US20210292936A1 - Flame resistant knit fabric - Google Patents

Flame resistant knit fabric Download PDF

Info

Publication number
US20210292936A1
US20210292936A1 US17/174,264 US202117174264A US2021292936A1 US 20210292936 A1 US20210292936 A1 US 20210292936A1 US 202117174264 A US202117174264 A US 202117174264A US 2021292936 A1 US2021292936 A1 US 2021292936A1
Authority
US
United States
Prior art keywords
yarns
flame resistant
knit
weft
weft yarn
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US17/174,264
Other languages
English (en)
Inventor
John W. Ringo, JR.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Milliken and Co
Original Assignee
Milliken and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Milliken and Co filed Critical Milliken and Co
Priority to US17/174,264 priority Critical patent/US20210292936A1/en
Assigned to MILLIKEN & COMPANY reassignment MILLIKEN & COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RINGO, JOHN W.
Publication of US20210292936A1 publication Critical patent/US20210292936A1/en
Abandoned legal-status Critical Current

Links

Images

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
    • D04B1/10—Patterned fabrics or articles
    • D04B1/102—Patterned fabrics or articles with stitch pattern
    • 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
    • D04B1/10—Patterned fabrics or articles
    • D04B1/12—Patterned fabrics or articles characterised by thread material
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
    • D06M11/79—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof with silicon dioxide, silicic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
    • D06M2200/30—Flame or heat resistance, fire retardancy properties
    • 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
    • D10B2505/00—Industrial
    • D10B2505/08—Upholstery, mattresses

