WO2007041129A2

WO2007041129A2 - Fire retardant polymer compositions and products produced using the same

Info

Publication number: WO2007041129A2
Application number: PCT/US2006/037592
Authority: WO
Inventors: Joseph P. Mcfadyen
Original assignee: Wellman, Inc.
Priority date: 2005-10-03
Filing date: 2006-09-28
Publication date: 2007-04-12
Also published as: WO2007041129A3

Abstract

Fire retardant polymer compositions are disclosed. The fire retardant compositions include a polymer and a fire retardant in an amount sufficient to impart fire retardant properties to the polymer composition. The fire retardant can include an oxygen scavenging agent and a synergistic agent for facilitating the conversion of the oxygen scavenging agent into a form suitable for reacting with oxygen. Alternatively, the fire retardant can include an oxygen scavenging agent and a synergistic agent for lowering the melt viscosity of the polymer, or for promoting char formation, or both. Also disclosed are fire retardant products produced using the fire retardant compositions, such as fiberfill materials and bedding materials.

Description

FIRE RETARDANT POLYMER COMPOSITIONS AND PRODUCTS PRODUCED USING THE SAME

BACKGROUND OF THE INVENTION

[0001] The present invention relates to polymeric compositions exhibiting fire retardant properties and to fire retardant products produced using the same. [0002] Polymeric fibers exhibit many desirable properties useful for various applications. Polyester fiber, for example, can exhibit good tensile strength, resiliency, stretch and shrink resistance, and corrosion resistance, among others. Accordingly, polyester fiber is widely used in the manufacture of many textile articles. Due to its resilient nature, polyester fiber can be particularly useful as fiberfill material for home furnishings and bedding products, such as comforters, pillows, quilts, mattress pads, and the like. [0003] Thermoplastic polymers, such as unmodified polyester, can melt and drip when exposed to an open flame. This physical transformation can promote further fire development if the molten thermoplastic is trapped by cellulosic material, as can be the case in many bedding products. Despite this melt characteristic, thermoplastic polymers such as polyester typically are not prone to smoldering. The same physical transformation into a molten plastic when exposed to a smoldering heat source can accordingly help move the thermoplastic away from the heat source. Thus, polyester batting can perform well as measured by fire resistance tests set forth in 16 CFR 1632 (Standard for the Flammability of Mattresses and Mattress Pads, often referred to as the Cigarette Ignition Standard), as well as other tests, such as the Upholstered Furniture Action Council's (UFACs) Cigarette Smoldering Test and California Standard TB 106.

[0004] At the time the legislation codified at 16 CFR 1632 was enacted, cigarette ignited bed fires were a statistically significant leading cause of bed fires. While bedroom fires caused by cigarette ignition have declined, the percentage of fires caused by small open flames have increased, as reported in "Flammability: The issue heats up," Gordon Damant, BEDtimes, December 2001, pp. 25-32. Accordingly, increasingly stringent government regulations have been proposed to regulate the production of fire retardant consumer products, particularly bedding products. [0005] For example, California Assembly Bill 603 (AB603) required the California

Bureau of Home Furnishings and Thermal Insulation to create an open-flame standard for residential mattresses before January 1, 2004. This standard became known as Technical Bulletin 603. As an extension of AB603, the Bureau was also required to create a standard for filled articles used on top of the bed. The most recent draft of this standard, TB604 - Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing, issued October 1, 2004. The California Bureau tested filled bedding products, including comforter and pillow samples, and developed a small scale weight loss test (§§ 1 and 2), which evaluates fire resistance of a product as a function of weight loss over time. Contemporaneously, the National Institute of Standards and Technology (NIST) also conducted studies to evaluate the effect of small open flames on bed clothing. See "Effect of Bed Clothes Modifications on Fire Performance of Bed Assemblies, " Thomas J. Ohlemiller and Richard G. Gann, NIST Technical Note 1449, February 2003.

[0006] Polymer fiberfill materials can be modified to improve fire retardancy by replacing a portion or all of the polymer fiber with fire retardant fibers. Certain fire retardant fibers function via a fire poisoning mechanism to chemically bind free radical oxygen in the vapor space above a burning substrate. Other fire retardant fibers form a char when exposed to an ignition source. The char is typically substantially inflammable and further can assist in stopping the combustion cycle by insulating the fuel or preventing the oxygen and heat from reaching more fuel.

[0007] Despite the desired fire resistance properties of such materials, many conventional flame poisoning and/or char formation fibers can have limited resiliency. Accordingly, it can be difficult to manipulate conventional fire retardant fibers to form textile articles, particularly woven or knit fabrics. Further, fabrics formed of many conventional fire retardant fibers can have undesirable aesthetics, resulting in a product that is harsh to the touch. Fire retardant fibers can also be expensive, thereby increasing the costs associated with articles manufactured using the same, yet without the aesthetic properties consumers have come to expect.

[0008] Fire retardant agents can be topically applied to fibers and/or articles formed of the same to impart fire retardancy thereto. These treatments, however, typically are not durable to home launderings, and accordingly coatings of this type can wear or wash away over time. In addition, such finishes can negatively impact otherwise desirable textile properties of the fibers (e.g., hand and aesthetic appeal). Accordingly, fibers and/or other textile articles topically treated with conventional fire retardant coatings can be stiff and harsh to the touch.

BRIEF SUMMARY OF THE INVENTION

[0009] The present invention provides polymer compositions exhibiting fire retardant properties. The fire retardant compositions of the invention can be particularly useful for the production of fibers and other textile products, such as bedding products. In the invention, fire retardants are incorporated into a polymer composition and are not applied as a finish or other surface treatment to a substrate. According, products produced from the compositions of the invention can be inherently fire retardant. As such, the products can retain desired fire retardant characteristics following numerous launderings. In addition, products produced in accordance with the invention can maintain many properties inherent to the polymer, such as softness and other desirable aesthetic characteristics, mechanical strength, and the like. Such products can also exhibit good resiliency, in contrast to many conventional fire retardant products. Accordingly, fibers and other products of the invention can be more readily manipulated to form downstream articles. The resilient nature of the fibers of the invention can also render the fibers useful as fiberfill. The compositions can also be less expensive than many conventional fire retardant materials.

[0010] The fire retardant polymer compositions of the invention can include a polymer and a fire retardant in an amount sufficient to impart fire retardant properties to the polymer composition. The fire retardant can include an oxygen scavenging agent, which can decompose in the presence of heat to release oxygen scavenging species capable of chemically binding free radical oxygen in the vapor space above a burning substrate to aid in stopping the combustion cycle. Exemplary oxygen scavenging agents include brominated compounds, such as polybrominated polymeric compounds. Polybrominated polymeric compounds can be particularly advantageous due to their limited water solubility, thereby reducing environmental and/or health concerns that can be associated with the use of brominated compounds that are water soluble.

[0011] In one aspect of the invention, the fire retardant can further include a synergistic agent that can facilitate the conversion of the oxygen scavenging agent into a form suitable for reacting with oxygen. For example, it is currently believed that certain metallic compounds can improve the effectiveness of oxygen scavenging agents by reducing the vapor pressure of the oxygen scavenging agent, such as brominated compounds as noted above. This can facilitate the release of oxygen scavenging species from the oxygen scavenging agent (e.g., facilitate the release of bromine species in the case of brominated oxygen scavenging agents) into the vapor phase so that the oxygen scavenging species are more readily available to react with oxygen radicals. Exemplary synergistic agents capable of facilitating the conversion of the oxygen scavenging agent into a form more suited to react with oxygen include various metallic compounds, including antimony compounds. Sodium antimonite can be particularly useful because of its limited adverse interaction with various polymers, such as polyester.

[0012] In this aspect of the invention, the synergistic agent can be present as a plurality of particles having an average particle size selected to facilitate fiber production. The synergistic agent can have an average particle size that is sufficiently small to allow the composition to readily pass through spinneret apertures and to minimize clogging or other problems associated with the introduction of particles into a fiber spinning process. The particles can also have an average size selected to minimize deterioration of other fiber properties, such as tensile strength. As an example, the particles can have an average particle diameter of about three microns or less, which can be useful in the production of fibers and filaments having a denier ranging from about 0.8 to about 45 dpf.

[0013] In an alternative aspect of the invention, the synergistic agent can include a compound capable of interacting with the polymer to reduce or lower its melt viscosity, for example, by attacking the polymer chain to break bonds therein. In this manner, the synergistic agent can degrade or reduce the molecular weight of the polymer so that the polymer can melt away more quickly. Accelerating the physical transformation of the solid polymer into a molten form when exposed to a smoldering heat source is currently believed to help move the polymer away from the heat source. The synergistic agent can also promote char formation in addition to or as an alternative to degrading the polymer molecular weight. [0014] Exemplary synergistic agents in accordance with this embodiment of the invention include phosphorous compounds. Suitable phosphorous compounds include inorganic and organic phosphorous compounds. Alternatively, the phosphorous compound can be incorporated into the polymer chain.

[0015] The present invention can also include fibers having a cross sectional configuration selected to increase the surface area of the fiber, as compared to a fiber having a conventional round cross section with the same volume of polymer. The fibers can have any of various fiber cross sectional configurations to provide the desired increased fiber surface area, such as multilobed fibers having two, three, four, five, or more lobes extending outwardly from a central core region of the fiber. The increased surface area of the fibers in accordance with this embodiment of the invention is believed to improve the effectiveness of the oxygen scavenging agent by increasing the amount of oxygen scavenger exposed to the fiber surface and thus available for conversion into the vapor phase upon combustion. [0016] The present invention can further include textile products produced using the fire retardant compositions. Exemplary textile products in accordance with these aspects of the invention include, for example, fibers, filaments, yarns, fabrics, and articles, such as bedding products, fiberfill and the like. These and other products in accordance with the invention can exhibit desirable fire retardant properties, including fire retardant properties in compliance with the standards set forth in the Pillow Burn Test, California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004. The products of the invention can exhibit desired fire retardancy with minimal compromise of other desired properties, including aesthetic and mechanical properties.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: [0018] Figures IA-G illustrate cross sectional shapes of various multilobal fibers in accordance with exemplary embodiments of the invention; and

[0019] Figures 2 and 3 are graphs illustrating the fire retardant properties of pillows filled with polyester fiberfill modified with different fire retardant agents as determined using the Pillow Burn Test, California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004.

