WO2006029077A2 - Knit tube flame resistant barriers - Google Patents
Knit tube flame resistant barriers Download PDFInfo
- Publication number
- WO2006029077A2 WO2006029077A2 PCT/US2005/031538 US2005031538W WO2006029077A2 WO 2006029077 A2 WO2006029077 A2 WO 2006029077A2 US 2005031538 W US2005031538 W US 2005031538W WO 2006029077 A2 WO2006029077 A2 WO 2006029077A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- flame resistant
- barrier material
- tubular fabric
- yarn
- flame
- Prior art date
Links
- 230000004888 barrier function Effects 0.000 title claims description 34
- 239000004744 fabric Substances 0.000 claims abstract description 50
- 238000010276 construction Methods 0.000 claims abstract description 8
- 238000005520 cutting process Methods 0.000 claims abstract description 3
- 238000009998 heat setting Methods 0.000 claims abstract description 3
- 239000000835 fiber Substances 0.000 claims description 32
- 239000000463 material Substances 0.000 claims description 20
- 229920003235 aromatic polyamide Polymers 0.000 claims description 12
- -1 poly(diphenylether) Polymers 0.000 claims description 10
- 239000004760 aramid Substances 0.000 claims description 9
- 230000009970 fire resistant effect Effects 0.000 claims description 8
- 229920000728 polyester Polymers 0.000 claims description 8
- 229920000877 Melamine resin Polymers 0.000 claims description 6
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims description 6
- 229920002821 Modacrylic Polymers 0.000 claims description 5
- 239000004734 Polyphenylene sulfide Substances 0.000 claims description 4
- 229920000297 Rayon Polymers 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 229920001778 nylon Polymers 0.000 claims description 4
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 4
- 239000004677 Nylon Substances 0.000 claims description 3
- 239000004693 Polybenzimidazole Substances 0.000 claims description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 3
- 230000009977 dual effect Effects 0.000 claims description 3
- 229910052760 oxygen Inorganic materials 0.000 claims description 3
- 239000001301 oxygen Substances 0.000 claims description 3
- 229920002480 polybenzimidazole Polymers 0.000 claims description 3
- 229920001601 polyetherimide Polymers 0.000 claims description 3
- 229920006282 Phenolic fiber Polymers 0.000 claims description 2
- 239000004962 Polyamide-imide Substances 0.000 claims description 2
- 239000004642 Polyimide Substances 0.000 claims description 2
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 2
- 229920002312 polyamide-imide Polymers 0.000 claims description 2
- 229920001721 polyimide Polymers 0.000 claims description 2
- 229920001470 polyketone Polymers 0.000 claims description 2
- 238000000034 method Methods 0.000 claims 5
- 238000007789 sealing Methods 0.000 claims 3
- 229920000265 Polyparaphenylene Polymers 0.000 claims 1
- 229920002313 fluoropolymer Polymers 0.000 claims 1
- 239000004811 fluoropolymer Substances 0.000 claims 1
- 239000003365 glass fiber Substances 0.000 claims 1
- 238000009958 sewing Methods 0.000 claims 1
- 239000000126 substance Substances 0.000 description 11
- 239000006260 foam Substances 0.000 description 10
- 239000002131 composite material Substances 0.000 description 7
- 238000007706 flame test Methods 0.000 description 7
- 229920000271 Kevlar® Polymers 0.000 description 6
- 229920005830 Polyurethane Foam Polymers 0.000 description 5
- 239000004761 kevlar Substances 0.000 description 5
- 239000011496 polyurethane foam Substances 0.000 description 5
- 229920006232 basofil Polymers 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 239000011152 fibreglass Substances 0.000 description 4
- 239000003063 flame retardant Substances 0.000 description 4
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 4
- 239000004810 polytetrafluoroethylene Substances 0.000 description 4
- 229920000742 Cotton Polymers 0.000 description 3
- 239000004809 Teflon Substances 0.000 description 3
- 229920006362 Teflon® Polymers 0.000 description 3
- 229920000561 Twaron Polymers 0.000 description 3
- CZBZUDVBLSSABA-UHFFFAOYSA-N butylated hydroxyanisole Chemical compound COC1=CC=C(O)C(C(C)(C)C)=C1.COC1=CC=C(O)C=C1C(C)(C)C CZBZUDVBLSSABA-UHFFFAOYSA-N 0.000 description 3
- 238000009940 knitting Methods 0.000 description 3
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- 229920000915 polyvinyl chloride Polymers 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical compound FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 3
- 239000004762 twaron Substances 0.000 description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- 239000002033 PVDF binder Substances 0.000 description 2
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 238000010042 air jet spinning Methods 0.000 description 2
- 235000015107 ale Nutrition 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 235000004879 dioscorea Nutrition 0.000 description 2
- USIUVYZYUHIAEV-UHFFFAOYSA-N diphenyl ether Chemical compound C=1C=CC=CC=1OC1=CC=CC=C1 USIUVYZYUHIAEV-UHFFFAOYSA-N 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 229920000747 poly(lactic acid) Polymers 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 229920001291 polyvinyl halide Polymers 0.000 description 2
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 2
- 230000000979 retarding effect Effects 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 239000012209 synthetic fiber Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- BQCIDUSAKPWEOX-UHFFFAOYSA-N 1,1-Difluoroethene Chemical compound FC(F)=C BQCIDUSAKPWEOX-UHFFFAOYSA-N 0.000 description 1
- YCGKJPVUGMBDDS-UHFFFAOYSA-N 3-(6-azabicyclo[3.1.1]hepta-1(7),2,4-triene-6-carbonyl)benzamide Chemical compound NC(=O)C1=CC=CC(C(=O)N2C=3C=C2C=CC=3)=C1 YCGKJPVUGMBDDS-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 244000198134 Agave sisalana Species 0.000 description 1
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 description 1
- 241000169624 Casearia sylvestris Species 0.000 description 1
- 229920013683 Celanese Polymers 0.000 description 1
- 229920001634 Copolyester Polymers 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 229920001780 ECTFE Polymers 0.000 description 1
- 229920013633 Fortron Polymers 0.000 description 1
- 239000004738 Fortron® Substances 0.000 description 1
- 229920000544 Gore-Tex Polymers 0.000 description 1
- 240000000797 Hibiscus cannabinus Species 0.000 description 1
- 229920006370 Kynar Polymers 0.000 description 1
- 229920000433 Lyocell Polymers 0.000 description 1
- 229920000784 Nomex Polymers 0.000 description 1
- 239000004936 P-84 Substances 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920013632 Ryton Polymers 0.000 description 1
- 239000004736 Ryton® Substances 0.000 description 1
- 229920003367 Teijinconex Polymers 0.000 description 1
- 229920004738 ULTEM® Polymers 0.000 description 1
- 229920004878 Ultrapek® Polymers 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229920006397 acrylic thermoplastic Polymers 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 210000000085 cashmere Anatomy 0.000 description 1
- 229920002301 cellulose acetate Polymers 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 239000004951 kermel Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 210000000050 mohair Anatomy 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- NQBKFULMFQMZBE-UHFFFAOYSA-N n-bz-3-benzanthronylpyrazolanthron Chemical compound C12=CC=CC(C(=O)C=3C4=CC=CC=3)=C2C4=NN1C1=CC=C2C3=C1C1=CC=CC=C1C(=O)C3=CC=C2 NQBKFULMFQMZBE-UHFFFAOYSA-N 0.000 description 1
- 239000004763 nomex Substances 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229920001643 poly(ether ketone) Polymers 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920000927 poly(p-phenylene benzobisoxazole) Polymers 0.000 description 1
- 229920003366 poly(p-phenylene terephthalamide) Polymers 0.000 description 1
- 229920003223 poly(pyromellitimide-1,4-diphenyl ether) Polymers 0.000 description 1
- 229920002577 polybenzoxazole Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920000131 polyvinylidene Polymers 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 239000004765 teijinconex Substances 0.000 description 1
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
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: I) A woven polymer coated 100% fiberglass flame barrier (Sandel®
- thermoplastic polyvinyl halide composition such as polyvinyl chloride (Firegard® Seating Barriers, Intek; Firegard® Brand Products, Chiquola Fabrics, LLC, Alessandra FR barrier cloth, McKinnon-Land, LLC)
- the disadvantages of the above mentioned flame baffler solutions for more stringent open-flame applications in upholstered furniture, mattress, foundations and other fiber-filled applications include: a) Woven flame bafflers, especially when coated with FR materials, impart a stiff "hand" to the composite article, which negatively affect the feel of the final product.
- 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:
- Inherently flame-retardant fibers such as; 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
- Fluoropolymeric fibers such as polytetrafluoroethylene (PTFE), for example, those sold under the tradenames TEFLON TFE by E. I. Du Pont de Nemours and Co., LENZING PTFE by Lenzing A.G., RASTEX by W.R. Gore and Associates, GORE- TEX by W.R. Gore and Associates, PROFILEN by Lenzing A.G. and TOYOFLON PTFE by Toray Industries Inc., poly (ethylene-chlorotrifluoroethylene) (E-CTFE), for example, those sold under the tradenames HALAR by Albany International Corp.
- PTFE polytetrafluoroethylene
- E-CTFE poly (ethylene-chlorotrifluoroethylene)
- PVDF polyvinylidene fluoride
- PFA polyperfluoroalkoxy
- FEP polyfluorinated ethylene-propylene
- Non-flame-retardant fibers such as: Cotton, wool, silk, mohair, cashmere, kenaf, jute, sisal, nylons, polyesters, polyolefins, rayons, lyocells, acrylics, cellulose acetates and polylactides, such as those available from fibers made with polylactide polymers from Cargill Dow Polymers; low-melt bicomponent polyesters, such as CELBOND sold by Kosa company; low melt copolyester fibers, typical "low-melt" fibers (polyester and polyolefins) used in the industry have melting points of 10OC to 21 OC while standard polyester fiber melts at approximately 260C; polypropylenes, such as T-I 51 as sold by Fiber Innovation Technology or by American Fibers and Yams Co.; and combinations thereof.
- Non-flame-retardant fibers such as: Cotton, wool, silk, mohair, cashmere, kenaf, jute, sisal
- 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 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.
- PROTEX PBX triblend sliver of modacrylic
- BASOFIL melamine
- 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 x 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 (KEVLAE.) thread.
- the above constructed mattress was tested at Underwriters Laboratories (Northbrook, IL) according to California Test Bulletin 603.
- the Peak Rate of Heat Release was 55 KW (maximum allowable rate of heat release is 200KW) and the Total Heat Release was 8.0 MJ (maximum allowable in first 10 minutes is 25 MJ). This test was considered a significant pass of CAL TB 603.
- 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.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Knitting Of Fabric (AREA)
- Treatment Of Fiber Materials (AREA)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP05794272A EP1789621A2 (en) | 2004-09-07 | 2005-09-07 | Knit tube flame resistant barriers |
CA 2579178 CA2579178A1 (en) | 2004-09-07 | 2005-09-07 | Knit tube flame resistant barriers |
MX2007002587A MX2007002587A (es) | 2004-09-07 | 2005-09-07 | Barreras resistentes a las flamas de tubo de punto. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US60736604P | 2004-09-07 | 2004-09-07 | |
US60/607,366 | 2004-09-07 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2006029077A2 true WO2006029077A2 (en) | 2006-03-16 |
WO2006029077A3 WO2006029077A3 (en) | 2009-04-23 |
Family
ID=36036922
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2005/031538 WO2006029077A2 (en) | 2004-09-07 | 2005-09-07 | Knit tube flame resistant barriers |
Country Status (5)
Country | Link |
---|---|
US (1) | US20060160451A1 (es) |
EP (1) | EP1789621A2 (es) |
CA (1) | CA2579178A1 (es) |
MX (1) | MX2007002587A (es) |
WO (1) | WO2006029077A2 (es) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014052568A2 (en) * | 2012-09-28 | 2014-04-03 | Axitek, Llc. | Heat curable composite textile |
US10053801B2 (en) | 2014-01-28 | 2018-08-21 | Inman Mills | Sheath and core yarn for thermoplastic composite |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090042474A1 (en) * | 2007-08-06 | 2009-02-12 | New Fibers Textile Corporation | Fire-retardant cloth structure |
JP2012530195A (ja) * | 2009-06-12 | 2012-11-29 | フェデラル−モーグル パワートレイン インコーポレイテッド | 高温耐磨耗性コーティングを有する織物スリーブ、ならびにその組立、構築および硬化方法 |
CN106283374A (zh) * | 2015-06-08 | 2017-01-04 | 东丽纤维研究所(中国)有限公司 | 一种经编面料和用途 |
US10648107B2 (en) * | 2016-02-08 | 2020-05-12 | Pbi Performance Products, Inc. | Fabric containing PBI-p fiber |
US20180220807A1 (en) | 2017-02-09 | 2018-08-09 | Fosbrooke, Inc. | Flame retardant cover |
US10827845B2 (en) | 2017-02-24 | 2020-11-10 | Sealy Technology, Llc | Support cushions including a support insert with a bag for directing air flow, and methods for controlling surface temperature of same |
WO2019014461A1 (en) | 2017-07-14 | 2019-01-17 | Bedgear, Llc | REFRESHING FABRIC AND BEDDING ARTICLE |
US11160386B2 (en) | 2018-06-29 | 2021-11-02 | Tempur World, Llc | Body support cushion with ventilation system |