Definitions

  • the present invention generally relates to flame resistant knit fabrics for use as coverings for support articles such as mattresses.
  • a flame resistant knit fabric having a first weft yarn set and a second weft yarn set.
  • the first weft yarn set contains flame resistant yarns and the second weft yarn set contains second weft yarns.
  • the knit fabric is knitted such that the first weft yarns are interlinked with one another by a plurality of knit stitches, the second weft yarns are interlinked with one another by a plurality of knit stitches, and the first weft yarns are not interlinked with the second weft yarns.
  • a flame resistant support article containing the flame resistant knit fabric as well as methods for making the knit fabric and support article are also disclosed.
  • FIGS. 1 and 2 illustrate schematically exemplary flame resistant knit fabrics.
  • FIG. 3 is a micrograph of the outer surface of one exemplary flame resistant knit fabric.
  • FIG. 4 is a micrograph of the inner surface of one exemplary flame resistant knit fabric.
  • FIG. 5 illustrates schematically the exemplary flame resistant fabric after burning.
  • FIG. 6 illustrates schematically one embodiment of a flame resistant support article being a mattress.
  • Fiber resistant in this application means a material that provides a thermal barrier and reduces body burn as described in NFPA 1971 and allows the user time to escape the flames and/or fire. Such a fiber, yarn, fabric, or article would preferably resist ignition and be self-extinguishing.
  • 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: CPSC (Consumer Product Safety Council) CFR 1633, 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.
  • CPSC Consumer Product Safety Council
  • 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.
  • the flame resistant knit fabric may be formed in any suitable manner and pattern.
  • the knit fabric is a tubular fabric, and in another embodiment, the knit fabric is a circular knit. These knits are advantageous for use as a barrier material for support articles such as mattresses as the knit would only require two seams to enclose the mattress.
  • the knit fabric 10 contains a first weft yarn set and a second weft yarn set.
  • the first weft yarn comprises first weft yarns 100 being flame resistant yarns.
  • the second weft yarn set comprises second weft yarns 200 .
  • the knit fabric is knitted such that the first weft yarns are interlinked with one another by a plurality of knit stitches and the second weft yarns are interlinked with one another by a plurality of knit stitches. The first weft yarns and the second weft yarns are not interlinked.
  • the first weft yarn set has a repeating pattern of a knit stitch on a first needle and a welt on a second needle.
  • a welt is also referred to as weft, miss, or float stitch. This stitch is created by not allowing the needle to raise high enough to receive a new yarn, causing the yarn to float behind the face stitches.
  • the second weft yarn set has the same repeating pattern of stitches by offset from the first weft yarn set by one course so that its repeating pattern would be a welt on a first needle and a knit stitch on a second needle.
  • Suitable patterns include a knit stitch, a welt, and a welt or a knit stitch, a knit stitch, and a welt. Any combination and repeat pattern of knit stitches, tuck stitches, welts, and any other stitch may be used in the first and/or second weft yarn sets so long as the first weft yarn set is interlinked.
  • the second weft yarns are interlinked with one another by a plurality of knit stitches and the first weft yarns and the second weft yarns are not interlinked.
  • the first weft yarns 100 of the first weft yarn set are flame resistant yarns. These may be any suitable flame resistant yarn including inherently flame resistant yarns and chemically treated flame resistant yarns.
  • the flame resistant yarns comprise continuous filament silica fibers also referred to as fiberglass fibers.
  • the flame resistant yarns can be flame resistant core spun yarns which has a core of a typically flame resistant material surrounded by at least one sheath of other fibers/yarns. More information on the core spun yarns and the method of making the yarns may be found in U.S. Pat. No. 6,410,140 (Land et al.), which is incorporated herein in its entirety.
  • the size of the product yarn will vary depending on the final application of the yarn and the particular fabric characteristics desired but is preferably within the range of from about 30/1 to 1/1 conventional cotton count, preferably from about 21/1 to 5/1 conventional cotton count for one embodiment.
  • the second weft yarns 200 of the second weft yarn set may be any suitable yarn.
  • the second weft yarns 200 are flame resistant spun yarns.
  • the second weft yarns do not contain continuous fibers such as monofilament or multifilament fibers.
  • the second weft yarns do not contain fiberglass.
  • the second weft yarns comprise monofilament or multifilament fibers.
  • the second weft yarns 200 are formed from a blend of at least two of the following: fire resistant rayon, modacrylic, and cotton, polyester staple fibers. When exposed to flame, the second weft yarns may melt and/or degrade.
  • the second weft yarn set comprises an alternating arrangement of an A yarn 201 and a B yarn 203 .
  • These yarns are alternated in the set preferably in a 1:1 alternating pattern (but the pattern could also be 2:2, 1:2, 2:1, or other suitable ratio and pattern).
  • the A yarn comprises a blend of polyester and flame resistant rayon fibers.
  • the A yarn consists essentially of (being defined as the yarn contains at least 97% by weigh) a blend of polyester and flame resistant rayon fibers.
  • all of the fibers in the A yarns are staple yarns.
  • the B yarn comprises a blend of cotton and modacrylic fibers.
  • the A yarn consists essentially of (being defined as the yarn contains at least 97% by weigh) a blend of cotton and modacrylic fibers.
  • all of the fibers in the B yarns are staple yarns.
  • the flame resistant knit fabric has an upper surface and a lower surface (thought the upper and lower surfaces can be reversed and do not indicate the orientation that the fabric is used in a finished article), wherein the majority of the upper surface comprises the first weft yarns and the majority of the lower surface comprises the second weft yarns.
  • Majority means greater than 50% by weight.
  • FIG. 3 is a micrograph of the outer surface of one exemplary flame resistant knit fabric.
  • FIG. 4 is a micrograph of the inner surface of one exemplary flame resistant knit fabric.
  • the second weft yarns 200 are compromised. These yarns may be completely melted, disintegrated, or have a significant reduction in their physical properties.
  • the first weft yarns 100 will remain and provide the integrity of the knit fabric. Because the first weft yarns are interlinked with one another through the plurality of knit stitches, the first weft yarns will still form an interconnected grid and the knit will still have integrity after burning.
  • An illustration of the knit fabric 15 having the second weft yarns 200 removed through burning is shown in FIG. 5 .
  • the flame resistant knit fabric 10 may be used as a flame barrier to any suitable article.
  • FIG. 6 illustrates a flame resistant support article 20 (in this Figure a mattress 12 ) surrounded by the flame resistant knit fabric 10 (part of the knit fabric 10 was removed in order to show lower layers in the Figure).
  • the flame resistant knit fabric 10 preferably completely encapsulates the support article.
  • the support article may be any article providing support and flame resistance.
  • Some examples of support articles include, but are not limited to, upholstered furniture, mattresses, foundations, automotive seating, public transportation seating, aircraft seating, and the like.
  • the support article is a mattress.
  • the first weft yarn set was yarns of continuous filament fiberglass.
  • the second weft yarn set was in an alternating pattern of A yarns and B yarns such as illustrated in FIG. 2 .
  • the A yarns were formed from a blend of 25% wt polyester and 75% wt flame resistant rayon staple fibers and the B yarns were formed from a blend of 50% wt cotton and 50% wt modacrylic staple fibers.
  • the first and second weft yarn sets were circular knitted into a 3.4 ounce per square yard single knit, knit welt knit construction as shown in FIGS. 3 and 4 .

