WO2005118290A1 - Treated inherently flame resistant polyester fabrics - Google Patents

Treated inherently flame resistant polyester fabrics Download PDF

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Publication number
WO2005118290A1
WO2005118290A1 PCT/US2004/015754 US2004015754W WO2005118290A1 WO 2005118290 A1 WO2005118290 A1 WO 2005118290A1 US 2004015754 W US2004015754 W US 2004015754W WO 2005118290 A1 WO2005118290 A1 WO 2005118290A1
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WO
WIPO (PCT)
Prior art keywords
fabric
saturating
composition
textile article
article according
Prior art date
Application number
PCT/US2004/015754
Other languages
French (fr)
Inventor
John M. Smith, Iii
Bradley B. Coston
Charles W. Duckett
Original Assignee
Precision Fabric Groups, Inc.
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 Precision Fabric Groups, Inc. filed Critical Precision Fabric Groups, Inc.
Priority to PCT/US2004/015754 priority Critical patent/WO2005118290A1/en
Priority to AU2004320319A priority patent/AU2004320319A1/en
Priority to EP04752723A priority patent/EP1750942A4/en
Priority to CA2567347A priority patent/CA2567347C/en
Publication of WO2005118290A1 publication Critical patent/WO2005118290A1/en

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Classifications

    • 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
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/08—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with halogenated hydrocarbons
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
    • 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
    • D06M11/68—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 phosphorus or compounds thereof, e.g. with chlorophosphonic acid or salts thereof
    • D06M11/70—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 phosphorus or compounds thereof, e.g. with chlorophosphonic acid or salts thereof with oxides of phosphorus; with hypophosphorous, phosphorous or phosphoric acids or their salts
    • D06M11/71—Salts of phosphoric acids
    • 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
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/244—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing sulfur or phosphorus
    • D06M13/282—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing sulfur or phosphorus with compounds containing phosphorus
    • D06M13/288—Phosphonic or phosphonous acids or derivatives thereof
    • 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
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/50—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with organometallic compounds; with organic compounds containing boron, silicon, selenium or tellurium atoms
    • D06M13/51—Compounds with at least one carbon-metal or carbon-boron, carbon-silicon, carbon-selenium, or carbon-tellurium bond
    • D06M13/513—Compounds with at least one carbon-metal or carbon-boron, carbon-silicon, carbon-selenium, or carbon-tellurium bond with at least one carbon-silicon bond
    • 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
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/244—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons
    • D06M15/256—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons containing fluorine
    • 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
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
    • 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
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/16—Synthetic fibres, other than mineral fibres
    • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M2101/32—Polyesters
    • 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

Definitions

  • the present invention relates to inherently flame resistant (FR) polyester fabrics and to a system for imparting soil, fluid, or microbial resistance properties to inherently flame resistant fabrics while substantially maintaining the flame resistant properties of the fabric.
  • Inherently flame resistant polyester has been produced for applications where durable flame resistance is required.
  • the flame resistance of the polyester is the result of incorporating an organic phosphorous compound into the polyethylene terephthalate chain during the fiber production process.
  • the flame resistant effect of incorporating this copolymer into a fiber results from two physical properties. First, incorporation of the copolymer makes it difficult for combustion to take place because the incorporated copolymer gives the polyester fabric a lower melting point than regular polyester.
  • the polyester which is a thermoplastic material, melts and shrinks away from flames.
  • the phosphorous component prevents the meltmg drips from burning by influencing the composition of the pyrolisis gases. Since the chemical flammability resistance is built into the polyethylene terephthalate chain, the flammability properties will not wash or dry clean out during • laundering as long as proper washing procedures are followed.- In contrast, topically applied flame resistant treatments are known to wash off with laundering, resulting in inconsistent flame resistant behavior over the life of the textile. Additionally, topically treated fabrics are susceptible to inconsistency of application of the FR additive, causing variable flammability results.
  • Inherently flame resistant polyester fabrics including knits, wovens, and non- woven fabrics, have found a market in such diverse areas as bedding, draperies, clothing, and particularly for hospitality and medical uses.
  • the inherent FR fabrics used in the medical, hospitality and clothing areas would also benefit from having additional properties such as soil and stain resistance and/or resistance to the growth of bacteria, fungi, yeast or algae.
  • Stain resistance, microbial resistance and water repellency are desirable qualities to have in many textile materials.
  • tablecloths are often subject to rapid water penetration and frequent staining. Hospitals also have a need to prevent staining and microbial growth on their linens, due to appearance and health-related concerns.