DETAILED DESCRIPTION OF THE INVENTION

[0020] The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0021] The fire retardant polymer compositions of the invention can include a thermoplastic polymer, although the invention is not so limited. The term thermoplastic polymer is used herein in its broadest sense, which is typically, although not necessarily exclusively, as defined in Hawley's Condensed Chemical Dictionmy, Eleventh Edition, as a polymer that softens when exposed to heat and returns to its original condition when cooled to room temperature.

[0022] Thermoplastic polymers contemplated as useful in the present invention include synthetic polymers capable of being processed to form filaments or fibers, for example, by melt spinning techniques as known in the art. Exemplary thermoplastic polymers suitable for the present invention include but are not limited to polyesters, polyamides, polyolefins, polycarbonates, polyacrylics, polyurethanes, and the like, as well as co- and/or terpolymers thereof and mixtures of such polymers with one another and/or with other polymers.

[0023] The present invention can be particularly useful for the production of fire retardant condensation polymer compositions, including polyester and polyamide polymer compositions. Polyester polymers useful in the invention include aromatic and aliphatic polyester polymers. Exemplary polyester polymers include but are not limited to polyethylene terephthalate (PET), polybutylene terephthalate, polytrimethylene terephthalate, polycyclohexylene-l,4-dimethylene terephthalate, and the like, as well as co- and/or terpolymers (such as isophthalate copolymers, polyethylene glycol copolymers, and the like) and mixtures thereof. As a non-limiting example, the polyester can be a polyester copolymer of polyester and polyethylene glycol, with the polyethylene glycol being present in an amount of between about six and 10% by weight, such as discussed in a number of commonly assigned issued patents, including U.S. Patent Nos. 6,214,270; 6,291,066; 6,294,254; 6,303,739; 6,322,886; 6,399,705; 6,454,982; 6,485,829; 6,509,091; 6,582,817; and 6,623,853, the contents of which are incorporated entirely herein by reference. Also contemplated as useful in the invention are polylactic acid (PLA) and polylactides and mixtures thereof.

[0024] Exemplary polyamide polymers useful in the present invention include without limitation nylon 6, nylon 6/6, nylon 4/6, nylon 11, nylon 12, nylon 6/10, nylon 6/12, nylon 12/12, copolymers of caprolactam and alkylene oxide diamine, and the like, as well as other co- and/or terpolymers and mixtures thereof.

[0025] The invention can also be useful for the production of fire retardant polyolefin compositions. Suitable polyolefins include without limitation polyethylene, e.g., high density polyethylene, medium density polyethylene, low density polyethylene and linear low density polyethylene; polypropylene, e.g., isotactic polypropylene, syndiotactic polypropylene, blends of isotactic polypropylene and atactic polypropylene, and blends thereof; polybutylene, e.g., poly(l-butene) and poly(2-butene); polypentene, e.g., poly(l- pentene) and poly(2-pentene); poly(3-methyl-l-pentene); poly(4-methyl 1-pentene); and co- and/or terpolymers and combinations thereof. Suitable co- and/or terpolymers include random and block copolymers prepared from two or more different unsaturated olefin monomers, such as ethylene/propylene and ethylene/butylene copolymers. [0026] These choices for the polymer used in practicing the invention herein are examples only and are not intended to limit the scope of the invention. In fact, the polymer may include blends of any of these polymer choices as necessary or desired. [0027] The thermoplastic polymers suitable for use in the practice of the invention may be made according to any of the methods known by those skilled in the art. Furthermore, the polymers used in the practice of the invention may also include additives commonly utilized in the production of these polymers. For example, the invention encompasses the use of polymers that incorporate colorants and additives such as stabilizers, branching agents, static dissipaters, delusterants, and the like and mixtures thereof. The methods of making all of these polymers as well as the use of additives to improve or impart specific properties are well known in the art. Accordingly, the methods of making these polymers are not discussed in detail herein.

[0028] The fire retardant polymer compositions according to the present invention can further include a fire retardant. Suitable fire retardants useful in this invention can include fire retardants capable of imparting fire-resistant or fire retardant properties to the compositions and to articles formed of the same. Filled products or articles including one or more components formed of the fire retardant compositions of the invention can, for example, comply with the fire resistance criteria set forth in the Pillow Burn Test, California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004 (referred to herein as "TB 604"), the entire disclosure of which is incorporated by reference. TB 604, §§ 1 and/or 2, measures fire resistance of a product as a function of weight loss over time. In this regard, filled articles in accordance with the present invention can exhibit a gross weight loss of less than 30% after three minutes, based on one test, and an average gross weight loss of less than 25% after three minutes, based on the average of three tests. Other fire resistance criteria can also be used in evaluating the fire retarding properties of the compositions and articles of the invention.

[0029] Fire retardant agents useful in the present invention can include oxygen scavenging fire retardant agents, which can decompose upon exposure to heat to release oxygen scavenging species capable of chemically binding free radical oxygen in the vapor space above a burning substrate to thereby aid in stopping the combustion cycle. Such fire retardant oxygen scavenging agents can also be referred to as flame poisoning agents. Suitable fire retardant agents that can act as oxygen scavengers useful in the present invention include halogenated compounds, which can include bromine, chlorine, fluorine, and/or a combination thereof. Generally, such halogenated compounds can decompose to release halogenated species capable of reacting with oxygen species. Exemplary halogenated fire retardant agents useful in the invention include without limitation brominated compounds such as polybrominated biphenyl compounds, polybrominated diphenyl ether compounds, polybrominated polymeric compounds, and the like, and mixtures thereof. Exemplary polybrominated biphenyl and polybrominated diphenyl ether compounds useful in the invention include without limitation tetrabromobisphenol A (TBA), polybromodiphenylether (PBDPE), and the like, and mixtures thereof. Exemplary halogenated polymeric compounds useful in the invention include without limitation brominated polystyrene, brominated poyphenylene ether, and the like, and mixtures thereof. Halogenated polymeric compounds that are not water soluble can be particularly useful in the present invention because of reduced environmental and/or health concerns associated with the use of the same.

[0030] The term brominated polystyrene as used herein includes homopolymers of dibromostyrene and post-brominated polystyrene. Brominated polystyrene useful in accordance with the present invention can have a molecular weight ranging from about 200 to about 200,000 g/mol, although the present invention is not so limited and compounds having a molecular weight outside of the recited ranges can also be useful in various aspects of the invention. Exemplary brominated polystyrene compounds can also include compounds having a bromine content of at least about 20%, and typically at least about 50%, or higher, although again the present invention is not so limited and compounds having a bromine content outside of this range can also be useful in various aspects of the invention. Exemplary brominated polyphenylene ethers can also have a molecular weight ranging from about 200 to about 200,000 g/mol and a bromine content of at least about 20%, and typically at least about 50%, or higher, although compounds having a molecular weight and/or bromine content outside of these recited ranges can also be useful in various aspects of the present invention. These and other exemplary brominated polymeric compounds are known in the art and are commercially available, for example, from Great Lakes Chemical Corporation under the Firemaster® family of fire retardant products, including without limitation Firemaster® BP41 1; from China Wanda Group Co. Ltd.; and from Albemarle Corporation under the SAYTEX® and PYRO-CHEK® families of flame retardant products. [0031] The fire retardant polymer compositions of the invention can further include at least one additional fire retardant agent that can have a synergistic effect when used in combination with the oxygen scavenging fire retardant agents described herein. In one aspect of the invention, the fire retardant polymer compositions can include at least one additional fire retardant agent that is capable of facilitating the conversion of the oxygen scavenging fire retardant agent into a form suitable for reacting with oxygen. Although not wishing to be bound by any explanation or theory of the invention, it is currently believed that certain metallic compounds can improve the effectiveness of oxygen scavenging fire retardant agents, such as the halogenated fire retardant agents described herein, by reducing the vapor pressure of the oxygen scavenging agent. This, in turn, is currently believed to facilitate decomposition of the oxygen scavenging agent and facilitate the release of oxygen scavenging species into the vapor phase so that the oxygen scavenging species can be more readily available to react with oxygen radicals (for example, can increase the rate of release of such oxygen scavenging species).

[0032] Exemplary metallic fire retardant agents capable of facilitating the conversion of an oxygen scavenging fire retardant agent into a form suitable for reacting with oxygen in accordance with this aspect of the invention can include antimony compounds, although other metallic compounds including tin, zinc, molybdenum, zirconium, barium, and the like, and mixtures thereof, can also be useful in this aspect of the invention. Exemplary metallic compounds suitable for use in this embodiment of the invention can include without limitation antimony trioxide, antimony pentaoxide, sodium antimonate, tin oxide, tin hydroxide, zinc stannate, zinc hydroxystannate, molybdenum oxide, ammonium molybdate, zirconium oxide, zirconium hydroxide, zinc borate, zinc metaborate and barium metaborate, and the like, and mixtures thereof. Sodium antimonate can be useful in polyester compositions because it can minimally degrade the polymer chain.

[0033] The metallic fire retardant agent can be generally provided in particulate form, for example, as a powder, flat particles (i.e. platelets) and elongated particles (needles), and the like, and mixtures thereof. The average particle size (diameter) of the metallic fire retardant agent can be selected to promote fiber production. As an example, the average particle size of the metallic fire retardant can be small enough to readily pass through spinneret apertures and/or polymer distribution media to thereby minimize clogging or other problems associated with the introduction of particles into a fiber spinning process. Selection of an appropriate average particle size can also depend on other factors, such as polymer processing conditions, fiber diameter, and the like. The particles can also have an average size selected to minimize deterioration of other fiber properties, such as tensile strength. For particles that are flat or elongated, the particle size refers to the length along the long axis of the particle (i.e. the long dimension of an elongated particle or the average diameter of the face of a platelet).

[0034] In this aspect of the invention, the metallic fire retardant agent particles can have an average particle diameter of about three microns or less. Metallic fire retardant agent particles in accordance with this aspect of the invention having an average particle diameter of about one micron or less can be particularly useful. Metallic fire retardant agent particles having an average particle size of about three or less microns, and about one micron or less, can be useful in the production of fibers and filaments having a denier ranging from about 0.8 to about 45 dpf, for example from about 1 to about 45 dpf, for example from about 3 to about 45 dpf, and for example from about 3 to about 10 dpf.

[0035] The fire retardant agents, including the oxygen scavenging agent and the synergistic agent capable of facilitating the conversion of the oxygen scavenging agent into a form suitable for reacting with oxygen, can be present in the polymer composition in an amount sufficient to impart the desired fire retardant properties to the composition and to articles, such as fibers and filaments, produced from the fire retardant polymer composition. As a non-limiting example, the fire retardant agents can be present in the composition in an amount sufficient to impart fire retardant properties to filled articles including one or more components produced therefrom sufficient to comply with the fire resistance criteria set forth in TB 604, §§ 1 and/or 2, as discussed above.

[0036] As an additional non-limiting example, the composition can include the oxygen scavenging agent in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the composition. The composition can also include the synergistic agent capable of facilitating the conversion of the oxygen scavenging agent into a form suitable for reacting with oxygen in an amount ranging from about 0.5 to about 10, for example from about 1 to about 7, for example from about 2 to about 7, percent by weight, based on the total weight of the composition. Exemplary compositions can include, for example, brominated polymeric compounds and antimony compounds in amounts sufficient to provide an atomic halogen to atomic antimony ratio ranging from about 3: 1 to about 8:1. The fire retardants can also be present in the composition in amounts outside of these ranges, so long as the resultant composition exhibits the desired fire retardant properties. [0037] In an alternative aspect of this embodiment of the invention, the fire retardant polymer composition of the invention can include an oxygen scavenging fire retardant agent as described herein in combination with at least one additional fire retardant agent that can have a synergistic effect when used in combination with the oxygen scavenging fire retardant agent, which additional synergistic fire retardant agent operates via a different mechanism than that described above with respect to antimony and other metallic fire retardant agents. In this aspect of the invention, the additional synergistic fire retardant agent can include fire retardant agents capable of reducing or lowering polymer melt viscosity. Although not wishing to be bound by any explanation or theory of this aspect of the invention, it is currently believed that the additional fire retardant agent can attack (and/or can react to form a compound capable of attacking) a polymer chain to scission or break bonds therein. In this manner, the additional fire retardant agent can degrade or reduce the molecular weight of the polymer so that the polymer can melt away more quickly. Accelerating the physical transformation of the solid polymer into a molten form when exposed to a smoldering heat source is currently believed to help move the polymer away from the heat source. [0038] Also in this aspect of the invention, the additional synergistic fire retardant agent can include fire retardant agents capable of promoting char formation, in addition to or as an alternative to reducing polymer melt viscosity. Also without being bound by any explanation or theory of the invention, it is currently believed that various compounds having a plurality of carbon atoms in close proximity and/or high density can promote char formation by cross linking reactions. [0039] An exemplary non-limiting category of compounds useful in this aspect of the invention can include phosphorous compounds exhibiting fire retardant properties. Exemplary phosphorous compounds useful in the invention can include phosphoric acid and/or phosphorous compounds capable of creating phosphoric acid in the presence of heat, which in turn can attack the polymer chains and reduce polymer melt viscosity, as described herein. Other exemplary phosphorous compounds can promote char formation, such as cyclic phosphorous compounds as described herein, in addition to or in the alternative to lowering polymer melt viscosity.

[0040] Various phosphorous fire retardants can be useful, including without limitation inorganic phosphorous compounds, such as phosphoric acid, and the like, and mixtures thereof. Additional representative classes of phosphorous fire retardants can include organic phosphorous compounds, such as but not limited to fire retardant phosphates, phosphites, phosphonates, phosphonium salts, and the like, and derivatives and mixtures thereof.

[0041] Representative phosphate fire retardants useful in the present invention include, for example, ammonium phosphate, ammonium polyphosphate, guanidine phosphate, triphenylphosphate, tricresylphosphate, tris(betachloroethyl)phosphate, tris(dichloropropyl)phosphate, tributyl phosphate, tributoxyethylphosphate, cresyldiphenylphosphate, 2-ethylhexyldiphenyl-phosphate, tris (2-ethylhexyl)phosphate, poly (m-phenylenephenylphosphate), resorcinol bis(diphenylphosphate), bisphenol A bis(diphenylphosphate), resorcinol bis(dicresylphosphate), bisphenol A bis(dicresylphosphate), resorcinol bis(di-2,6-xylenylphosphate), tris(2,3- dibromopropyOphosphate, tris(2,3-bromochloropropyl)phosphate, tris(tribromoneopentyl)phosphate, bis(2,3-dibromopropyl)2,3-dichloropr-opyl phosphate, and the like, and mixtures thereof. Representative phosphite fire retardants useful in the present invention include, for example, diphenyldecylphosphite, phenyldidecylphosphite, tridecylphosphite, tri(2-ethylhexyl)phosphate, trimethylphosphite, triphenylphosphite, tri(isodecyl)phosphate, distearylpentaerythrityldiphosphite, and the like, and mixtures thereof. Also useful are phosphorous compounds commercially available from Albemarle Corporation under the Antiblaze® family of fire retardants, such as phosphonic acid, methyl- , bis[5-ethyl-2-methyl-2-oxido-l,3,2-dioxaphosphorinan-5-yl)methyl]ester. Representative phosphonate fire retardants useful in the invention include, for example, vinyl phosphonates, poly(m-phenylene phenylphosphonate), poly (4,4'-oxyphenylenesulfone phenylphosphonate), poly (m-phenylene chloromethylphosphonate), and the like, and mixtures thereof. Representative phosphonium salt fire retardants useful in the present invention include, for example, tetrakis hydroxymethy] phosphonium sulfate, tetrakis hydroxy phosphonium chloride (i.e., tetrakis hydroxymethyl phosphonium chloride), and the like, and mixtures thereof. Compounds that can be useful in char formation can include cycloorganic phosphorous compounds having carbon atoms in sufficiently close proximity and/or density to one another to promote crossl inking. Exemplary phosphorous compounds that can be useful for char formation in accordance with this aspect of the invention can include the Amgard family of phosphorous compounds commercially available from Rhodia. These and other phosphorous compounds useful as fire retardant agents are also commercially available. [0042] Alternatively, or in addition to, the fire retardant phosphorous compounds described above, the fire retardant phosphorous compound can be incorporated into the polymer chain. As a non-limiting example, a phosphorous compound can be incorporated into a polyester polymer chain (such as a polyethylene terephthalate polymer chain) during the polymer production process. The general aspects of various techniques for the incorporation of phosphorous into a polymer chain, including the incorporation of phosphorous into a condensation polymer such as a polyester, are generally well established. Accordingly, persons of ordinary skill in this art will be able to carry out this aspect of the invention without undue experimentation. Polymers including a phosphorous compound incorporated into the polymer chain are commercially available as well, including the Avora® series of polyester polymers commercially available from Invista. Additives and/or comonomers suitable for incorporating phosphorous into a polymer chain are also commercially available from various sources, including Eastman Chemical Company and Schill + Seilacher.

[0043] In this aspect of the invention, the fire retardant agents, including the oxygen scavenging agent and the synergistic agent capable of interacting with the polymer to reduce or lower its melt viscosity and/or promote char formation, or both, can be present in the polymer composition in an amount sufficient to impart the desired fire retardant properties to the compositions and to articles, such as fibers and filaments, produced from the fire retardant polymer composition. As a non-limiting example, the fire retardant agents can be present in the composition an amount sufficient to impart fire retardant properties to filled articles including one or more components produced therefrom sufficient to comply with the fire resistance criteria set forth in TB 604, §§ 1 and/or 2, as discussed above. [0044] As an additional non-limiting example, the composition can include the oxygen scavenging agent in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the composition. The composition can also include the synergistic agent capable of capable of interacting with the polymer to reduce or lower its melt viscosity, and/or promote char formation, or both, such as the phosphorous compounds described herein, in an amount ranging from about 0.1 to about 4, and higher, percent by weight, for example, from about 0.1 to about 1.0 percent by weight, based on the total weight of the composition. Stated differently, the composition can include elemental phosphorous in an amount ranging from about 0.01 to about 1 percent by weight, based on the total weight of the composition, although amounts outside of this range can also be used in accordance with the invention. The fire retardants can also be present in the composition in amounts outside of these ranges, so long as the resultant composition exhibits the desired fire retardant properties.

[0045] In other aspects of this embodiment of the invention, the composition can include an oxygen scavenging fire retardant agent as described above in combination with at least two additional fire retardant agents, each of which can have a synergistic effect when used in combination with the oxygen scavenging fire retardant agent, and each of which can operate via different mechanisms. As an example, the composition can include a fire retardant oxygen scavenging agent, such as the halogenated compounds described above; at least a first synergistic agent capable of facilitating the conversion of an oxygen scavenging fire retardant agent into a form suitable for reacting with oxygen, such as the antimony and other metallic compounds described above having a particle size of about 3 microns or less; and at least a second synergistic agent capable of interacting with the polymer to reduce or lower its melt viscosity, or promote char formation, or both, such as the phosphorous compounds described above.