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Knitting Of Fabric (AREA)
US17/174,264 2020-03-19 2021-02-11 Flame resistant knit fabric Abandoned US20210292936A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US17/174,264 US20210292936A1 (en) 2020-03-19 2021-02-11 Flame resistant knit fabric

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202062991662P 2020-03-19 2020-03-19
US17/174,264 US20210292936A1 (en) 2020-03-19 2021-02-11 Flame resistant knit fabric

Publications (1)

Publication Number Publication Date
US20210292936A1 true US20210292936A1 (en) 2021-09-23

Family

ID=75108845

Family Applications (1)

Application Number Title Priority Date Filing Date
US17/174,264 Abandoned US20210292936A1 (en) 2020-03-19 2021-02-11 Flame resistant knit fabric

Country Status (2)

Country Link
US (1) US20210292936A1 (fr)
WO (1) WO2021188273A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220162782A1 (en) * 2019-02-22 2022-05-26 Jess Black Inc. Fire-resistant double-faced fabric of knitted construction
US11873587B2 (en) 2019-03-28 2024-01-16 Southern Mills, Inc. Flame resistant fabrics

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0359690A1 (fr) * 1988-09-14 1990-03-21 Cetriko, S.A. Tricot double
US20160183694A1 (en) * 2013-07-29 2016-06-30 Fine Cotton Factory Inc. Fire resistant fabric

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6410140B1 (en) 1999-09-28 2002-06-25 Basf Corporation Fire resistant corespun yarn and fabric comprising same
JP4230293B2 (ja) * 2003-06-30 2009-02-25 オカモト株式会社 合成樹脂レザー
JP5676209B2 (ja) * 2010-10-29 2015-02-25 オカモト株式会社 合成樹脂レザー
CN102733057B (zh) * 2012-07-18 2014-06-11 杭州田野提花织造有限公司 用于床垫的阻燃纬编针织提花织物及其制备方法
KR20180072895A (ko) * 2016-12-21 2018-07-02 현대자동차주식회사 차량 시트 커버링 원단, 이를 포함하는 차량용 시트 및 차량 시트 커버링원단의 제조 방법

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0359690A1 (fr) * 1988-09-14 1990-03-21 Cetriko, S.A. Tricot double
US20160183694A1 (en) * 2013-07-29 2016-06-30 Fine Cotton Factory Inc. Fire resistant fabric

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220162782A1 (en) * 2019-02-22 2022-05-26 Jess Black Inc. Fire-resistant double-faced fabric of knitted construction
US11905630B2 (en) * 2019-02-22 2024-02-20 Jess Black Inc. Fire-resistant double-faced fabric of knitted construction
US11873587B2 (en) 2019-03-28 2024-01-16 Southern Mills, Inc. Flame resistant fabrics

Also Published As

Publication number Publication date
WO2021188273A1 (fr) 2021-09-23

Similar Documents

Publication Publication Date Title
US20220389627A1 (en) Flame Resistant Knit Fabric
US20210292936A1 (en) Flame resistant knit fabric
US20070077839A1 (en) Flame resistant matelasse fabrics
AU2015255859B2 (en) Flame resistant fabric having wool blends
US20170067192A1 (en) Flame Resistant Composite Fabrics
AU612131B2 (en) Knitted fabric having improved electrical charge dissipation and absorption properties
US10736433B2 (en) Fire resistant fabric
WO2006125083A3 (fr) Tissus matelasses ignifuges utilisant des fils tisses et a filaments ignifuges
US8536076B1 (en) Thermal energy resistant textile fleece fabric for use in safety apparel
US20120255128A1 (en) Enhanced Knit Fabric Fire Barrier for Mattresses
WO2012121759A2 (fr) Tissus composites ignifuges
US20060211319A1 (en) Textile woven and knit fabrics with enhanced flame retardancy and comfort for bedclothing products
US20220389628A1 (en) Flame Resistant Knit Fabric
GB2179067A (en) Fire resistant fabric
US20090075047A1 (en) Textile knit fabrics with enhanced flame retardancy for mattress and household products
JP4352413B2 (ja) シート材
US20210102315A1 (en) Flame Retardant Support Article
KR102205344B1 (ko) 매트리스용 원단의 제조방법
US20090094754A1 (en) Foam core article with flexible heat-resistant knitted fabric
US20090056029A1 (en) Foam core article with flexible heat-resistant knitted fabric
US20030101777A1 (en) Elastomeric knit fabric with antiflame properties
US20090061717A1 (en) Foam core article with flexible heat-resistant knitted fabric
US20210047761A1 (en) Fire-resistant glass fiber knit fabric
US20220325445A1 (en) Fireproof fabric and seat
US20180038020A1 (en) Fire retardant fabric for latex foam beds

Legal Events

Date Code Title Description
AS Assignment

Owner name: MILLIKEN & COMPANY, SOUTH CAROLINA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:RINGO, JOHN W.;REEL/FRAME:055685/0578

Effective date: 20210303

STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION