flowing at a temperature that is lower (i.e., has a lower softening point) than the softening point of any of the other discontinuous fibers in the fiber blend. Coated / core two-component fibers are preferred as binder fibers, especially bicomponent binder fibers having a polyester homopolymer core and a copolyester shell which is a binder material, such as those commercially available. from Unitika Co., Japan (for example, sold under the registered trademark MELTY®). Useful types of fibers - binders may include those made of polypropylene, polyethylene, or polyester polymers or copolymers, fibers containing only that polymer or copolymer, or as a two-component fiber in side-by-side or shell / core configuration. The elastic layer of the multi-layer high-fluff fiber mattress contains 0 to 50 parts by weight of. modacrylic fibers, 50 to "85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material." The elastic layer preferably functions as the outer layer of the mattress of "high-flux fibers" of multiple layers, providing an elastic structure that is fused as a sacrifice in the flame and optionally, releases gases to suppress the flames. The elastic layer is typically white or clear in color and also preferably protects any coloration of the base layer. The elastic layer contains 50 to 85 parts in weight of polyester fiber to provide elasticity to the multi-layer fiber mattress. If more than 85 parts by weight of polyester fibers are used, it is believed that the fiber mattress becomes too flammable to be used in fire-blocking agents Polyester fibers are well known in the art and can be obtained from many. The preferred fiber-polyester is made from poly (ethylene terephthalate) (PET) polymer., however, they can be used, such as homopolymers, copolymers, terpolymers and mixtures etc., of polyester polymers and monomers of poly (propylene terephthalate), poly (butylene terephthalate), poly (1,4-cyclohexylene-dimethylene) terphthalate) and copolymers and mixtures thereof. One type of PET fiber useful in this invention is commercially available from Invista, Inc. of Wilmington, Delaware under the trademark DACRON® Type 808. Single hole hollow fiber having a linear density of 7.2 dtex / filament (6.5 denier). / filament) that has a cut length of 3.8 c (1.5 inches). The elastic layer also contains 15 to 25 parts by weight of binder material. As in the base layer, the preferred binder material is a binder fiber that is activated by the application of heat. Generally the same binder can be used for both elastic and base layers, however, this is not a requirement. The elastic layer optionally also contains 0 to 50 parts by weight of modacrylic fibers. Modacrylic fiber is useful in this outer layer of the fiber mattress because this fiber releases halogen-containing gases that suppress flames when burned. By modacrylic fiber is meant acrylic synthetic fiber made of a polymer comprising acrylonitrile. Preferably the polymer is a copolymer comprising 30 to 70 weight percent of an acrylonitrile and 70 to 30 weight percent of a vinyl monomer containing halogen. The halogen-containing vinyl monomer is at least one monomer selected, for example, from vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, etc. Examples of copolymerizable vinyl monomers are acrylic acid, methacrylic acid, salts or esters of such acids, acrylamide, methacrylamide, vinyl acetate, etc. The preferred modacrylic fibers used in this invention are acrylonitrile copolymers combined with vinylidene chloride, the copolymer having in addition an antimony oxide or antimony oxides to improve fire retardancy. Such useful modacrylic fibers include, but are not limited to, fibers described in US Patent No. 3,193,602 which have 2 percent by weight of antimony trioxide, the fibers described in US Pat. No. 3,748,302 made of various antimony oxides. which are present in an amount of at least 2 weight percent and preferably not more than 8 weight percent, and the fibers described in US Patent Nos. 5,208,105 and 5,506,042 having from 8 to 40 weight percent of a composed of antimony. Preferred modacrylic fiber Protex C is commercially available from Kaneka Corporation, Japan, which is said to contain 10 to 15 by weight of antimony oxide, despite fibers having less antimony oxide, in the range of 6 percent. in weight or less, they can also be used. In the multi-layer high fluff fiber mattress, the base layer is present in an amount of 20 to 70 parts by weight and the elastic layer is present in an amount of 80 to 30 parts by weight, based on the total weight of the base and elastic layers. Preferably the base layer is present in an amount of 40 to 55 parts by weight and the elastic layer is present in an amount of 60 to 45 parts by weight. This invention also relates to a process for manufacturing a high-high flame resistant fiber mattress, comprising the steps of: a) forming a basecoat fiber blend comprising 10 to 30 parts by weight of heat resistant fibers, to 55 parts by weight of a cellulose fiber - which retains at least 10 percent of its fiber weight when heated in air at 700aC at a rate of 20 degrees C per minute, and 15 to 25 parts by weight of binder fibers; b) forming a blend of elastic layer fiber comprising 0 to 50 parts by weight of modacrylic fibers, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder fibers; c) forming a multi-layer fiber mattress having a total thickness of at least 1.25 centimeters (0.5 inches) where one layer contains the basecoat fiber blend and another layer contains the layer-fiber blend layer; and d) heating the multi-layer fiber mattress to activate the binder fibers and form a mattress of high fluff fibers.