[0046] The fire retardant agents in accordance with this aspect of the invention can be present in amounts as also described above. In this aspect of the invention, it is noted that the fire retardant performance of formulations including relatively small amounts of an oxygen scavenging agent, such as the halogenated polymeric compounds described herein, and a synergistic agent capable of facilitating the conversion of an oxygen scavenging Fire retardant agent into a form suitable for reacting with oxygen, such as the antimony and other metallic compounds described herein, can be effectively boosted to desired levels by the addition of relatively small quantities of a second synergistic agent, such as the compounds described herein capable of interacting with the polymer to reduce or lower its melt viscosity, or promote char formation, or both. In this manner, the amounts of the various flame retardants can be reduced to levels approaching the lower end of the ranges set forth herein, and even in amounts less than the amounts set forth above. As a non-limiting example, useful compositions in accordance with this aspect of the invention can include an oxygen scavenging agent (such as a brominated polymeric compound) in an amount of less than or about 5 percent by weight, and even less than or about 3 percent by weight; a synergistic agent capable of facilitating the conversion of an oxygen scavenging fire retardant agent into a form suitable for reacting with oxygen (such as an antimony compound) in an amount of less than or about 2 weight percent, and even less than or about 1 weight percent; and a second synergistic agent as described herein capable of interacting with the polymer to reduce or lower its melt viscosity, or promote char formation, or both, such as a phosphorous compound, in an amount sufficient to provide about 1500 ppm elemental phosphorous, although lesser or greater amounts of such compounds can also be effective. Stated differently, compositions including a combination of at least three fire retardant agents as described herein can include reduced amounts of one or more of the fire retardants and still exhibit useful fire retardant properties.

[0047] The fire retardants can be added to the composition using techniques known in the art. The general aspects of various techniques for the incorporation of additives such as fire retardants to a polymer composition are generally well established. Furthermore, those familiar with the production of polymers will recognize that the details of a given technique can and will vary, depending upon the relevant circumstances. Accordingly, descriptions given herein are most appropriately given in a general and schematic sense with the recognition that those persons of skill in this art will be able to carry out the invention based on the disclosures herein without undue experimentation.

[0048] As a non-limiting example, the fire retardants can be admixed with the polymer using traditional masterbatching processes. As known in the art, in a masterbatch process, a desired additive, in this case a fire retardant as described herein, is dispersed at a relatively highly concentrated level within a carrier polymer. In a following process step, the masterbatch of polymer and high concentration of fire retardant is introduced to a melt of the polymer (for example to the melt spinning system of the polymer) and blended with virgin polymer at a ratio to achieve the desired fire retardant properties of the resultant product, such as a fiber. Alternatively, the highly concentrated carrier polymer/additive blend can be admixed with the virgin polymer in dry form. In yet another alternative, one or more of the additives can be suspended or dissolved in an aqueous media, and the resultant suspension or solution can be mixed with the polymer in dry or melt form at a ratio to achieve the desired fire retardant properties of the resultant fiber.

[0049] Alternatively, instead of preparing a masterbatch, the fire retardant can be added directly to the base chip polymer in the extruder or just prior to a manifold system. Thereafter, the melt phase polymer is spun into filament form using a block, pack, and spinneret from which filaments are forwarded to appropriate take-up system that typically includes various finishing and packaging steps. The invention is also useful in direct-coupled continuous polymerization and spinning systems that omit the chip-making and extrusion steps and instead direct the polymerized melt directly to the spinneret. In such cases the fire retardant can be added to a manifold system prior to the spinneret. [0050] The present invention further includes articles exhibiting fire retardant properties formed of the fire retardant polymer compositions described herein, including without limitation fibers and filaments produced using melt spinning techniques. Wet- spinning and dry-spinning may also be used. The term "fiber" as used herein refers to fibers of finite length, such as conventional staple fiber, and to substantially continuous structures, such as continuous filaments (e.g., partially oriented yarn (POY), flat-drawn yarn, or textured yarn), unless otherwise indicated. Thus, the terms "fiber" and "filament" are somewhat interchangeable and are used interchangeably herein. If a more precise meaning is required for either of these terms, such meaning will be easily understood by those of ordinary skill in the art based on the contextual use of these terms.

[0051] The fibers of the invention can be hollow or non-hollow fibers and further can have a substantially round or circular cross section or a non-circular cross section (for example, oval, rectangular, multi-lobed, and the like). In one embodiment of the invention, the fibers can have a cross sectional configuration selected to increase the surface area of the fiber, as compared to a fiber having a conventional substantially round cross section with the same volume of polymer.

[0052] The fibers can have any of various fiber cross sectional configurations to provide the desired increased fiber surface area. As a non-limiting example, the fiber can be a muitilobed fiber, for example, a fiber having two, three, four, five, or more lobes extending outwardly from a central core region of the fiber. Figures IA- IG illustrate several exemplary fiber cross sectional configurations useful in accordance with the present invention. Figure IA illustrates, in cross section, an exemplary bilobal fiber 10 having two lobes 12 and 14. Figures IB, C, and D each illustrate, in cross section, exemplary trilobal fibers 20, 20' and 20." Each of fibers 20, 20' and 20" has three lobes, namely, lobes 22, 24 and 26; lobes 22', 24' and 26'; and 22", 24" and 26", respectively. The three lobes of fibers 20, 20' and 20" are positioned about 160 degrees relative to one another. In addition, Figure ID illustrates a trilobal fiber in which each lobe further includes a cap or end portion 28. Although illustrated with respect to the tribobal fibers, any of the muitilobed fiber cross sections in accordance with the present invention can include a cap or end portion as a part of one or more lobes. Figures IE and F illustrate in cross section quadrilobal fibers 30 and 30.' Fiber 30 includes four lobes 42, 44, 46 and 48 arranged in a generally cross like configuration, and fiber 30' includes four lobes 42', 44', 46' and 48' arranged in a generally star-like configuration. Figure IG illustrates, in cross-section, a pentalobal bicomponent fiber 50 having five lobes 52, 54, 56, 58 and 60 arranged at approximately 72-degree angles to each other. [0053] The skilled artisan will appreciate that the fire retardant fibers of the invention exhibiting the above noted surface area to volume ratio are not limited to the illustrated cross sections. Accordingly, the present invention also includes fire retardant fibers with more than five lobes as well as fibers having cross sectional configurations different from those illustrated, so long as a particular cross section provides the noted increased surface area. [0054] The fire retardant fibers of the invention can be monocomponent fibers, i.e., having a single polymeric component or segment along the length of fiber. Alternatively, the fibers of the invention can be multicomponent fibers, i.e., having two or more structured polymeric components or segments along the length of the fiber, including without limitation cross-sectional configurations such as a sheath/core, pie/wedge, side-by-side, segmented round, segmented oval, segmented rectangular, segmented multilobal, and the like. [0055] Any size fiber may be made according to the present invention. Exemplary fibers in accordance with the present invention can, for example, have a denier ranging from abut 0.8 to about 45 dpf. Fibers having a denier ranging from about 1 to about 45 dpf, from about 3 to about 45 dpf, and/or from about 3 to about 10 dpf, can also be useful, particularly in the manufacture of fire retardant bedding products.

[0056] The present invention also provides fire retardant articles including the fire retardant fibers and/or filaments described herein. For example, continuous filaments produced in accordance with the present invention can be drawn and processed to form continuous filament yarns. Alternatively, the continuous filaments can be cut into staple fiber that is then used to form yarns by methods known in the art, such as twisting or air entanglement.

[0057] The yarns in accordance with the invention can include the fire retardant fibers and/or filaments as described herein, optionally blended with at least one additional fiber and/or filament. As a non-limiting example, the yarns can include fibers exhibiting fire retardant properties, such as char formation (also "char in place") fibers. Char formation fibers are known in the art and can be generally described as fibers that form a char (or residue that is substantially inflammable) upon exposure to heat. Exemplary materials useful for the production of char in place type fibers and other fire retardant fibers useful in the invention include, for example, cellulosic materials such as cotton, aramids (such as Kevlar® and Nomex®), carbon, carbonizable compositions, metal, glass, polybenzimidazoles, polyimides, polyarenes, and the like, and mixtures thereof. The yarns of the invention can also include other fiber types, including without limitation synthetic polymer fibers such as polyester fibers, polyamide fibers, polyolefin fibers, polyacrylic fibers, elastomeric fibers, and the like, and mixtures thereof.

[0058] The invention further provides fire retardant fabrics including the fire retardant fibers described herein. The fabrics of the invention can be produced by knitting, weaving, or other methods using conventional processes and machinery. Nonwoven fabrics can also be made according to any of the known processes for making nonwoven fabrics, including processes that use mechanical, electrical, pneumatic, or hydrodynamic means for assembling fibers into a web. For example, nonwoven webs can be prepared by melt spinning the fire retardant polymer composition of the invention into fibers and forming the fibers into a web by carding, airlaying, or wetlaying. Nonwoven webs can also be formed by melt spinning the fire retardant composition directly into fibrous webs by spunbonding or meltblowing processes. The webs can be bonded using techniques as known in the art, such as but not limited to mechanical bonding (such as hydroentanglement or needlepunching), thermal bonding (such as through air bonding, calendering, or microwave or other RF treatments), and the like, to form a coherent fabric structure.

[0059] The fabrics of the invention can further include additional fibers and/or yarn also having fire retardant properties, such as char forming fibers including cellulosic materials (such as cotton), aramids (such as Kevlar® and Nomex®), carbon, carbonizable compositions, metal, glass, polybenzimidazoles, polyimides, polyarenes, and the like, and mixtures thereof, as described above. The fabrics of the invention can also include other fiber and/or yarn types, including without limitation synthetic polymer fibers such as polyester fibers, polyamide fibers, polyolefin fibers, polyacrylic fibers, elastomeric fibers, and the like, and mixtures thereof, also as described above.

[0060] The fire retardant fibers of the present invention can also be useful in the production of a various other textile products. Examples of products that can be prepared using the fire retardant fibers of the invention include, but are not limited to, bedding materials (such as bedclothing, mattresses, mattress and pillow covers, mattress ticking, and the like); filling materials and battings (such as loose polymer fiber and bonded battings); absorbent cores; apparel (such as protective apparel for firefighters, military personnel, and the like); home and office furnishings (such as draperies, upholstery components, and the like); seating components for vehicles such as automobiles, trucks, trains, airplanes, buses, and the like; and building materials (such as wall coverings, wall panels, office panel partitions, ceiling panels, floor coverings and the like).

[0061] Similar to the yarns and fabrics described herein, these and other such articles of the invention can also include at least one additional fiber having fire retardant properties, for example, fibers and/or yarns formed of fire retardant materials including cellulosic materials, aramids (such as Kevlar® and Nomex®), carbon, carbonizable compositions, metal, glass, polybenzimidazoles, polyimides, polyarenes, and the like, and mixtures thereof. The textile articles can also include other fiber types, including without limitation synthetic polymer fibers such as polyester fibers, polyamide fibers, polyolefin fibers, polyacrylic fibers, elastomeric fibers, and the like, and mixtures thereof.

[0062] The present invention is particularly useful in the production of filled bedding materials, such as filled bedclothing and/or top-of-the-bed articles, including without limitation comforters, quilts, quilted duvet covers, quilted bed pads, bedspreads, bed pillows, bed rest cushions, mattress pads, quilted bed shams, quilted pillow cases, padded bed headboards, foam topper pads, and the like. The present invention is also particularly useful for the production of batting or filler materials for filled bedclothing and/or top-of-the-bed articles and/or other home furnishing articles.

[0063] Figures 2 and 3 graphically illustrate the improved fire retardant properties exhibited by various articles produced in accordance with this aspect of the invention. Figure 2 is a plot of the gross weight loss of various sample pillows over time following ignition. The evaluated samples include pillows with a standard, unmodified polyester fiberfill (e.g., a polyester fiberfill that is not treated for fire retardancy) and pillows with a polyester fiberfill topically treated with a fire retardant formulation including halogen and antimony ("A" and "B").

[0064] Figure 3 is also a plot of the gross weight loss of various sample pillows over time following ignition. Sample pillows include various polyester fiberfill materials, including polyester fiberfill modified in accordance with the present invention. In the examples in which the fiberfill includes bromine, antimony and phosphorus, phosphorous is applied to the fiberfill material as an aqueous solution. The phosphorous is believed to diffuse into amorphous regions of the polymer, generally in an amount of about 1500 ppm elemental phosphorous. Even these small quantities of phosphorous can be sufficient to boost the performance of the bromine/antimony based fire retardant. This application can also have sufficient durability to withstand conventional home laundering temperatures. [0065] In the drawings and specification there has been set forth exemplary embodiments of the invention, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

Claims

THAT WHICH IS CLAIMED IS:

1. A polymer composition exhibiting fire retardant properties, comprising: a polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said polymer composition, said fire retardant comprising an oxygen scavenging agent and a synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said synergistic agent comprises a plurality of particles having an average particle size of less than or about 3 microns.

2. The polymer composition of Claim 1 , wherein said synergistic agent comprises a plurality of particles having an average particle size of less than or about 1 micron.

3. The polymer composition of Claim 1, wherein said fire retardant is present in said composition in an amount sufficient so that an article comprising said composition passes the Pillow Burn Test as set forth in California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004.

4. The polymer composition of Claim 3, wherein said fire retardant is present in said composition in an amount sufficient so that an article comprising said composition tested in accordance with California TB 604, §§ 1 and/or 2, exhibits a gross weight loss of less than 30% after three minutes, based on one test, and an average gross weight loss of less than 25% after three minutes, based on the average of three tests.

5. The polymer composition of Claim 1, wherein said oxygen scavenging agent comprises a halogenated compound having oxygen scavenging properties.

6. The polymer composition of Claim 5, wherein said halogenated compound comprises a compound including bromine, chlorine, fluorine or a combination thereof.

7. The polymer composition of Claim 6, wherein said halogenated compound comprises bromine.

8. The polymer composition of Claim 7, wherein said brominated compound is selected from the group consisting of polybrominated biphenyl compounds, polybrominated diphenyl ether compounds, polybrominated polymeric compounds, and mixtures thereof.

9. The polymer composition of Claim 8, wherein said brominated compound comprises a polybrominated polymeric compound.

10. The polymer composition of Claim 9, wherein said polybrominated polymeric compound has a molecular weight ranging from about 200 g/mol to about 200,000 g/mol.

11. The polymer composition of Claim 9, wherein said polybrominated polymeric compound comprises polybrominated polystyrene.

12. The polymer composition of Claim 5, wherein said synergistic agent lowers the vapor pressure of said oxygen scavenging agent.

13. The polymer composition of Claim 12, wherein said synergistic agent comprises a metallic compound.

14. The polymer composition of Claim 13, wherein said metallic compound comprises a metal selected from the group consisting of antimony, tin, zinc, molybdenum, zirconium, barium, and mixtures thereof.

15. The polymer composition of Claim 14, wherein said metallic compound comprises an antimony compound.

16. The polymer composition of Claim 15, wherein said antimony compound is selected from the group consisting of antimony trioxide, antimony pentaoxide, sodium antimonate, and mixtures thereof.

17. The polymer composition of Claim 16, wherein said antimony compound comprises sodium antimonate.

18. The polymer composition of Claim 15, comprising atomic halogen and atomic antimony in a ratio ranging from about 3: 1 to about 8:1.

19. The polymer composition of Claim 15, comprising said halogenated compound in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the composition, and comprising said antimony compound in an amount ranging from about 0.5 to about 10 percent by weight, based on the total weight of the composition.

20. The polymer composition of Claim 19, comprising said antimony compound in an amount ranging from about 2 to about 7 percent by weight, based on the total weight of the composition.

21. The polymer composition of Claim 1 , further comprising at least an additional synergistic agent for lowering the melt viscosity of said polymer, or for promoting char formation, or both.

22. The polymer composition of Claim 15, further comprising at least an additional synergistic agent comprising a phosphorous compound.

23. The polymer composition of Claim 19, further comprising at least an additional synergistic agent comprising a phosphorous compound, wherein the phosphorous compound is present in the composition in an amount sufficient to provide from about 0.01 to about 1 weight percent elemental phosphorous, based on the total weight of the composition.

24. The polymer composition of Claim 1, wherein said polymer comprises a thermoplastic polymer.

25. The polymer composition of Claim 24, wherein said thermoplastic polymer comprises a condensation polymer.

26. The polymer composition of Claim 25, wherein said condensation polymer comprises a polyester polymer.

27. The polymer composition of Claim 26, wherein said polyester polymer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polycyclohexylene-l,4-dimethylene terephthalate, co- and terpolymers thereof, and mixtures thereof.

28. The polymer composition of Claim 27, wherein said polyester polymer comprises polyethylene terephthalate.

29. The polymer composition of Claim 25, wherein said condensation polymer comprises a polyamide polymer.

30. The polymer composition of Claim 29, wherein said polyamide polymer is selected from the group consisting of nylon 6, nylon 6/6, nylon 4/6, nylon 1 1, nylon 12, nylon 6/10, nylon 6/12, nylon 12/12, copolymers of caprolactam and alkylene oxide diamine, and mixtures thereof.

31. The polymer composition of Claim 24, wherein said thermoplastic polymer is selected from the group consisting of polyolefins, polycarbonates, polyacrylics, polyurethanes, and mixtures thereof.

32. The polymer composition of Claim 31 , wherein said thermoplastic polymer comprises a polyolefin polymer.

33. The polymer composition of Claim 32, wherein said polyolefin polymer is selected from the group consisting of polypropylene, polyethylene, polybutylene, polypentene, co- and terpolymers thereof and mixtures thereof.

34. The polymer composition of Claim 24, wherein said thermoplastic polymer comprises polylactic acid.

35. A polymer composition exhibiting fire retardant properties, comprising: a thermoplastic polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said polymer composition, said fire retardant comprising a brominated polymeric component and an antimony compound, wherein said antimony compound comprises a plurality of particles having an average particle size of less than or about 3 microns.

36. The polymer composition of Claim 35, wherein: said thermoplastic polymer comprises a condensation polymer; said brominated polymeric component comprises brominated polystyrene; and said antimony compound comprises sodium antimonate in the form of a plurality of particles having an average particle size of less than or about 3 microns.

37. The polymer composition of Claim 36, wherein said condensation polymer comprises polyester.

38. The polymer composition of Claim 35, further comprising at least one additional synergistic agent for lowering the melting point of said polymer, or for promoting char formation, or both, wherein said at least one additional synergistic agent comprises a phosphorous compound.

39. The polymer composition of Claim 36, comprising: said brominated polystyrene in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the composition; and said sodium antimonate in an amount ranging from about 2 to about 7 percent by weight, based on the total weight of the composition.

40. The polymer composition of Claim 39, further comprising elemental phosphorous in an amount ranging from about 0.01 to about 1 weight percent, based on the total weight of the composition.

41. A filament exhibiting fire retardant properties, comprising: a polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said filament, said fire retardant comprising an oxygen scavenging agent and a synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said synergistic agent comprises a plurality of particles having an average particle size of less than or about 3 microns.

42. The filament of Claim 41, wherein said synergistic agent comprises a plurality of particles having an average particle size of less than or about 1 micron.

43. The filament of Claim 41, wherein said fire retardant is present in said filament in an amount sufficient so that an article comprising said filament passes the Pillow Burn Test as set forth in California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004.

44. The filament of Claim 43, wherein said fire retardant is present in said filament in an amount sufficient so that an article comprising said filament tested in accordance with California TB 604, §§ 1 and/or 2, exhibits a gross weight loss of less than 30% after three minutes, based on one test, and an average gross weight loss of less than 25% after three minutes, based on the average of three tests.

45. The filament of Claim 41 , wherein said oxygen scavenging agent comprises a halogenated compound having oxygen scavenging properties.

46. The filament of Claim 45, wherein said halogenated compound comprises a compound including bromine, chlorine, fluorine or a combination thereof.

47. The filament of Claim 46, wherein said halogenated compound comprises bromine.

48. The filament of Claim 47, wherein said brominated compound is selected from the group consisting of polybrominated biphenyl compounds, polybrominated diphenyl ether compounds, polybrominated polymeric compounds, and mixtures thereof.

49. The filament of Claim 48, wherein said brominated compound comprises a polybrominated polymeric compound.

50. The filament of Claim 49, wherein said polybrominated polymeric compound has a molecular weight ranging from about 200 g/mol to about 200,000 g/mol.

51. The filament of Claim 49, wherein said polybrominated polymeric compound comprises polybrominated polystyrene.

52. The filament of Claim 45, wherein said synergistic agent lowers the vapor pressure of said oxygen scavenging agent.

53. The filament of Claim 52, wherein said synergistic agent comprises a metallic compound.

54. The filament of Claim 53, wherein said metallic compound comprise a metal selected from the group consisting of antimony, tin, zinc, molybdenum, zirconium, barium, and mixtures thereof.

55. The filament of Claim 54, wherein said metallic compound comprises an antimony compound.

56. The filament of Claim 55, wherein said antimony compound is selected from the group consisting of antimony trioxide, antimony pentaoxide, sodium antimonate, and mixtures thereof.

57. The filament of Claim 56, wherein said antimony compound comprises sodium antimonate.

58. The filament of Claim 55, comprising atomic halogen and atomic antimony in a ratio ranging from about 3:1 to about 8:1.

59. The filament of Claim 55, comprising said halogenated compound in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the filament, and comprising said antimony compound in an amount ranging from about 0,5 to about 10 percent by weight, based on the total weight of the filament.

60. The filament of Claim 59, comprising said antimony compound in an amount ranging from about 2 to about 7 percent by weight, based on the total weight of the filament.

61. The filament of Claim 41 , further comprises at least an additional synergistic agent for lowering the melt viscosity of said polymer, or for promoting char formation, or both.

62. The filament of Claim 55, further comprising at least an additional synergistic agent comprising a phosphorous compound.

63. The filament of Claim 59, further comprising at least an additional synergistic agent comprising a phosphorous compound, wherein the phosphorous compound is present in the composition in an amount sufficient to provide from about 0.01 to about 1 weight percent elemental phosphorous, based on the total weight of the composition.

64. The filament of Claim 41, wherein said polymer comprises a thermoplastic polymer.

65. The filament of Claim 64, wherein said thermoplastic polymer comprises a condensation polymer.

66. The filament of Claim 65, wherein said condensation polymer comprises a polyester polymer.

67. The filament of Claim 66, wherein said polyester polymer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polycyclohexylene-l^-dimethylene terephthalate, co- and terpolymers thereof, and mixtures thereof.

68. The filament of Claim 67, wherein said polyester polymer comprises polyethylene terephthalate.

69. The filament of Claim 65, wherein said condensation polymer comprises a polyamide polymer.

70. The filament of Claim 69, wherein said polyamide polymer is selected from the group consisting of nylon 6, nylon 6/6, nylon 4/6, nylon 11, nylon 12, nylon 6/10, nylon

6/12, nylon 12/12, copolymers of caprolactam and alkylene oxide diamine, and mixtures thereof.

71. The filament of Claim 64, wherein said thermoplastic polymer is selected from the group consisting of polyolefins, polycarbonates, polyacrylics, polyurethanes, and mixtures thereof.

72. The filament of Claim 71, wherein said thermoplastic polymer comprises a polyolefin polymer.

73. The filament of Claim 72, wherein said polyolefin polymer is selected from the group consisting of polypropylene, polyethylene, polybutylene, polypentene, co- and terpolymers thereof and mixtures thereof.

74. The filament of Claim 64, wherein said thermoplastic polymer comprises polylactic acid.

75. A filament exhibiting fire retardant properties, comprising: a thermoplastic polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said filament, said fire retardant comprising a brominated polymeric component and an antimony compound, wherein said antimony compound comprises a plurality of particles having an average particle size of less than or about 3 microns.

76. The filament of Claim 75, wherein: said thermoplastic polymer comprises a condensation polymer; said brominated polymeric component comprises brominated polystyrene; and said antimony compound comprises sodium antimonate in the form of a plurality of particles having an average particle size of less than or about 3 microns.

77. The filament of Claim 76, wherein said condensation polymer comprises polyester.

78. The filament of Claim 75, further comprising at least one additional synergistic agent for lowering the melting point of said polymer or for promoting char formation, or both, wherein said at least one additional synergistic agent comprises a phosphorous compound.

79. The filament of Claim 76, comprising: said brominated polystyrene in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the filament; and said sodium antimonate in an amount ranging from about 2 to about 7 percent by weight, based on the total weight of the filament.

80. The filament of Claim 79, further comprising elemental phosphorous in an amount ranging from about 0.01 to about 1 weight percent, based on the total weight of the composition.

81. A fiber cut from the filament of Claim 41.

82. A fiber cut from the filament of Claim 75.

83. A yarn comprising the fiber of Claim 81.

84. A yarn comprising the fiber of Claim 82.

85. The yarn of Claim 83, wherein said yarn further comprises at least one other fiber selected from the group consisting of cellulosic fibers, aramid fibers, carbon fibers, carbonizable composition fibers, metal fibers, glass fibers, polybenzimidazole fibers, polyimide fibers, polyarene fibers, polyester fibers, polyamide fibers, polyolefin fibers, polyacrylic fibers, elastomeric fibers, and mixtures thereof.

86. The yarn of Claim 84, wherein said yarn further comprises at least one other fiber selected from the group consisting of cellulosic fibers, aramid fibers, carbon fibers, carbonizable composition fibers, metal fibers, glass fibers, polybenzimidazole fibers, polyimide fibers, polyarene fibers, polyester fibers, polyamide fibers, polyolefin fibers, polyacrylic fibers, elastomeric fibers, and mixtures thereof.

87. A fabric comprising the fiber of Claim 81, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

88. A fabric comprising the yarn of Claim 83, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

89. A fabric comprising the fiber of Claim 82, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

90. A fabric comprising the yarn of Claim 84, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

91. An article comprising a composition exhibiting fire retardant properties, said composition comprising a polymer and a fire retardant in an amount sufficient to impart fire retardant properties to said polymer composition, said fire retardant comprising an oxygen scavenging agent and a synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said synergistic agent comprises a plurality of particles having an average particle size of less than or about 3 microns.

92. The article of Claim 91, wherein: said polymer comprises a thermoplastic polymer; and said fire retardant comprises a brominated polymeric component and an antimony compound, wherein said antimony compound comprises a plurality of particles having an average particle size of less than or about 3 microns.

93. The article of Claim 92, wherein: said thermoplastic polymer comprises a condensation polymer; said brominated polymeric component comprises brominated polystyrene; and said antimony compound comprises sodium antimonate in the form of a plurality of particles having an average particle size of less than or about 3 microns.

94. The article of Claim 93, wherein said condensation polymer comprises polyester.

95. The article of Claim 92, further comprising at least one additional synergistic agent for lowering the melting point of said polymer, or for promoting char formation, or both, wherein said at least one additional synergistic agent comprises a phosphorous compound.

' 96, The article of Claim 93, comprising: said brominated polystyrene in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the composition; and said sodium antimonate in an amount ranging from about 2 to about 7 percent by weight, based on the total weight of the composition.

97. The article of Claim 96, further comprising elemental phosphorous in an amount ranging from about 0.01 to about 1 weight percent, based on the total weight of the composition.

98. The article of Claim 91, wherein said article is selected from the group consisting of bedding materials, fiberfill materials, absorbent cores, apparel, home furnishings, office furnishings, vehicle seating components, and building materials.

99. The article of Claim 98, wherein said article comprises a bedding material.

100. The article of Claim 98, wherein said article comprises a fiberfill material.

101. A polymer composition exhibiting fire retardant properties, comprising: a polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said polymer composition, said fire retardant comprising an oxygen scavenging agent; a first synergistic agent for lowering the melt viscosity of said polymer, or for promoting char formation, or both; and a second synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said second synergistic agent comprises a plurality of particles having an average particle size of less than or about 3 microns.

102. The polymer composition of Claim 101, wherein said fire retardant is present in said composition in an amount sufficient so that an article comprising said composition passes the Pillow Burn Test as set forth in California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004.

103. The polymer composition of Claim 102, wherein said fire retardant is present in said composition in an amount sufficient so that an article comprising said composition tested in accordance with California TB 604, §§ 1 and/or 2, exhibits a gross weight loss of less than 30% after three minutes, based on one test, and an average gross weight loss of less than 25% after three minutes, based on the average of three tests.

104. The polymer composition of Claim 101, wherein said oxygen scavenging agent comprises a halogenated compound having oxygen scavenging properties.

105. The polymer composition of Claim 104, wherein said halogenated compound comprises a compound including bromine, chlorine, fluorine or a combination thereof.

106. The polymer composition of Claim 105, wherein said halogenated compound comprises bromine.

107. The polymer composition of Claim 106, wherein said brominated compound is selected from the group consisting of polybrominated biphenyl compounds, polybrominated diphenyl ether compounds, polybrominated polymeric compounds, and mixtures thereof.

108. The polymer composition of Claim 107, wherein said brominated compound comprises a polybrominated polymeric compound.

109. The polymer composition of Claim 108, wherein said polybrominated polymeric compound has a molecular weight ranging from about 200 g/mol to about 200,000 g/mol.

110. The polymer composition of Claim 108, wherein said polybrominated polymeric compound comprises polybrominated polystyrene.

111. The polymer composition of Claim 101, wherein said first synergistic agent comprises a phosphorous compound.

112. The polymer composition of Claim 111, wherein said phosphorous compound is selected from the group consisting of inorganic phosphorous compounds, organic phosphorous compounds, and mixtures thereof.

1 13. The polymer composition of Claim 1 12, wherein said phosphorous compound is selected from the group consisting of phosphates, phosphites, phosphonates, phosphonium salts, and derivatives and mixtures thereof.

114. The polymer composition of Claim 111, wherein said phosphorous compound is incorporated into said polymer.

1 15. The polymer composition of Claim 111, comprising from about 0.01 to about. 1 weight percent elemental phosphorous, based on the total weight of the composition.

116. The polymer composition of Claim 101, wherein said second synergistic agent comprises a plurality of particles having an average particle size of less than or about 1 micron.

117. The polymer composition of Claim 104, wherein said second synergistic agent lowers the vapor pressure of said oxygen scavenging agent.