  • the present invention provides an a textile article having flame resistant properties comprising a plurality of inherently flame resistant fibers formed into a fabric, and a finish on the fabric, wherein the finish imparts a property selected from the group consisting of: an antimicrobial agent, a soil repellant and a fluid repellant.
  • Figure 1 is a perspective view of a bed illustrating a bedspread made from fabric according to the present invention.
  • Figure 2 is a perspective view of a piece of furniture upholstered with a fabric according to the present invention.
  • Figure 3 is a perspective view of a window illustrating drapery fabric according to the present invention.
  • the inherently flame resistant fiber is first made into a fabric. Any of the known methods of doing so, including weaving, knitting and non- woven fabric formation can be used. Other techniques such as tufting may also be adopted.
  • the fabric is scoured prior to the application of the chemical treatments. Scouring removes residual processing aids, which may be present on the textile material, as well as dirt and/or oily materials.
  • the scouring of the textile material to remove any residual textile processing aids, dirt, oil residues, and the like can be readily accomplished by passing the textile material through an aqueous detergent. After passing the textile material through the aqueous detergent, it should be in order to remove any residual detergent.
  • the amount of the detergent constituent employed in the aqueous detergent containing solution can vary widely as can the type of detergent. Generally, desirable results can be obtained when the amount of the detergent constituent employed is from about 0.10 to about 1.0 weight percent, based on the total weight of the detergent solution.
  • the detergent to be employed is typically selected from a group that does not react negatively with the fabric to be scoured or with the fabric's flame resistant properties. Typical examples of suitable detergents that can be employed in the detergent scouring of the textile material, include Solpon 1159,. Solpon SPI, and Picoscour Jet. After the fabric has been scoured and rinsed, the scoured material may then be subjected to a chemical treatment step.
  • the chemical treatment of the present invention comprises exposing the inherently FR textile material to an aqueous solution of a wetting agent and a flame retardant and one or more of: an antimicrobial agent, a water repellant agent, or a soil resistance agent.
  • a flame retardant may be added to the chemical treatment composition to ensure that the inherent flame retardant remains chemical coupled with the polyester fiber. It is thought that the presence of the flame retardant in the chemical coating composition may help to kinetically drive the inherently coupled flame retardant to remain chemically bound within the polyethylene terephthalate chain of the polyester fibers.
  • the flame retardant in the chemical coating composition is preferably the same flame retardant that comprises the inherently flame retardant fabric.
  • Typical examples of suitable flame-retardants include Cyclic Phosphonate, Apex Flameproof #1525, Pyron N-75, and Antiblaze NT.
  • the flame retardant to be added to the chemical treatment preferably comprises about 2% to about 10 % by weight of the chemical treatment composition. More preferably, the flame retardant comprises about 4.8 % by weight of the chemical treatment composition.
  • the wetting agent of the chemical coating composition reduces the hydrophobicity of the dry fabric and to ensure that the entire fabric is sufficiently contacted with all the chemical treatments.
  • the wetting agent to be added to the chemical treatment preferably comprises between about 0.5% to about 2.0 % by weight of the chemical treatment composition. More preferably, the wetting agent comprises about 0.96 % by weight of the chemical treatment composition.
  • the wetting agent is an alcohol. More preferably, the wetting agent is an aliphatic alcohol such as Isopropanol. Typical examples of suitable wetting agents include Nonionic Ethylene Ether Condensates, such as Dexopal 555, or Aqueous Cationic Non-rewetting surfactants solutions, such as MykonNRW-3. For those cases where antimicrobial properties are desired, an antimicrobial agent is added to the chemical treatment to reduce the growth of microorganisms on the inherently flame resistant fabric. By “antimicrobial agent” is meant any substance or combination of substances that kills or prevents the growth of microorganisms, and includes antibiotics, antifungal, antiviral and antialgal agents.
  • the antimicrobial agent can be either a "leaching” antimicrobial agent or a "molecularly bonded” antimicrobial agent.
  • Leaching antimicrobials work by leaching or moving from the surface of the fabric to contact and kill a nearby microorganism.
  • Molecularly bonded antimicrobial agents work by remaining affixed to the fabric and kill the microorganism as it contacts the surface to which the bonded antimicrobial has been applied. See White et al., "A Comparison of Antimicrobials for the Textile Industry", www.microbeshield. com.
  • the antimicrobial agent to be added to the chemical treatment composition preferably comprises about 0.2% to about 2.0 % by weight of the chemical treatment composition.