US11691379B2 (en) * | 2019-06-20 | 2023-07-04 | Milliken & Company | Fire-resistant textile composite |
US20220307168A1 (en) * | 2021-03-29 | 2022-09-29 | Hornwood, Inc. | Mesh fabric and mesh fabric garment |
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US4794767A (en) * | 1987-08-14 | 1989-01-03 | Lombardi Victor J | Circular knit two-layer upholstery fabric and method |
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US3115693A (en) * | 1959-05-11 | 1963-12-31 | Du Pont | Process of making a knitted fabric |
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GB1557161A (en) * | 1975-06-04 | 1979-12-05 | Iws Nominee Co Ltd | Upholstery fabrics |
US4067210A (en) * | 1975-10-14 | 1978-01-10 | The United States Of America As Represented By The Secretary Of The Army | Warp knit fabric containing weft of protective yarn-covered activated-carbon yarn |
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DE9302039U1 (es) * | 1993-02-12 | 1993-04-01 | Hoechst Ag, 6230 Frankfurt, De | |
EP0675220B1 (de) * | 1994-03-31 | 1998-08-05 | Akzo Nobel Faser AG | Vandalismus-Schutzschicht |
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US6410140B1 (en) * | 1999-09-28 | 2002-06-25 | Basf Corporation | Fire resistant corespun yarn and fabric comprising same |
US6146759A (en) * | 1999-09-28 | 2000-11-14 | Land Fabric Corporation | Fire resistant corespun yarn and fabric comprising same |
US6287686B1 (en) * | 2000-05-31 | 2001-09-11 | Chapman Thermal Products, Inc. | Fire retardant and heat resistant yarns and fabrics made therefrom |
ES2190725B1 (es) * | 2001-03-02 | 2004-05-01 | Relats, S.A. | Utilizacion de una maquina de genero de punto por urdido para la fabricacion de un tubo de proteccion abierto o cerrado de cables, conductosy similares, y tubo de proteccion fabricado con dicha maquina. |
US6644070B2 (en) * | 2001-03-29 | 2003-11-11 | Asahi Kasei Kabushiki Kaisha | Three-dimensional fabric for seat |
US6688143B2 (en) * | 2001-12-05 | 2004-02-10 | Milliken & Company | Elastomeric knit fabric with antiflame properties |
US6800367B2 (en) * | 2002-04-25 | 2004-10-05 | Chapman Thermal Products, Inc. | Fire retardant and heat resistant yarns and fabrics incorporating metallic or other high strength filaments |
US6840066B2 (en) * | 2003-04-28 | 2005-01-11 | Hickory Springs Manufacturing Company | Webbing reinforced with high-performance polymeric yarns |
US7484256B2 (en) * | 2004-11-26 | 2009-02-03 | Murtzco, Llc | Fire retardant cover for mattresses |
-
2005
- 2005-09-07 WO PCT/US2005/031538 patent/WO2006029077A2/en active Application Filing
- 2005-09-07 EP EP05794272A patent/EP1789621A2/en not_active Withdrawn
- 2005-09-07 CA CA 2579178 patent/CA2579178A1/en not_active Abandoned
- 2005-09-07 US US11/219,881 patent/US20060160451A1/en not_active Abandoned
- 2005-09-07 MX MX2007002587A patent/MX2007002587A/es unknown
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4066812A (en) * | 1975-03-10 | 1978-01-03 | The William Carter Company | Fire retardant polyester textile materials and method of making same |
US4377195A (en) * | 1980-06-17 | 1983-03-22 | Hans Jack Weil | Private cubicle enclosure |
US4794767A (en) * | 1987-08-14 | 1989-01-03 | Lombardi Victor J | Circular knit two-layer upholstery fabric and method |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014052568A2 (en) * | 2012-09-28 | 2014-04-03 | Axitek, Llc. | Heat curable composite textile |
WO2014052568A3 (en) * | 2012-09-28 | 2014-05-22 | Axitek, Llc. | Heat curable composite textile |
US10053801B2 (en) | 2014-01-28 | 2018-08-21 | Inman Mills | Sheath and core yarn for thermoplastic composite |
US10815590B2 (en) | 2014-01-28 | 2020-10-27 | Inman Mills | Sheath and core yarn for thermoplastic composite |
Also Published As
Publication number | Publication date |
---|---|
WO2006029077A3 (en) | 2009-04-23 |
US20060160451A1 (en) | 2006-07-20 |
CA2579178A1 (en) | 2006-03-16 |
MX2007002587A (es) | 2007-05-16 |
EP1789621A2 (en) | 2007-05-30 |
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