Multilayer fiber and mattress fiber mixtures can be formed by any method that can create low density fabrics. For example, agglomerations of crimped staple fibers and binding fibers obtained from fiber bales that can be opened by a device such as a fuller. Preferably these fibers are staple fibers having 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 / filament) with the linear density range from about 1 to 33 dtex / filament (0.9 to 30 denier / filament) being more preferred. The fibers generally have a cut length of about 1.3 cm to 10.2 cm (0.5 to 4 inches) and a preferred curl frequency of about 2.4 to 5.9 crimps per cm (6 to about 15 crimps / inch). The open fiber mixture can then be mixed by any available method, such as air transport, to form a more uniform mixture. Alternatively, the fibers can be mixed to form a uniform mixture prior to opening the fiber in the fuller. The fiber mixture can then be converted into a fibrous web for use in a device such as a card, although other methods, such as air placement of the fibers can be used. The fibrous web can then be sent via a conveyor to a device such as a transverse web straightener to create a folded structure of high sponginess by placing individual webs on top of another in a zig-zig structure. The fiber opening and cross-sectional velocity is controlled to create cross-stretched structures of high fluffiness of the desired height. Representative processes useful in achieving transversely laid structures, including processes for transverse laying of an air-laying or other veil otherwise formed on a belt or apron, are well known in the art and generally described in U.S. Patent Nos. 3,558,029 to Manns; 3,877,628 to Asselin et al .; 4,984,772 Freund; 6,195,844 to Jourde et al., And British Patent Number 1,527,230 to Jowett. To create a multi-ply high fluff fiber mattress of this invention, two or more high fluff structures having different compositions, preferably the compositions of the above-mentioned base and elastic layers, can be manufactured simultaneously or sequentially and then coated, one over the other, on a conveyor or belt. This multilayer, high-fluff, high-fluff veil mattress is stabilized by applying heat, preferably by use of a heated furnace and preferably without compression of the fiber mattress, to activate the binder material. The mattress of high fluff fibers is then cooled to stabilize the binder material. In the preferred process, the mattress edges of multi-layer high fluff fibers are then cut to provide a fiber mat with a uniform width. The portion of the high-cut fibrous fiber mattress is then recycled into the process, preferably by processing this material through the fuller, which separates the cut edges into individual fibers. This recycled portion contains fibers from both the base and elastic layers, and therefore to maintain the color consistency of the elastic layer, the recycled portion is preferably added to the base layer. However, since the base layer provides integrity to the multi-layer fiber mattress in flame, and the recycled material contains flammable fibers, the amount of the 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, through this recycling process, the base layer can additionally contain polyester fiber in an amount of up to 15 parts by weight and modacrylic fiber in an amount of up to 5 gears by weight of the base layer. This invention also includes a fire-blocking article comprising the multi-layer high-fluff fiber mattress described herein. Preferably, this article is a mattress comprising a cushion panel incorporating the high fluff veil fiber mattress of this invention. The mattress padding panel can be formed by combining layers of cuticle fabric, one or more layers of the multi-layer high fluff mattress of this invention, optionally foam, and if desired, a grid backing, which is used on he . side of the mattress padding that will be oriented to the interior of the mattress. The cuti fabric is usually a very durable woven or knitted fabric using any number of ligaments and tends to have base weights in the range of 68 to 271 grams per meter. square (2 to 8 ounces per square yard). Typical cuti fabrics may contain but are not limited to cotton, polyester fibers, or rayon fibers. The foam is typically a polyurethane foam. The grid backing is generally a layer of a non-woven fabric of 0.14 to 0.28 kg / m2 (0.5-1 oz / yd2) (generally non-woven fabric made of fused filaments). The layers of the mattress padding panel can be securely joined together by sewing lines with thread.

The multi-ply high fluff fiber mattress of this invention can be incorporated into mattresses, bases, and / or box springs as a fire-blocking layer. For example, the panels and edges of mattresses, bases, and / or box springs may use the previously described mattress padding or any other variant that incorporates as a component the multi-layer high fluffness mattress of this invention. . The seam can be sewn with non-flame retardant yarn, however, a fire retardant yarn, such as one made of Kevlar® aramid fiber, is preferred for sewing, especially for sewing the edges of the mattress, base, and / or box springs. This invention additionally relates to a method for blocking fire to an article, comprising the steps of: a) combining a layer of a cuti fabric or upholstery, and a mattress of high fluff fibers, and optionally a back-stitched backing layer , the high-fluff fiber mattress comprising a base layer comprising 10 to 30 parts by weight of heat-resistant fibers, 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when it is heated in air at 70 SC at a rate of 20 degrees C per minute, and 15 to 25 parts by weight of binder material; and an elastic layer comprising 0 to 50 parts by weight of modacrylic fibers, 50 to 85 parts by weight of polyester fiber, and 15 to 25 parts by weight of binder material; the base layer comprising 20 to 70 parts by weight and the elastic layer comprising 80 to 30 parts by weight of the fiber mattress, based on the total weight of those two layers, the fiber mattress having a total thickness of at least 1.25. centimeters (0.5 inches), b) sew the layers together to form a quilting that blocks fire or upholstery fabric, or e) incorporate the quilting that blocks fire or upholstery fabric in the article.

METHODS OF TEST ThermoGravimetric Analysis. The fibers used in this invention retain a portion of their fiber weight when heated at a high temperature at a specific heating rate. This fiber weight was measured using a Thermogravimetric Analyzer (TGA) Model 2950 available from TA Instruments- (a division of Waters Corporation) of Newark, Delaware. The TGA provides an oration of the weight loss of the sample against the increased temperature. Using the Universal TA Analysis program, the loss of weight percentage can be measured at any recorded temperature. The temperature profile consists of balancing the sample at 50 degrees C; bringing the temperature from 10 or 20 degrees C per minute from 50 to 1000 C; using air as the gas, provided at 10 ml / minute; and using a 500 microliter ceramic cup sample container (PN 952018910). The sample procedure is as follows. The TGA was programmed using the TGA screen on the TA System Controller 2900. The sample ID was entered and the planned temperature increase program of 20 degrees was selected. The empty sample cup was tapped using the tare function of the instrument.-The fiber sample was cut to approximately 1/16"and the sample tray was poorly filled with the sample. be in the range of 10 to 50 mg.The TGA has a balance so the exact weight does not have to be determined in advance.None of the sample should be off the tray.The full sample tray was loaded onto the cable. the balance making sure that the thermocouple is close to the top edge of the tray but not touching it The oven rises over the tray and starts the TGA Once the program is complete, the TGA will automatically lower the oven, remove the tray from shows, and will go to a cooling mode.The TA Systems 2900 Universal Analysis program is then used to analyze and produce the TGA scan for the percentage loss in weight over the temperature range. The fiber content can be measured using ASTM D5736-95 (Reapproved 2001). - Performance of Mattress Burn. The Office of Home Furnishings and Thermal Insulation of the California Department of Consumer Affairs (3485 Orange Grove Avenue, North Highlands, California 95660-5595, USA) published Technical Bulletin 603"Requirements and Test Procedure for Resistance of a Residential Mattress / Box Spring Game to a Long Open Flame" dated February 2003 to quantify the flammability performance of games of mattress. The bulletin was later revised in July 2003, requiring that the Peak Heat Release (PR) limit be less than 200 kilowatts and the Total Heat release limit in 10 minutes be less than 25 megajoules . This protocol provides a means of determining the burn behavior of mattress / base sets by measuring the specific fire test responses when the mattress plus base is exposed to a specified flame ignition source under well-ventilated conditions. This is based on the National Institute of Standards and Technology Publication entitled "Test Protocol for Mattress Sets / Base Using a Pair of Gas Burners" dated February 2003. Test data describing burn during and subsequent to the application- of a specific pair of gas burners from the point of ignition until (1) all the burning of the sleeping set has finished, (2) a period of 30 minutes has elapsed, or (3) discharge of the fourth Test seems inevitable. The rate of heat release of the burn test specimen (the energy generated by the fire) is measured by oxygen consumption calorimetry. A discussion of the principles, limitations, and requirement instrumentation is found in ASTM E 1590"Standard Mattress Fire Test Test Method". Terminology associated with the test is defined in ASTM E 176"Standard Fire Standard Terminology". In general, the test protocol uses a pair of propane burners, designed to mimic the levels of heat flow and durations imposed on a mattress and base by burning bedding. The burners impose different flows during different times on the top of the mattress and the mattress / base side. During and subsequent to this exposure, measurements are made of the time-dependent heat release rate of the test specimen.

The mattress / base is placed on top of a short bed structure that sits on a grip surface. During the test, the smoke plume is captured by a hood that is instrumented to measure the rate of heat release. For practicality, mattresses and individual size bases were tested. After ignition by the burners, the specimen was allowed to burn freely under well ventilated conditions. The test specimen includes a mattress that is placed over. the base with the. set of T-shaped burners to burn the specimen. A burner incurs flame on the upper surface of the mattress and is fixed 39 mm from the surface of the mattress. The second burner incites flame vertically on the side of the mattress / base combination and is fixed at 42 mm from the side of the specimen. The side burner and the top burner are not fixed in the same place along the length of the specimen but are offset from another along the length approximately 18 to 20 cm. The burners "are specially constructed and aligned by the test method. The test specimen is conditioned for 24 hours prior to the test at an ambient temperature of about 12 Celsius (54 Fahrenheit) and a relative humidity of less than 70 percent. The mattress and base test specimen centers on each other and the frame and grip surface.

If the mattress is 1 to 2 cm narrower than the base, the mattress can run until the sides of the mattress and base are aligned vertically. The burners are aligned and spaced from the specimen by the standard. The recording of data and recording devices in the log are turned on for at least one minute before ignition. The burners ignite and the upper burner is allowed to burn for 70 seconds while the side burner is allowed to burn for 50 seconds (if possible) and then these are removed from the area. Data collection continues until all signs of burning and incandescence have ceased or until one hour has elapsed. EXAMPLE A two-layer high sponge fiber mattress having a base layer and an elastic layer was made, the fibers in both layers being held in place by the use of a PET-coated binder fiber / PET copolymer core having a softening temperature of 120SC. Conventional carding machines / garnet and cross-vein machines were used to 'open and mix the fibers and form the individual high-fluff padding layers, which were combined together and stabilized with heat using a gas-fired oven. high fluff fibers after it was cooled. A portion of the high-fluff fiber mattress was recycled into the cards and the fibers of this recycled portion became part of the base layer. The basecoat, excluding the recycled material, contained Type 970 Kevlar® aramid fiber (available from DuPont) having a single filament denier of 2.2 dpf and an average cut length of 5.08 cm (2"), Type 33AP Visil® cellulose fiber. (available from Sateri) having a single filament denier of 3.5 dpf and an average cut length of 50 mm, and the binder fiber (available from Nan Ya) having a single filament denier of 4 dpf and an average cut length 51 mm layer had PET polyester fiber (available from KG) having a single filament denier of 15 dpf and an average cut length of 64 mm, modacrylic fiber Protex C (available from Kaneka) having a denier of individual filament of 7 dpf and an average cutting length of 51 mm, and the same binder fiber as the base layer.The test articles, proportion of fiber mixture by weight, basis weight for the base layer and top layer are shown in the table. The articles had a thickness in the range of approximately 2.5 to 3.8 cm (1 to 1.5 inches).