  • the antimicrobial agent comprises about 0.48 % by weight of the chemical treatment composition.
  • suitable antimicrobial agents include Ultrafresh DM-25, an octhilinone or Bioshield AM 500, an organosilane.
  • the antimicrobial agent is a "molecularly bonded" antimicrobial agent.
  • the antimicrobial agent is an organofuctional silane.
  • the antimicrobial agent is an organosilane composition comprising about 16 % by weight of chloropropyltrihydroxysilane and about 84% by weight of Octadecylan ⁇ nodimemyltrihydroxysilylpropyl Ammonium Chloride, available from Aegis under the trademark AEM 5700TM.
  • a fluid or soil repellent agent is added to the chemical treatment composition to improve the fabric's water repellency and the fabric's resistance to staining.
  • a combination fluid repellent/soil resistant agent may be added to the chemical treatment composition.
  • the fluid repellent agent and soil resistant agent is added as a combination fluid repellent/soil resistant agent.
  • the fluid repellent/soil resistant agent is a fluorochemical.
  • the fluid repellent/soil resistant agent is a fluorochemical available from Dupont under the trademark ZONYL 7040TM.
  • the combination fluid repellent/soil resistant agent to be added to the chemical treatment preferably comprises about 2% to about 10 % by weight of the chemical treatment composition. More preferably, the fluid repellent/soil resistant agent comprises about 3.6 % by weight of the chemical treatment composition.
  • the chemical treatment may be applied by various methods known in the art, such as by spraying, dipping or pad application. In a preferred embodiment, the chemical treatment is applied to the scoured fabric using a pad applicator.
  • the pressure of the squeeze rollers is controlled to achieve a wet pick-up of between about 25 % and about 60% of the chemical treatment. Preferably, the pressure of the squeeze rollers is controlled to achieve a wet pick-up of approximately 45% of the chemical composition.
  • the chemically treated fabric is then dried through exposure to between about 320° F and 420° F for between about 20 seconds and 60 seconds in a hot air oven. Preferably, the fabric is dried through exposure to 380° F for 30 seconds in a hot air oven.
  • an inherently flame resistant fiber such as that marketed by Kosa, Inc., trademarked as AVORATM
  • AVORATM is woven into a fabric and treated with a chemical composition comprising an antimicrobial agent, a fluid repellent agent, a stain resistant agent and a flame retardant such that the chemically treated fabric has a flame resistance substantially similar to untreated inherently flame resistance fabric.
  • AVORATM inherently flame resistant fibers were made into a woven fabric having the properties in Table 1 was first scoured with an aqueous detergent prior to the application of chemical treatments. After thoroughly rinsing the scoured fabric, it was dried in a hot air oven.
  • a chemical treatment composition was then prepared in an aqueous-based solution comprising 0.96 % by weight of Isopropanol, 4.8 % by weight of Flame Retardant 50, 3.6 % by weight of ZONYL 7040TM and 0.48 % by weight of AEM 5700TM as seen in Table 2.
  • the chemical treatment composition was applied to the scoured AVORATM fabric using a pad applicator.
  • the pressure of the squeeze rollers was controlled to achieve a wet pick-up of approximately 45% of the chemical treatment composition.
  • the fabric was then dried through exposure to 380 F for 30 seconds in a hot air oven. After drying, the finished fabric was tested according to standard published test protocols to assess its properties. These properties are summarized in Table 3. Table 3:
  • the post- weave chemical treatment that includes the Flame Retardant 50 has a flame resistance substantially similar to the untreated inherently flame resistance fabric. It is thought that the presence of the flame retardant in the chemical coating composition may kinetically drive the inherent flame retardant to remain chemically bound within the polyethylene terephthalate chain of the polyester fibers. The fluid repellency has an excellent spray rating resistance. Finally, the test for the presence of the antimicrobial agent also passed.
  • Example 2 Another large-scale plant trial was conducted.
  • the AVORATM inherently flame resistant fibers were made into a woven fabric having the properties in Table 1 was first scoured with an aqueous detergent prior to the application of chemical treatments. After thoroughly rinsing the scoured fabric, it was dried in a hot air oven.
  • Table 4 Table 4:
  • the chemical treatment composition in Table 4. was applied to the scoured fabric using a pad applicator.
  • the pressure of the squeeze rollers was controlled to achieve a wet pick-up of approximately 45% of the chemical treatment composition.
  • the fabric was then dried through exposure to 380 F for 30 seconds in a hot air oven.
  • Example 3 a small-scale lab trial was conducted.
  • the AVORATM inherently flame resistant fabric having the properties in Table 1 was first scoured with an aqueous detergent prior to the application of chemical treatments. After thoroughly rinsing the scoured fabric, it was dried in a hot air oven.
  • the chemical treatment composition in Table 6 was applied to the scoured AVORATM fabric using a pad applicator. The pressure of the squeeze rollers was controlled to achieve a wet pick-up of approximately 45% of the chemical treatment composition.
  • the fabric was then dried through exposure to 375 F for 1 minute in a hot air oven. After drying, the finished fabric was tested according to standard published test protocols to assess its flame resistance properties. Table 6:
  • the present invention unlike the prior art teachings, has unexpectedly found that the addition of chemical treatments to inherently FR fibers, has substantially equal flame resistance as compared to untreated inherently FR fibers.
  • EXAMPLE 9 Another inherently resistant fiber, Trevira CS is similar to AVORA, the two fibers having previously been available as European and American versions of the product from the same manufacturer, which has recently been divided into two separate organizations, each selling its own inherently FR fiber.
  • Trevira CS fibers was also tested in a woven fabric having the following construction:
  • the fabric was dried through exposure to 375° F for 1 minute in a hot air oven.
  • the pad pressure was 6 psi and the air flow set at 100%.
  • the finished fabric was tested with these results:

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

A textile article having flame resistant properties includes a plurality of inherently flame resistant polyester fibers formed into a fabric, and a finish on the fabric including a cyclic phosphonate flame retardant. The finish imparts a property selected from the group consisting of : a molecularly bound antimicrobial agent which is an organosilane; a fluorochemical soil and fluid repellant, and the finished textile article has a flame resistance that passes the standard method NFPA 701 - 1996 edition testing protocol.

Description

TREATED INHERENTLY FLAME RESISTANT POLYESTER FABRICS
Background of the Invention The present invention relates to inherently flame resistant (FR) polyester fabrics and to a system for imparting soil, fluid, or microbial resistance properties to inherently flame resistant fabrics while substantially maintaining the flame resistant properties of the fabric. Inherently flame resistant polyester has been produced for applications where durable flame resistance is required. The flame resistance of the polyester is the result of incorporating an organic phosphorous compound into the polyethylene terephthalate chain during the fiber production process. The flame resistant effect of incorporating this copolymer into a fiber results from two physical properties. First, incorporation of the copolymer makes it difficult for combustion to take place because the incorporated copolymer gives the polyester fabric a lower melting point than regular polyester. Thus, the polyester, which is a thermoplastic material, melts and shrinks away from flames. Second, if any burning does take place during the shrinkage from the flame, the phosphorous component prevents the meltmg drips from burning by influencing the composition of the pyrolisis gases. Since the chemical flammability resistance is built into the polyethylene terephthalate chain, the flammability properties will not wash or dry clean out during • laundering as long as proper washing procedures are followed.- In contrast, topically applied flame resistant treatments are known to wash off with laundering, resulting in inconsistent flame resistant behavior over the life of the textile. Additionally, topically treated fabrics are susceptible to inconsistency of application of the FR additive, causing variable flammability results. Inherently flame resistant polyester fabrics, including knits, wovens, and non- woven fabrics, have found a market in such diverse areas as bedding, draperies, clothing, and particularly for hospitality and medical uses. The inherent FR fabrics used in the medical, hospitality and clothing areas would also benefit from having additional properties such as soil and stain resistance and/or resistance to the growth of bacteria, fungi, yeast or algae. Stain resistance, microbial resistance and water repellency are desirable qualities to have in many textile materials. In restaurants, for example, tablecloths are often subject to rapid water penetration and frequent staining. Hospitals also have a need to prevent staining and microbial growth on their linens, due to appearance and health-related concerns. These properties necessitate frequent cleaning and/or replacement of such items, leading to a loss of time and money. The prior art, however, denied these users access to fabrics that are inherently FR and treated to provide these additional desirable properties. Manufacturers of inherently flame resistant fibers have specifically warned against adding chemical treatments to their fabrics because of the potential loss of the flame resistance properties. Kosa, Inc., the manufacturer of the trademarked AVORA™ for flame resistant fibers, warns that acrylic resins, silicone and fluorocarbon compounds should be avoided because of their potential for damaging the inherent flame resistant properties of the AVORA™ fabric. See Kosa, "AVORA™FR" publication, p.6. Therefore, inherently flame resistant polyester fabrics are sold scoured substantially free from intentional or non-intentional chemical treatments. Hospitals and restaurants, in particular, have a need for inherently flame resistant linens in order to provide a safe environment for their patients and patrons. Yet these industries have no way to obtain inherently flame resistant linens with additional chemical treatments for stain resistance, microbial resistance and water repellency. Thus, there remains a need for imparting stain, fluid and microbial resistance properties in inherently flame resistant fabric while substantially maintaining the fabric's original flame resistant characteristics. Summary of the Invention The present invention provides an a textile article having flame resistant properties comprising a plurality of inherently flame resistant fibers formed into a fabric, and a finish on the fabric, wherein the finish imparts a property selected from the group consisting of: an antimicrobial agent, a soil repellant and a fluid repellant.
Brief Description of the Drawings Figure 1 is a perspective view of a bed illustrating a bedspread made from fabric according to the present invention.
Figure 2 is a perspective view of a piece of furniture upholstered with a fabric according to the present invention.
Figure 3 is a perspective view of a window illustrating drapery fabric according to the present invention.
Description of the Preferred Embodiments In the present invention, the inherently flame resistant fiber is first made into a fabric. Any of the known methods of doing so, including weaving, knitting and non- woven fabric formation can be used. Other techniques such as tufting may also be adopted. Once the fabric is formed, it is scoured prior to the application of the chemical treatments. Scouring removes residual processing aids, which may be present on the textile material, as well as dirt and/or oily materials. The scouring of the textile material to remove any residual textile processing aids, dirt, oil residues, and the like, can be readily accomplished by passing the textile material through an aqueous detergent. After passing the textile material through the aqueous detergent, it should be in order to remove any residual detergent. The amount of the detergent constituent employed in the aqueous detergent containing solution can vary widely as can the type of detergent. Generally, desirable results can be obtained when the amount of the detergent constituent employed is from about 0.10 to about 1.0 weight percent, based on the total weight of the detergent solution. The detergent to be employed is typically selected from a group that does not react negatively with the fabric to be scoured or with the fabric's flame resistant properties. Typical examples of suitable detergents that can be employed in the detergent scouring of the textile material, include Solpon 1159,. Solpon SPI, and Picoscour Jet. After the fabric has been scoured and rinsed, the scoured material may then be subjected to a chemical treatment step. The chemical treatment of the present invention comprises exposing the inherently FR textile material to an aqueous solution of a wetting agent and a flame retardant and one or more of: an antimicrobial agent, a water repellant agent, or a soil resistance agent. While, not wishing to be bound to a particular theory, a flame retardant may be added to the chemical treatment composition to ensure that the inherent flame retardant remains chemical coupled with the polyester fiber. It is thought that the presence of the flame retardant in the chemical coating composition may help to kinetically drive the inherently coupled flame retardant to remain chemically bound within the polyethylene terephthalate chain of the polyester fibers. The flame retardant in the chemical coating composition is preferably the same flame retardant that comprises the inherently flame retardant fabric. Typical examples of suitable flame-retardants include Cyclic Phosphonate, Apex Flameproof #1525, Pyron N-75, and Antiblaze NT. The flame retardant to be added to the chemical treatment preferably comprises about 2% to about 10 % by weight of the chemical treatment composition. More preferably, the flame retardant comprises about 4.8 % by weight of the chemical treatment composition. The wetting agent of the chemical coating composition reduces the hydrophobicity of the dry fabric and to ensure that the entire fabric is sufficiently contacted with all the chemical treatments. The wetting agent to be added to the chemical treatment preferably comprises between about 0.5% to about 2.0 % by weight of the chemical treatment composition. More preferably, the wetting agent comprises about 0.96 % by weight of the chemical treatment composition.
Preferably, the wetting agent is an alcohol. More preferably, the wetting agent is an aliphatic alcohol such as Isopropanol. Typical examples of suitable wetting agents include Nonionic Ethylene Ether Condensates, such as Dexopal 555, or Aqueous Cationic Non-rewetting surfactants solutions, such as MykonNRW-3. For those cases where antimicrobial properties are desired, an antimicrobial agent is added to the chemical treatment to reduce the growth of microorganisms on the inherently flame resistant fabric. By "antimicrobial agent" is meant any substance or combination of substances that kills or prevents the growth of microorganisms, and includes antibiotics, antifungal, antiviral and antialgal agents. The antimicrobial agent can be either a "leaching" antimicrobial agent or a "molecularly bonded" antimicrobial agent. Leaching antimicrobials work by leaching or moving from the surface of the fabric to contact and kill a nearby microorganism. Molecularly bonded antimicrobial agents work by remaining affixed to the fabric and kill the microorganism as it contacts the surface to which the bonded antimicrobial has been applied. See White et al., "A Comparison of Antimicrobials for the Textile Industry", www.microbeshield. com. The antimicrobial agent to be added to the chemical treatment composition preferably comprises about 0.2% to about 2.0 % by weight of the chemical treatment composition. More preferably, the antimicrobial agent comprises about 0.48 % by weight of the chemical treatment composition. Typical examples of suitable antimicrobial agents include Ultrafresh DM-25, an octhilinone or Bioshield AM 500, an organosilane. Preferably, the antimicrobial agent is a "molecularly bonded" antimicrobial agent. More preferably, the antimicrobial agent is an organofuctional silane. Even more preferably, the antimicrobial agent is an organosilane composition comprising about 16 % by weight of chloropropyltrihydroxysilane and about 84% by weight of Octadecylanύnodimemyltrihydroxysilylpropyl Ammonium Chloride, available from Aegis under the trademark AEM 5700™. For those cases where fluid or soil repellent properties are desired, a fluid or soil repellent agent is added to the chemical treatment composition to improve the fabric's water repellency and the fabric's resistance to staining. Also, a combination fluid repellent/soil resistant agent may be added to the chemical treatment composition. Preferably, in the present invention, the fluid repellent agent and soil resistant agent is added as a combination fluid repellent/soil resistant agent. Mote preferably, the fluid repellent/soil resistant agent is a fluorochemical. Even more preferably, the fluid repellent/soil resistant agent is a fluorochemical available from Dupont under the trademark ZONYL 7040™. The combination fluid repellent/soil resistant agent to be added to the chemical treatment preferably comprises about 2% to about 10 % by weight of the chemical treatment composition. More preferably, the fluid repellent/soil resistant agent comprises about 3.6 % by weight of the chemical treatment composition. The chemical treatment may be applied by various methods known in the art, such as by spraying, dipping or pad application. In a preferred embodiment, the chemical treatment is applied to the scoured fabric using a pad applicator. The pressure of the squeeze rollers is controlled to achieve a wet pick-up of between about 25 % and about 60% of the chemical treatment. Preferably, the pressure of the squeeze rollers is controlled to achieve a wet pick-up of approximately 45% of the chemical composition. The chemically treated fabric is then dried through exposure to between about 320° F and 420° F for between about 20 seconds and 60 seconds in a hot air oven. Preferably, the fabric is dried through exposure to 380° F for 30 seconds in a hot air oven.
EXAMPLE 1
The following is a description of one preferred method- of the present invention. By way of example, an inherently flame resistant fiber, such as that marketed by Kosa, Inc., trademarked as AVORA™, is woven into a fabric and treated with a chemical composition comprising an antimicrobial agent, a fluid repellent agent, a stain resistant agent and a flame retardant such that the chemically treated fabric has a flame resistance substantially similar to untreated inherently flame resistance fabric. In Example 1, large-scale plant trials were conducted. The AVORA™ inherently flame resistant fibers were made into a woven fabric having the properties in Table 1 was first scoured with an aqueous detergent prior to the application of chemical treatments. After thoroughly rinsing the scoured fabric, it was dried in a hot air oven.
Table 1:
Figure imgf000008_0001
A chemical treatment composition was then prepared in an aqueous-based solution comprising 0.96 % by weight of Isopropanol, 4.8 % by weight of Flame Retardant 50, 3.6 % by weight of ZONYL 7040™ and 0.48 % by weight of AEM 5700™ as seen in Table 2.
Table 2:
Figure imgf000008_0002
The chemical treatment composition was applied to the scoured AVORA™ fabric using a pad applicator. The pressure of the squeeze rollers was controlled to achieve a wet pick-up of approximately 45% of the chemical treatment composition. The fabric was then dried through exposure to 380 F for 30 seconds in a hot air oven. After drying, the finished fabric was tested according to standard published test protocols to assess its properties. These properties are summarized in Table 3. Table 3:
Figure imgf000009_0001
As summarized in Table 3, the post- weave chemical treatment that includes the Flame Retardant 50 has a flame resistance substantially similar to the untreated inherently flame resistance fabric. It is thought that the presence of the flame retardant in the chemical coating composition may kinetically drive the inherent flame retardant to remain chemically bound within the polyethylene terephthalate chain of the polyester fibers. The fluid repellency has an excellent spray rating resistance. Finally, the test for the presence of the antimicrobial agent also passed.
EXAMPLE 2
In Example 2, another large-scale plant trial was conducted. The AVORA™ inherently flame resistant fibers were made into a woven fabric having the properties in Table 1 was first scoured with an aqueous detergent prior to the application of chemical treatments. After thoroughly rinsing the scoured fabric, it was dried in a hot air oven. Table 4:
Figure imgf000010_0001
The chemical treatment composition in Table 4. was applied to the scoured fabric using a pad applicator. The pressure of the squeeze rollers was controlled to achieve a wet pick-up of approximately 45% of the chemical treatment composition. The fabric was then dried through exposure to 380 F for 30 seconds in a hot air oven.
Table 5:
Figure imgf000010_0002
After drying, the finished fabric was tested according to standard published test protocols to assess its flame resistance properties. As summarized in Table 5, the post-weave chemical treatment in Table 4, which omits the Flame Retardant 50, failed the NFPA 701 - 1996 Edition flame resistance test. (The fill data is not required for NFPA 701 test) As taught by the Kosa, "AVORA™ FR" publication, the inherently flame resistance properties of the AVORA™ fabric degrade after a post- weave chemical treatment. However, the present inventor has found that if a flame retardant is added during the chemical treatment coating process, the fabric retains a flame resistance substantially similar to untreated inherently flame resistance fabric. EXAMPLE 3
In Example 3, a small-scale lab trial was conducted. The AVORA™ inherently flame resistant fabric having the properties in Table 1 was first scoured with an aqueous detergent prior to the application of chemical treatments. After thoroughly rinsing the scoured fabric, it was dried in a hot air oven. The chemical treatment composition in Table 6 was applied to the scoured AVORA™ fabric using a pad applicator. The pressure of the squeeze rollers was controlled to achieve a wet pick-up of approximately 45% of the chemical treatment composition. The fabric was then dried through exposure to 375 F for 1 minute in a hot air oven. After drying, the finished fabric was tested according to standard published test protocols to assess its flame resistance properties. Table 6:
Figure imgf000011_0001
Several further small-scale lab trials were then conducted. The lab procedures followed were identical to that in Example 3. The only differences between Examples 4-8 were the types of chemical treatments applied. The treatments for each Example in 4-8 are summarized in Tables 7-11. The results of the NFPA 701 - 1996 Edition flame resistance tests are also summarized in Tables 7-11. EXAMPLE 4
Table 7:
Figure imgf000012_0001
EXAMPLE 5
Table 8:
Figure imgf000012_0002
EXAMPLE 6
Table 9:
Figure imgf000013_0001
EXAMPLE 7
Table 10:
Figure imgf000013_0002
EXAMPLE 8
Table 11:
Figure imgf000014_0001
While not wishing to be bound by any particular theory, after summarizing the small-scale experiments in Tables 7-11, it was thought that the addition of flame retardant to the chemical treatments does not harm the flame resistant properties of untreated inherently FR fibers and may, in some cases with heavy chemical loading, assist in kinetically driving the inherent flame retardant to remain chemically bound within the polyethylene terephthalate chain of the polyester fibers. But, it is not a requirement for the present invention to require the addition of flame retardant to the desired chemical treatment in order for the treated fabric to have an equal flame resistance to the untreated inherently FR fibers. Therefore, the present invention, unlike the prior art teachings, has unexpectedly found that the addition of chemical treatments to inherently FR fibers, has substantially equal flame resistance as compared to untreated inherently FR fibers. EXAMPLE 9 Another inherently resistant fiber, Trevira CS is similar to AVORA, the two fibers having previously been available as European and American versions of the product from the same manufacturer, which has recently been divided into two separate organizations, each selling its own inherently FR fiber.
Accordingly, Trevira CS fibers was also tested in a woven fabric having the following construction:
Warp Filling Denier 165 Denier 165 Filaments 64 Filaments 64 X-section trilobal X-section trilobal Luster bright Luster bright Textured no Textured no Fiber polyester Fiber polyester
Without finishing the fabric had these NFPA 701 Burn Test Results:
Figure imgf000015_0001
An additional sample of Trevira CS of the same construction' was finished with:
Figure imgf000015_0002
The fabric was dried through exposure to 375° F for 1 minute in a hot air oven. The pad pressure was 6 psi and the air flow set at 100%. The finished fabric was tested with these results:
Figure imgf000016_0001
It should now be understood by those skilled in the art that the amounts and ratios of the chemical freatment compositions as well as the type of treatment desired may be varied depending on the desired result of the chemical coating treatment. It should also be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.

Claims

We Claim:
1. A textile article having flame resistant properties comprising a plurality of inherently flame resistant fibers formed into a fabric, and a finish on the fabric, wherein the finish imparts a property selected from the group consisting of: an antimicrobial agent, a soil repellant and a fluid repellant.
2. The textile article according to claim 1 wherein the finished textile article has a flame resistance that passes the standard method NFPA 701 - 1996 edition testing protocol.
3. The textile article according to claim 1 wherein the article is made of polyester fibers.
■ 4. The textile article according to claim 3 wherein the article is made of AVORA™ fibers.
5. The textile article according to claim 1 wherein the antimicrobial agent is a molecularly bound antimicrobial agent.
6. The textile article according to claim 5 wherein the antimicrobial agent is an organosilane.
7. The textile article according to claim 6 wherein the antimicrobial agent is AEM 5700™.
8. The textile article according to claim 1 wherein the fluid repellent is a fluorochemical.
9. The textile article according to claim 8 wherein the fluid repellent is also a soil repellent.
10. The textile article according to claim 9 wherein the fluid is ZONYL 7040™.
11. The textile article according to claim 1 wherein the textile article is a bedspread.
12. The textile article according to claim 1 wherein the textile article is a drapery.
13. The textile article according to claim 1 wherein the textile article is upholstery fabric.
14. The textile article according to claim 1 wherein the finish includes a flame retardant.
15. The textile article according to claim 14 wherein the flame retardant is a phosphonate.
1 . The textile article according to claim 15 wherem the flame retardant is a cyclic phosphonate.
17. The textile article according to claim 16 wherein the finish includes
Flame Retardant 50.
18. The textile article according to claim 1 wherein the article is made from Trevira CS fibers.
19. A textile article having flame resistant properties comprising a plurality of inherently flame resistant polyester fibers formed into a fabric, and a finish on the fabric including a cyclic phosphonate flame retardant, wherein the finish includes a molecularly bound antimicrobial agent which is an organosilane, and a fluorochemical soil and fluid repellant, and wherein the finished fabric has a flame resistance that passes the standard method NFPA 701 - 1996 edition testing protocol.
20. A textile article having flame resistant properties comprising a plurality of inherently flame resistant fibers formed into a fabric, and a finish on the fabric containing a fluorchemical, a cyclic phosponate and an organosilane.
21. The textile article according to claim 20 wherein the finished textile article has a flame resistance that passes the standard method NFPA 701 - 1996 edition testing protocol.
22. A method of finishing an inherently flame resistant fabric comprising: forming a fabric of inherently flame resistant fibers, saturating the fabric with a composition containing a fluorochemical and one or more of an antimicrobial agent, a flame retardant, a fluid repellant agent and a soil repellant agent, drying the fabric.
23. A method as claimed in claim 22 further comprising testing the fabric and determining that the fabric passes the standard method NFPΛ 701 - 1996 edition testing protocol.
24. A method as claimed in claim 22 wherein saturating is accomplished by padding.
25. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the flame retardant is a phosphonate.
26. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the flame retardant is a cyclic phosphonate.
27. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the flame retardant is Flame Retardant 50.
28. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the flame retardant comprises between about 2 % and 10 % by weight of the composition.
29. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the flame retardant comprises about 4.8 % by weight of the composition.
30. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the antimicrobial agent is a molecularly bound antimicrobial agent.
31. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the antimicrobial agent is an organosilane.
32. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the antimicrobial agent is AEM 5700™.
33. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the antimicrobial agent comprises between about 0.2 % and 2.0 % by weight of the composition.
34. A method as claimed in claim 22 wherem saturating the fabric includes saturating with a composition in which the antimicrobial agent comprises about 0.48 % by weight of the composition.
35. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the fluid repellant is also a soil repellant.
36. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the fluid repellant is a fluorochemical.
37. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the fluid repellant is ZONYL 7040™.
38. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the fluid repellant comprises between about 2
% and 10 % by weight of the composition.
39. A method as claimed in claim 22 wherein saturating the fabric includes saturating with a composition in which the fluid repellant comprises about 3.6 % by weight of the composition.
40. A method as claimed in claim 22 wherein forming includes fabric formation from Trevira CS fibers.
41. A method as claimed in claim 22 wherein forming includes fabric formation from AVORA ™ fibers.
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