1 18. The polymer composition of Claim 1 17, wherein said second synergistic agent comprises a metallic compound.

119. The polymer composition of Claim 118, wherein said metallic compound comprises a metal selected from the group consisting of antimony, tin, zinc, molybdenum, zirconium, barium, and mixtures thereof.

120. The polymer composition of Claim 119, wherein said metallic compound comprises an antimony compound.

121. The polymer composition of Claim 120, wherein said antimony compound is selected from the group consisting of antimony trioxide, antimony pentaoxide, sodium antimonate, and mixtures thereof.

122. The polymer composition of Claim 121, wherein said antimony compound comprises sodium antimonate.

123. The polymer composition of Claim 104, comprising said halogenated compound in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the composition, and wherein said first synergistic agent comprises a phosphorous compound in an amount ranging from about 0.1 to about 4 percent by weight, based on the total weight of the composition, and said second synergistic agent comprises an antimony compound in an amount ranging from about 0.5 to about 10 percent by weight, based on the total weight of the composition.

124. The polymer composition of Claim 101, wherein said polymer comprises a thermoplastic polymer.

125. The polymer composition of Claim 124, wherein said thermoplastic polymer comprises a condensation polymer.

126. The polymer composition of Claim 125, wherein said condensation polymer comprises a polyester polymer.

127. The polymer composition of Claim 126, wherein said polyester polymer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polycyclohexylene-l^-dimethylene terephthalate, co- and terpolymers thereof, and mixtures thereof.

128. The polymer composition of Claim 127, wherein said polyester polymer comprises polyethylene terephthalate.

129. The polymer composition of Claim 125, wherein said condensation polymer comprises a polyamide polymer.

130. The polymer composition of Claim 129, wherein said polyamide polymer is selected from the group consisting of nylon 6, nylon 6/6, nylon 4/6, nylon 1 1, nylon 12, nylon 6/10, nylon 6/12, nylon 12/12, copolymers of caprolactam and alkylene oxide diamine, and mixtures thereof.

131. The polymer composition of Claim 124, wherein said thermoplastic polymer is selected from the group consisting of polyolefins, polycarbonates, polyacrylics, polyurethanes, and mixtures thereof.

132. The polymer composition of Claim 131, wherein said thermoplastic polymer comprises a polyolefin polymer.

133. The polymer composition of Claim 132, wherein said polyolefin polymer is selected from the group consisting of polypropylene, polyethylene, polybutylene, polypentene, co- and terpolymers thereof and mixtures thereof.

134. The polymer composition of Claim 124, wherein said thermoplastic polymer comprises polylactic acid.

135. The polymer composition of Claim 101, wherein: said oxygen scavenging agent comprises a brominated polymeric compound present in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the composition; said first synergistic agent comprises a phosphorous compound present in the composition in an amount sufficient to provide elemental phosphorous in an amount ranging from about 0.01 to about 1 percent by weight, based on the total weight of the composition; and said second synergistic agent comprises an antimony compound in an amount ranging from about 0.5 to about 10 percent by weight, based on the total weight of the composition.

136. A polymer composition exhibiting fire retardant properties, comprising: a thermoplastic polymer; and a fire retardant comprising a brominated polymeric component, a phosphorous compound, and an antimony compound comprising a plurality of particles having an average particle size of less than or about 3 microns.

137. The polymer composition of Claim 136, wherein: said thermoplastic polymer comprises a condensation polymer; said brominated polymeric component comprises brominated polystyrene; said phosphorous compound comprises an organic phosphorous compound; and said antimony compound comprises sodium antimonate in the form of a plurality of particles having an average particle size of less than or about 3 microns.

138. The polymer composition of Claim 137, wherein said condensation polymer comprises polyester.

139. A polymer composition exhibiting fire retardant properties, comprising: a polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said polymer composition, said fire retardant comprising an oxygen scavenging agent and a synergistic agent for lowering the melt viscosity of said polymer, or for promoting char formation, or both, wherein said synergistic agent comprises a compound incorporated into said polymer chain.

140. The polymer composition of Claim 139, wherein said fire retardant is present in said composition in an amount sufficient so that an article comprising said composition passes the Pillow Burn Test as set forth in California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004.

141. The polymer composition of Claim 140, wherein said fire retardant is present in said composition in an amount sufficient so that an article comprising said composition tested in accordance with California TB 604, §§ 1 and/or 2, exhibits a gross weight loss of less than 30% after three minutes, based on one test, and an average gross weight loss of less than 25% after three minutes, based on the average of three tests.

142. The polymer composition of Claim 139, wherein said oxygen scavenging agent comprises a halogenated compound having oxygen scavenging properties.

143. The polymer composition of Claim 142, wherein said halogenated compound comprises a compound including bromine, chlorine, fluorine or a combination thereof.

144. The polymer composition of Claim 143, wherein said halogenated compound comprises bromine.

145. The polymer composition of Claim 144, wherein said brominated compound is selected from the group consisting of polybrominated biphenyl compounds, polybrominated diphenyl ether compounds, polybrominated polymeric compounds, and mixtures thereof.

146. The polymer composition of Claim 145, wherein said brominated compound comprises a polybrominated polymeric compound.

147. The polymer composition of Claim 146, wherein said polybrominated polymeric compound has a molecular weight ranging from about 200 g/mol to about 200,000 g/mol.

148. The polymer composition of Claim 146, wherein said polybrominated polymeric compound comprises polybrominated polystyrene.

149. The polymer composition of Claim 139, wherein said synergistic agent comprises a phosphorous compound.

150. The polymer composition of Claim 139, further comprising at least one additional synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said at least one additional synergistic agent comprises a plurality of particles having an average particle size of less than or about 3 microns.

151. The polymer composition of Claim 150, wherein said additional synergistic agent comprises a plurality of particles having an average particle size of less than or about 1 micron.

152. The polymer composition of Claim 150, wherein said additional synergistic agent lowers the vapor pressure of said oxygen scavenging agent.

153. The polymer composition of Claim 152, wherein said additional synergistic agent comprises a metallic compound.

154. The polymer composition of Claim 153, wherein said metallic compound comprises a metal selected from the group consisting of antimony, tin, zinc, molybdenum, zirconium, barium, and mixtures thereof.

155. The polymer composition of Claim 154, wherein said metallic compound comprises an antimony compound.

156. The polymer composition of Claim 155, wherein said antimony compound is selected from the group consisting of antimony trioxide, antimony pentaoxide, sodium antimonate, and mixtures thereof.

157. The polymer composition of Claim 156, wherein said antimony compound comprises sodium antimonate.

158. The polymer composition of Claim 139, wherein said polymer comprises a thermoplastic polymer.

159. The polymer composition of Claim 158, wherein said thermoplastic polymer comprises a condensation polymer.

160. The polymer composition of Claim 159, wherein said condensation polymer comprises a polyester polymer.

161. The polymer composition of Claim 160, wherein said polyester polymer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polycyclohexylene-l,4-dimethylene terephthalate, co- and terpolymers thereof, and mixtures thereof.

162. The polymer composition of Claim 161, wherein said polyester polymer comprises polyethylene terephthalate.

163. The polymer composition of Claim 159, wherein said condensation polymer comprises a polyamide polymer.

164. The polymer composition of Claim 163, wherein said polyamide polymer is selected from the group consisting of nylon 6, nylon 6/6, nylon 4/6, nylon 11, nylon 12, nylon 6/10, nylon 6/12, nylon 12/12, copolymers of caprolactam and alkylene oxide diamine, and mixtures thereof.

165. The polymer composition of Claim 158, wherein said thermoplastic polymer is selected from the group consisting of polyolefins, polycarbonates, polyacrylics, polyurethanes, and mixtures thereof.

166. The polymer composition of Claim 158, wherein said thermoplastic polymer comprises a polyolefin polymer.

167. The polymer composition of Claim 166, wherein said polyolefin polymer is selected from the group consisting of polypropylene, polyethylene, polybutylene, polypentene, co- and terpolymers thereof and mixtures thereof.

168. The polymer composition of Claim 158, wherein said thermoplastic polymer comprises polylactic acid.

169. A filament exhibiting fire retardant properties comprising: a polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said polymer composition, said fire retardant comprising an oxygen scavenging agent and a synergistic agent for lowering the melt viscosity of said polymer, or for promoting char formation, or both.

170. The filament of Claim 169, wherein said fire retardant is present in said filament in an amount sufficient so that an article comprising said filament passes the Pillow Burn Test as set forth in California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004.

171. The filament of Claim 170, wherein said fire retardant is present in said filament in an amount sufficient so that an article comprising said filament tested in accordance with California TB 604, §§ 1 and/or 2, exhibits a gross weight loss of less than 30% after three minutes, based on one test, and an average gross weight loss of less than 25% after three minutes, based on the average of three tests.

172. The filament of Claim 169, wherein said oxygen scavenger comprises a halogenated compound having oxygen scavenging properties.

173. The filament of Claim 172, wherein said halogenated compound comprises a compound including bromine, chlorine, fluorine or a combination thereof.

174. The filament of Claim 173, wherein said halogenated compound comprises bromine.

175. The filament of Claim 174, wherein said brominated compound is selected from the group consisting of polybrominated biphenyl compounds, polybrominated diphenyl ether compounds, polybrominated polymeric compounds, and mixtures thereof.

176. The filament of Claim 175, wherein said brominated compound comprises a polybrominated polymeric compound.

177. The filament of Claim 176, wherein said polybrominated polymeric compound has a molecular weight ranging from about 200 g/mol to about 200,000 g/mol.

178. The filament of Claim 176, wherein said polybrominated polymeric compound comprises polybrominated polystyrene.

179. The filament of Claim 169, wherein said synergistic agent comprises a phosphorous compound.

180. The filament of Claim 179, wherein said phosphorous compound is selected from the group consisting of inorganic phosphorous compounds, organic phosphorous compounds, and mixtures thereof.

181. The filament of Claim 180, wherein said phosphorous compound is selected from the group consisting of phosphates, phosphites, phosphonates, phosphonium salts, and derivatives and mixtures thereof.

182. The filament of Claim 179, wherein said phosphorous compound is incorporated into said polymer.

183. The filament of Claim 172, comprising said halogenated compound in an amount ranging from about 3 to about 30 percent by weight, based on the total weight of the filament.

184. The filament of Claim 183, comprising elemental phosphorus in an amount ranging from about 0.01 to about 1 weight percent, based on the total weight of the composition.

185. The filament of Claim 169, further comprising at least one additional synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said at least one additional synergistic agent comprises a plurality of particles having an average particle size of less than or about 3 microns.

186. The filament of Claim 185, wherein said additional synergistic agent comprises a plurality of particles having an average particle size of less than or about 1 micron.

187. The filament of Claim 186, wherein said synergistic agent comprises a metallic compound.

188. The filament of Claim 187, wherein said metallic compound comprises a metal selected from the group consisting of antimony, tin, zinc, molybdenum, zirconium, barium, and mixtures thereof.

189. The filament of Claim 188, wherein said metallic compound comprises an antimony compound.

190. The filament of Claim 189, wherein said antimony compound is selected from the group consisting of antimony trioxide, antimony pentaoxide, sodium antimonate, and mixtures thereof.

191. The filament of Claim 190, wherein said antimony compound comprises sodium antimonate.

192. The filament of Claim 169, wherein said polymer comprises a thermoplastic polymer.

193. The filament of Claim 192, wherein said thermoplastic polymer comprises a condensation polymer.

194. The filament of Claim 193, wherein said condensation polymer comprises a polyester polymer.

195. The filament of Claim 194, wherein said polyester polymer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polycyclohexylene-l,4-dimethylene terephthalate, co- and terpolymers thereof, and mixtures thereof.

196. The filament of Claim 195, wherein said polyester polymer comprises polyethylene terephthalate.

197. The filament of Claim 193, wherein said condensation polymer comprises a polyamide polymer.

198. The filament of Claim 197, wherein said polyamide polymer is selected from the group consisting of nylon 6, nylon 6/6, nylon 4/6, nylon 11, nylon 12, nylon 6/10, nylon 6/12, nylon 12/12, copolymers of caprolactam and alkylene oxide diamine, and mixtures thereof.

199. The filament of Claim 192, wherein said thermoplastic polymer is selected from the group consisting of polyolefins, polycarbonates, polyacrylics, polyurethanes, and mixtures thereof.

200. The filament of Claim 199, wherein said thermoplastic polymer comprises a polyolefin polymer.

201. The filament of Claim 200, wherein said polyolefin polymer is selected from the group consisting of polypropylene, polyethylene, polybutylene, polypentene, co- and terpolymers thereof and mixtures thereof.

202. The filament of Claim 192, wherein said thermoplastic polymer comprises polylactic acid.

203. A filament exhibiting fire retardant properties comprising: a thermoplastic polymer; and a fire retardant in an amount sufficient to impart fire retardant properties to said filament, said fire retardant comprising a brominated polymeric component and a phosphorous compound.

204. The filament of Claim 203, wherein: said thermoplastic polymer comprises a condensation polymer; said brominated polymeric component comprises brominated polystyrene; and said phosphorous compound comprises an organic phosphorous compound. <

205. The filament of Claim 203, further comprising at least one additional synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said at least one additional synergistic agent comprises an antimony compound in the form of a plurality of particles having an average particle size of less than or about 3 microns.

206. The filament of Claim 204, wherein said condensation polymer comprises polyester.

207. A fiber cut from the filament of Claim 169.

208. A fiber cut from the filament of Claim 203.

209. A yarn comprising the fiber of Claim 207.

210. A yarn comprising the fiber of Claim 208.

211. The yarn of Claim 209, wherein said yarn comprises at least one other fiber selected from the group consisting of cellulosic fibers, aramid fibers, carbon fibers, carbonizable composition fiber, metal fibers, glass fibers, polybenzimidazole fibers, polyimide fibers, polyarene fibers, polyester fibers, polyamide fibers, polyolefin fibers, polyacrylic fibers, elastomeric fibers, and mixtures thereof.

212. The yarn of Claim 210, wherein said yarn further comprises at least one other fiber selected from the group consisting of cellulosic fibers, aramid fibers, carbon fibers, carbonizable composition fiber, metal fibers, glass fibers, polybenzimidazole fibers, polyimide fibers, polyarene fibers, polyester fibers, polyamide fibers, polyolefin fibers, polyacrylic fibers, elastomeric fibers, and mixtures thereof.

213. A fabric comprising the fiber of Claim 207, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

214. A fabric comprising the yarn of Claim 209, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

215. A fabric comprising the fiber of Claim 208, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

216. A fabric comprising the yarn of Claim 210, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

217. An article comprising a plurality of fibers comprising a composition exhibiting fire retardant properties, said composition comprising a polymer and a fire retardant in an amount sufficient to impart fire retardant properties to said polymer composition, said fire retardant comprising an oxygen scavenging agent and a synergistic agent for lowering the melt viscosity of said polymer, or for promoting char formation, or both.

218. The article of Claim 217, wherein: said polymer comprises a thermoplastic polymer; said oxygen scavenging agent comprises a brominated polymeric component; and said synergistic agent comprises a phosphorous compound.

219. The article of Claim 218, wherein: said thermoplastic polymer comprises a condensation polymer; said brominated polymeric component comprises brominated polystyrene; and said phosphorous compound comprises an organic phosphorous compound.

220. The article Claim 218, further comprising at least one additional synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said at least one additional synergistic agent comprises an antimony compound in the form of a plurality of particles having an average particle size of less than or about 3 microns.

221. The article of Claim 219, wherein said condensation polymer comprises polyester.

222. The article of Claim 217, wherein said article is selected from the group consisting of bedding materials, fiberfill materials, absorbent cores, apparel, home furnishings, office furnishings, vehicle seating components, and building materials.

223. The article of Claim 222, wherein said article comprises a bedding material.

224. The article of Claim 222, wherein said article comprises a fiberfill material

225. A fiber exhibiting fire retardant properties, comprising a polymer and an oxygen scavenging fire retardant agent, wherein the fiber has a cross sectional configuration selected to increase the surface area of the fiber as compared to a fiber having a substantially round cross section with the same volume of polymer.

226. The fiber of Claim 225, wherein said fire retardant agent is present in said fiber in an amount sufficient so that an article comprising said fiber passes the Pillow Burn Test as set forth in California TB 604, §§ 1 and/or 2, titled "Test Procedure and Apparatus for the Flame Resistance of Filled Bedclothing" issued October 1, 2004.

227. The fiber of Claim 226, wherein said fire retardant agent is present in said fiber in an amount sufficient so that an article comprising said fiber tested in accordance with California TB 604, §§ 1 and/or 2, exhibits a gross weight loss of less than 30% after three minutes, based on one test, and an average gross weight loss of less than 25% after three minutes, based on the average of three tests.

228. The fiber of Claim 225, wherein said fiber is a multilobed fiber comprising at least two lobes extending outwardly from a core region of said fiber.

229. The fiber of Claim 228, wherein said multilobed fiber is a bilobal fiber having two lobes.

230. The fiber of Claim 228, wherein said multilobed fiber is a trilobal fiber having three lobes.

231. The fiber of Claim 228, wherein said multilobed fiber is a quatrilobal fiber having four lobes.

232. The fiber of Claim 228, wherein said multilobed fiber is a pentalobal fiber having five lobes.

233. The fiber of Claim 225, wherein said oxygen scavenging agent comprises a halogenated compound having oxygen scavenging properties.

234. The fiber of Claim 233, wherein said halogenated compound comprises a polybrominated polymeric compound.

235. The fiber of Claim 234, wherein said polybrominated polymeric compound comprises polybrominated polystyrene.

236. The fiber of Claim 233, further comprising a synergistic agent for facilitating the conversion of said oxygen scavenging agent into a form suitable for reacting with oxygen, wherein said synergistic agent comprises a plurality of particles having an average particle size of less than or about 3 microns.

237. The fiber of Claim 236, wherein said synergistic agent comprises an antimony compound.

238. The fiber of Claim 237, wherein said antimony compound comprises sodium antimonate.

239. The fiber of Claim 237, further comprising a phosphorous compound.

240. The fiber of Claim 233, further comprising a synergistic agent for lowering the melt viscosity of said polymer, or for promoting char formation, or both.

241. The fiber of Claim 240, wherein said synergistic agent comprises a phosphorous compound.

242. The fiber of Claim 241, wherein said phosphorous compound is selected from the group consisting of inorganic phosphorous compounds, organic phosphorous compounds, and mixtures thereof.

243. The fiber of Claim 242, wherein said phosphorous compound is selected from the group consisting of phosphates, phosphites, phosphonates, phosphonium salts, and derivatives and mixtures thereof.

244. The fiber of Claim 241, wherein said phosphorous compound is incorporated into said polymer.

245. The fiber of Claim 225, wherein said polymer comprises a thermoplastic polymer.

246. The fiber of Claim 245, wherein said thermoplastic polymer comprises a condensation polymer.

247. The fiber of Claim 246, wherein said condensation polymer comprises a polyester polymer.

248. The fiber of Claim 246, wherein said condensation polymer comprises a polyamide polymer.

249. The fiber of Claim 245, wherein said thermoplastic polymer is selected from the group consisting of polyolefins, polycarbonates, polyacrylics, polyurethanes, and mixtures thereof.

250. A yarn comprising the fiber of Claim 225.

251. A fabric comprising the fiber of Claim 225, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

252. A fabric comprising the yarn of Claim 250, wherein said fabric is selected from the group consisting of woven, nonwoven and knitted fabrics.

253. An article comprising at least one fiber exhibiting fire retardant properties, said fibers comprising a polymer and an oxygen scavenging fire retardant agent, wherein the at least one fiber has a cross sectional configuration selected to increase the surface area of the fiber as compared to a fiber having a substantially round cross section with the same volume of polymer.