Classifications

• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
  • D02G3/443—Heat-resistant, fireproof or flame-retardant yarns or threads
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
  • D04B1/16—Other fabrics or articles characterised primarily by the use of particular thread materials synthetic threads
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
  • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/04—Heat-responsive characteristics
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2503/00—Domestic or personal
  • D10B2503/06—Bed linen
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
  • Y10T442/425—Including strand which is of specific structural definition
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
  • Y10T442/45—Knit fabric is characterized by a particular or differential knit pattern other than open knit fabric or a fabric in which the strand denier is specified

Definitions

• the invention relates to the use of a flame resistant knit tube, made with either a seamless or seamed circular knit or a seamed or tubular warp knit fabric, used to protect a mattress, foundation, upholstery cushion, pillow, office panel, transportation seat or any other article requiring flame resistant protection.
• a tubular knit fabric is formed utilizing flame resistant yarn and then optionally heat-set to prevent curling during subsequent cuffing and processing. Heatsetting the knit fabric is especially preferred for circular knit constructions to prevent curling in subsequent processing.
• the knit tube is then cut to the length of the article to be flame protected, allowing enough additional length to sew a pocket closure on one end and a standard closure on the other end.
• one end of the tubular knit sock is sewn with a pocket closure seam, using a flame resistant thread or a suitable substitute.
• the open end of the tubular knit sock is then rolled up to the sewn pocket closure end so that it can be easily positioned over the article to be protected from flame.
• the rolled up knit sock is then unrolled down the length of the article to be flame protected.
• the second closure seam is then sewn with flame resistant thread, or a suitable substitute, over the open end of the article to completely encapsulate and protect the article.
• the invention has particular applicability in the formation of fire resistant foam mattresses and foundations that require passage of large open flame tests such as California's Test Bulletin 603 and Test Bulletin 129 and in the formation of fire resistant foam upholstery cushions that require passage of California's Test Bulletin 133 or British Standard 5852 using the crib 5 ignition source.
• FR chemically treated fabrics will self-extinguish and exhibit limited melt behavior when a flame is removed, they typically form brittle chars, shrink and crack open after exposure to a direct flame allowing the underlying materials to ignite.
• fabrics made with FR treated cotton, FR polyester and other FR treated fabrics are used in composite articles such as upholstered furniture and mattresses and foundations, these composite article are usually deemed unsuited for passing the more stringent open flame tests such as: California Test Bulletin 133 (TB 133), California Test Bulletin 129 “Flammability Test Procedure for Mattresses for use in Public Buildings”, October 1992 (TB 129), California Test Bulletin 603 (TB603), and British Standard 5852—Crib 5 (BS5 852) without the use of an additional flame barrier or FR backcoating materials.
• Some of the flame barrier fabrics currently being used with the goal to pass the more stringent open flame tests, such as TB 129, TB 133 and TB603 include:
• the term “flame barrier” means a product incorporated into or on top of a composite article that when tested with a composite type test method, such as: California Test Bulletin 129 (TB 129) or California Test Bulletin 603 (TB603) for mattresses and foundations and California Test Bulletin 133 (TB 133) for upholstered furniture, the flame barrier allows for the continued use of conventional materials such as dress cover fabrics, fiber-fillings and polyurethane foams, while still passing these stringent large open flame tests.
• flame bafflers made of the tubular knit flame barriers described in this invention can be made to pass less stringent open flame tests such California's Revised Test Bulletin 117 (TB 117—draft 02/02 version) and British Standard 5852.
• a fire resistant yarn is converted to a circular or warp knit fabric.
• the fire resistant yams include open-end, ring, air-jet, corespun or other spun yarn types; where the staple fibers in the yarn are selected so that the blended fibers have a Limiting Oxygen Index (LOI) of at least 22 (as measured by ASTM D 2863).
• LOI Limiting Oxygen Index
• the staple fibers selected for blending consist of one or more fiber types selected from the following two categories:
• melamine i.e. BASOFIL by Basofil Fibers LLC
• meta-aramids such as poly (m-phenylene isophthalamide), for example, those sold under the tradenames NOMEX by E. I. Du Pont de Nemours and Co., TEIJINCONEX by Teijin Limited and FENYLENE by Russian State Complex
• para-aramids such as poly (p-phenylene terephthalamide), for example, that sold under the tradename KEVLAR by E. I.
• polyamideimides for example, that sold under the tradename KERMEL by Argos Soditic
• partially oxidized polyacrylonitriles for example, those sold under the tradenames FORTAFIL OPF by Fortafil Fibers Inc., AVOX by Textron Inc., PYRON by Zoltek Corp., PANOX by SGLtechnik, THORNEL by American Fibers and Fabrics and PYROMEX by Toho Rayon Corp.
• novoloids for example, phenol-formaldehyde novolac, for example, that sold under the tradename KYNOL by Gun Ei Chemical Industry Co.
• poly (p-phenylene benzobisoxazole) (PBO) for example, that sold under the tradename ZYLON by Toyobo Co.
• poly (p-phenylene benzothiazoles) PBT
• polyphenylene sulfide for example, those sold under the tradenames RYTON by American
• E-CTFE poly (ethylene-chlorotrifluoroethylene)
• PVDF polyvinylidene fluoride
• PVDF polyvinylidene fluoride
• PLA polyperfluoroalkoxy
• Non-flame-retardant fibers such as:
• a flame resistant yarn with a cotton count between 2's to 50's is produced with fibers selected from the above group and according to the Limiting Oxygen Index criteria described above.
• the flame resistant yarn is knitted into a circular or warp construction.
• a non-limiting list of specific knitting constructions that are applicable to this invention include; simplex tricot, double needle bar tricot, V bed, rib, interlock, double knit and jersey.
• Jersey knit constructions, that do not have seams and are suitable for this invention, can be made with flame resistant yarns that are converted into 6.5 ounces per square yard fabrics on knitting machines with diameters from 9 inches to 60 inches.
• the tubular jersey knit can then be heat-set to produce finished widths with controlled stretch. This is especially preferred for jersey, and other circular knits, that tend to curl when they are cut.
• the fabric must be seamed with flame resistant thread, or a suitable substitute, to form a knit tube.
• the knit tube is then cut to the length of the article to be flame protected, allowing enough additional length to sew a closure seams to both ends of the tubular knit sock.
• one end of the tubular knit sock is sewn with a pocket closure seam, using a flame resistant thread.
• the open end of the sewn tubular knit sock is rolled up to the pocket closure end so that it can be easily positioned over the article to be protected from flame.
• the rolled up knit tube sock is then unrolled down the length of the article to be flame protected.
• a second closure seam is then sewn with a flame resistant thread, or a suitable substitute, over the open end of the article to completely encapsulate and flame protect the article.
• This invention has particular applicability in the formation of fire resistant foam mattresses and foundations that require passage of large open flame tests such as California's Test Bulletin 603 and Test Bulletin 129 and in the formation of fire resistant foam upholstery cushions that require passage of California's Test Bulletin 133 or British Standard 5852, crib 5.
• a flame resistant corespun yarn (ALES SANDRA, by McKinnon Land LLC) is produced on a Murata air-jet spinning frame, consisting of a dual core of continuous filament fiberglass and continuous nylon yarn wrapped with a triblend sliver of modacrylic (PROTEX PBX), melamine (BASOFIL) and polyester staple fibers to form a corespun yarn with a yarn count of 15.5's.
• ALES SANDRA by McKinnon Land LLC
• a Murata air-jet spinning frame consisting of a dual core of continuous filament fiberglass and continuous nylon yarn wrapped with a triblend sliver of modacrylic (PROTEX PBX), melamine (BASOFIL) and polyester staple fibers to form a corespun yarn with a yarn count of 15.5's.
• the above formed corespun yarn is then knitted into a 6.95 ounce per square yard 1 ⁇ 1 rib knit construction and seamed together with p-aramid (Kevlar) thread to form a tubular shape.
• the tubular knit sock is then cut to the length necessary to cover a 7′′ thick all-foam twin size mattress, consisting of a 4′′ base of standard polyurethane foam and a 3′′ top layer of viscoelastic polyurethane foam and both ends of the mattress.
• One end of the tubular knit sock is seamed together with p-aramid (KEVLAR) thread to form a pocket closure seam.
• the knit tube sock is rolled up from the open end to the pocket closure end and placed on one end of the all-foam mattress.
• the knit tube sock is then rolled down the all-foam mattress and the open end is then sewn closed with p-aramid (KEVLAR) thread.
• a flame resistant corespun yarn (ALES SANDRA, by McKinnon Land LLC) is produced on a Murata air-jet spinning frame, consisting of a dual core of continuous filament fiberglass and continuous nylon yarn wrapped with a triblend sliver of modacrylic (PROTEX PBX), melamine (BASOFIL) and polyester staple fibers to form a corespun yarn with a yarn count of 15.5's.
• ALES SANDRA by McKinnon Land LLC
• a Murata air-jet spinning frame consisting of a dual core of continuous filament fiberglass and continuous nylon yarn wrapped with a triblend sliver of modacrylic (PROTEX PBX), melamine (BASOFIL) and polyester staple fibers to form a corespun yarn with a yarn count of 15.5's.
• the above formed corespun yarn is then knitted into a jersey knit fabric of 6.5 ounces per square yard on a 33 inch diameter knitting machines to produce a tubular fabric without a seam.
• the knit fabric is then heat-set to produce a roll of tubular fabric with controlled stretch that has minimum curl after cutting.
• tubular knit sock is then cut to the length necessary to cover a 7′′ thick all-foam twin size mattress, consisting of a 4′′ base of standard polyurethane foam and a 3′′ top layer of viscoelastic polyurethane foam and both ends of the mattress.
• One end of the tubular knit sock is seamed together with p-aramid (KEVLAR) thread to form a pocket closure seam.
• the knit tube sock is rolled up from the open end to the pocket closure end and placed on one end of the all-foam mattress.
• the knit tube sock is then rolled down the all-foam mattress and the open end is then sewn closed with p-aramid (KEVLAR) thread.

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Citations (23)

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• 2005
  • 2005-09-07 CA CA 2579178 patent/CA2579178A1/fr not_active Abandoned
  • 2005-09-07 US US11/219,881 patent/US20060160451A1/en not_active Abandoned
  • 2005-09-07 EP EP05794272A patent/EP1789621A2/fr not_active Withdrawn
  • 2005-09-07 MX MX2007002587A patent/MX2007002587A/es unknown
  • 2005-09-07 WO PCT/US2005/031538 patent/WO2006029077A2/fr active Application Filing

Patent Citations (24)

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