TABLE Recycle composition - 20% binder, 15% Kevlar®, 25% Modacrylic, 15% PET The high-flux fiber mattresses were then tested by the TB 603 open flame test protocol on mattresses with single and double sides. Four individual side mattresses were prepared to test them. Two of the mattresses incorporated Item # 1 under the cuti on the top panel and two of the mattresses incorporated Item # 3 under the cuti on the top panel. The mattress edges of the four mattresses used a fabric comprised of two layers of fabric using a weaving process such as a fire blocker; One layer using a weaving process had a basis weight of 0.687 kg / m2 (2.5 oz / yd2) and was comprised of a blend of 50% / 50% Kevlar® aramid fiber and Visil® cellulose fiber. The other layer using a weaving process had a basis weight of 4.0 oz / yd2 and was comprised of a blend of Visil® fiber 33% / 67% and modacrylic fiber Protex C. This same fire blocker was used at the edges of the base. The fire blocker that was used on the base panel was a single layer using a weaving process that has a basis weight of 4.0 oz / yd2 and was comprised of a blend of 25% / 75% Kevlar® aramid fiber and Visil cellulose fiber ®. Four double-sized mattresses were also prepared to test them. These were prepared in the same way as individual side mattresses with the exceptions that Article # 1 was incorporated into two of the mattresses and Article # 4 was incorporated into two of the mattresses, and, since these were double-sided mattresses, multi-layer high-flux fiber mattresses were incorporated into both mattress panels. All the other materials were the same. When tested, all mattress sets had a peak heat release rate of less than 200 kilowatts within 30 minutes and a total heat release of less than 25 megajoules within 10 minutes when stolen in accordance with the Technical Bulletin 603 from the State of California, as revised July 2-003. It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims (9)

1. CLAIMS Having described the invention as above, the content of the following claims is claimed as property: 1. A flame-resistant fiber mattress with high sponginess, characterized in that it comprises: (a) a base layer comprising (i) 10 to 30 parts by weight of the heat-resistant fibers, (ii) 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air at 700 ° C at a rate of 20 degrees C per minute, and (iii) 15 to 25 parts by weight of the binder material; (b) an elastic layer comprising (i) 0 50 parts by weight of modacrylic fibers, (ii) 50 to 85 parts by weight of polyester fiber, and (iii) 15 to 25 parts by weight of the binder material; the base layer comprising 20 to 70 parts by weight and the elastic layer comprising 80 to 30 parts by weight of the fiber mattress, based on the total weight of those two layers, the fiber mattress having a total thickness of 1.25 centimeters (0.5 inches) or greater.
2. 2. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the heat-resistant fiber is an organic fiber that retains 90 percent of its fiber weight when heated in air at 500SC at a speed of 20 degrees C per minute.
3. 3. The flame-resistant fiber mattress with high fluff in accordance with claim 2, characterized in that the heat resistant fiber comprises a para-aramid polymer, polybenzazole, polybenzimidazole, or polyimide.
4. 4. The flame-resistant fiber mattress with high fluff in accordance with claim 3, characterized in that the para-aramid is poly (paraphenylene terephthalamide). 5. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the cellulose fiber is a viscous fiber containing silicic acid. 6. The flame-resistant fiber mattress with high fluffiness according to claim 1, characterized in that it has a total compound density of
5. 5. 25 to 32.03 grams per liter (0.33 to 2.0 pounds per cubic foot). 7. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that it has a basis in weight of 0.29 to 0.43 liters per square meter (8 to 12 ounces per square yard). 8. The flame-resistant fiber mattress with high fluffiness according to claim 1, characterized in that the modacrylic fibers are present in the elastic layer in the amount of 20 to 50 parts by weight. 9. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the polyester fibers are present in the elastic layer in the amount of 30 to 60 parts by weight. 10. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the heat resistant fibers are present in the base layer in the amount of 20 to 30 parts by weight. 11. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the cellulose fibers are present in the base layer in the amount of 40 to 50 parts by weight. 12. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the base layer additionally contains polyester fibers in the amount of up to 15 parts by weight. 13. The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the base layer additionally contains modacrylic fibers in the amount of up to 5 parts by weight. 1 . The flame-resistant fiber mattress with high fluff in accordance with claim 1, characterized in that the binder material is a binder fiber. 15. An article characterized in that it comprises the flame-resistant fiber mattress with high sponginess in accordance with claim 1, like a layer that blocks fire. 1
6. 6. A mattress characterized in that it comprises the flame-resistant fiber mattress with high fluff in accordance with claim 1, as a fire-blocking layer. 1
7. 7. A process for manufacturing a high-flux flame-resistant fiber mattress characterized in that it comprises the steps of: a) forming a basecoat fiber blend comprising (i) 10 to 30 parts by weight of heat-resistant fibers, ( ii) 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air to 700 C at a rate of 20 degrees C per minute, and (iii) 15 to 25 parts by weight of binder fibers; b) forming a fiber blend of elastic layer comprising (i) 0 to 50 parts by weight of modacrylic fibers, (ii) 50 to 85 parts by weight of polyester fiber, and (iii) 15 to 25 parts by weight of binder fibers. c) forming a multi-layer fiber mattress having a total thickness of at least 1.25 centimeters (0.5 inches), wherein one layer contains the base layer fiber mixture and another layer contains the elastic layer fiber mixture; and d) heating the multi-layer fiber mattress to activate the binder fibers and form a high-fluff fiber mattress. The process according to claim 17, characterized in that the basecoat fiber mixture is present in the multi-layer fiber mattress in an amount of 20 to 70 parts by weight of the total weight of the high-fluff fiber mattress . The process according to claim 17, characterized in that the elastic layer fiber blend is present in the multi-layer fiber mattress in an amount of 80 to 30 parts by weight of the total weight of the high-fluff fiber mattress . The process according to claim 17, characterized in that the multi-layer fiber mattress is formed by first forming the separate webs of the base layer fiber blend and the elastic layer fiber blend and then placing the webs on the base layer. top of each. The process according to claim 17, characterized in that it comprises the additional step: a) recycling a portion of the high-fluff fiber mattress where the fibers of the recycled portion become part of the basecoat fiber blend. 22. The process according to claim 21, characterized in that the recycled fibers comprise no more than 25 parts by weight of the basecoat fiber blend. 23. A fire blocking pad characterized in that it comprises an outer fabric ply or cover fabric layer, one or more layers of a multilayer high-flux flame-resistant fiber mattress, and optionally a stitched backing layer; wherein the high-fluff fiber mattress comprises a base layer comprising (i) 10 to 30 parts by weight of the heat-resistant fibers, (ii) 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air at 700aC at a rate of 20 degrees C per minute, and (iii) 15 to 25 parts by weight of the binder material; and an elastic layer comprising (i) 0 50 parts by weight of modacrylic fibers, (ii) 50 to 85 parts by weight of polyester fiber, and (iii) 15 to 25 parts by weight of the binder material; the base layer comprising 20 to 70 parts by weight and the elastic layer comprising 80 to 30 parts by weight of the padding, based on the total weight of those two layers, the fiber mattress having a total thickness of at least 1.25 centimeters (0.5 inches). 24. A method for blocking fire to an article, characterized in that it comprises the steps of a) combining a layer of a cuti fabric or upholstery, and a mattress of high fluff fibers, and optionally a back-stitched backing layer, the mattress of high fluff fibers comprising a base layer comprising (i) 10 to 30 parts by weight of the heat resistant fibers, (ii) 35 to 55 parts by weight of a cellulose fiber that retains at least 10 percent of its weight of fiber when heated in air at 7002C at a rate of 20 degrees C per minute, and (iii) 15 to 25 parts by weight of the binder material; and an elastic layer comprising (i) 0 50 parts by weight of modacrylic fibers, (ii) 50 to 85 parts by weight of polyester fiber, and (iii) 15 to 25 parts by weight of the binder material; the base layer comprising 20 to 70 parts by weight and the elastic layer comprising 80 to 30 parts by weight of the fiber mattress, based on the total weight of those two layers, the fiber mattress having a total thickness of at least 1.25 centimeters (0.5 inches). b) sew the layers together to form a quilting that blocks fire or upholstery fabric, and c) incorporate the quilting that blocks fire or upholstery fabric within the article. 25. The process according to claim 23, characterized in that the article is a mattress.