WO2007061423A2 - Flame resistant fiber blends, fire and heat barrier fabrics and related processes - Google Patents

Flame resistant fiber blends, fire and heat barrier fabrics and related processes Download PDF

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Publication number
WO2007061423A2
WO2007061423A2 PCT/US2005/043173 US2005043173W WO2007061423A2 WO 2007061423 A2 WO2007061423 A2 WO 2007061423A2 US 2005043173 W US2005043173 W US 2005043173W WO 2007061423 A2 WO2007061423 A2 WO 2007061423A2
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
component
nylon
fiber
amorphous silica
Prior art date
Application number
PCT/US2005/043173
Other languages
English (en)
French (fr)
Other versions
WO2007061423A3 (en
Inventor
Derek Bass
Brian Sparks
Doug Hope
William Dawson
William Edwards
Original Assignee
Propex Geosolutions Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US11/001,539 external-priority patent/US20060116043A1/en
Priority to EP05858690A priority Critical patent/EP1861524B1/en
Priority to CN2005800463661A priority patent/CN101263253B/zh
Priority to KR1020077015059A priority patent/KR101341293B1/ko
Priority to CA2589863A priority patent/CA2589863C/en
Priority to AT05858690T priority patent/ATE552368T1/de
Application filed by Propex Geosolutions Corporation filed Critical Propex Geosolutions Corporation
Priority to BRPI0516642A priority patent/BRPI0516642B1/pt
Priority to AU2005338024A priority patent/AU2005338024B2/en
Priority to DK05858690.0T priority patent/DK1861524T3/da
Priority to JP2007546712A priority patent/JP5312794B2/ja
Priority to ES05858690T priority patent/ES2385391T3/es
Publication of WO2007061423A2 publication Critical patent/WO2007061423A2/en
Priority to IL183618A priority patent/IL183618A/en
Publication of WO2007061423A3 publication Critical patent/WO2007061423A3/en

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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5416—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sea-island
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
    • D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D01F2/06—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from viscose
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/443—Heat-resistant, fireproof or flame-retardant yarns or threads
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/43—Acrylonitrile series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—Composite fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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    • D04H1/43825—Composite fibres
    • D04H1/4383—Composite fibres sea-island
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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    • D04H1/43838—Ultrafine fibres, e.g. microfibres
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/14—Carbides; Nitrides; Silicides; Borides

Definitions

  • This invention relates to a flame resistant fiber blend useful in preparing fabrics having flame resistance, including particularly non-woven flame resistant materials such as barrier fabrics.
  • This invention also relates to a single layer non- woven fabric useful in protecting items from fire and the related heat and a process for protecting adjacent materials in an assembly using the fire and heat barrier fabric.
  • FR materials are useful as barrier layers between the exterior fabric and the inner stuffing of furniture, comforters, pillows, and mattresses. Such materials can be woven or non-woven, knitted, or laminated with other materials.
  • Flame resistance is defined by ASTM as "the property of a material whereby flaming combustion is prevented, terminated, or inhibited following application of a flaming or non-flaming source of ignition, with or without the subsequent removal of the ignition source.”
  • the material that is flame resistant may be a polymer, fiber, or fabric.
  • a flame retardant is defined by ASTM as "a chemical used to impart flame resistance.”
  • the flame resistance properties of such FR materials are typically determined according to various standard methods, such as California TB117 and TB 133 for upholstery; NFPA701 for curtains and drapes; California Test Bulletin 129, dated October 1992, concerning flammability test procedures for mattresses in public buildings, and California Test Bulletin 603 concerning mattresses for residential use.
  • the FR material does not melt or shrink away from the flame, but forms a char that helps control the burn and shield the materials surrounded by the fabric.
  • the protection required of the flame and heat barrier fabric is related to the other components used in the final assembly of the desired product.
  • mattresses normally contain layers of foam and fiber batting for cushioning and ticking for durable cover. Most cushioning material is comprised of foam and fibers that burn when exposed to open flame. Much of the regulatory-driven effort to date has gone towards shielding the inner cushioning layers from open flame or ignition from the heat of the open flame without compromising the comfort or aesthetics of the mattress.
  • FR barrier fabrics include a white or other neutral color so as to not contaminate the manufacturing facility or change the look of the composite article; the ability to remain unaffected by ultraviolet light so as not to yellow and change the look of light-colored mattress ticking or upholstery fabrics; being soft to the touch, thereby imparting the feel desired by the consumer; and cost effectiveness.
  • Some fibers are known to have FR properties, such as halogen-containing, phosphorus-containing, and antimony-containing materials. These materials, however, are heavier than similar types of non-FR materials, and they have reduced wear life.
  • a filter fabric of this type ideally will have (1) a sufficient mechanical strength to withstand pressures developed during use and multiple cycles of flexing, (2) a resistance toward harsh chemicals for long periods of time, (3) an ability to be unaffected by continuous operating temperatures as high as 482° C (900 ° F), (4) a resistance toward hot sparks, (5) less than about 1% shrinkage at use temperature, (6) a high filtration efficiency, and (7) a resistance to being attacked by microorganisms. [13] There still remains a need for lower-cost flame and heat barrier fabrics that protect other components of an assembly of a desired product so that the assembly meets all customer and regulatory requirements. BRIEF SUMMARY OF THE INVENTION
  • the present invention provides a flame resistant (FR) fiber blend comprising amorphous silica fibers; and at least one fiber selected from the group consisting of FR fibers, binder fibers and mixtures thereof.
  • the present invention further provides a barrier fabric, manufactured from a blend of fibers comprising amorphous silica fibers; and at least one fiber selected from the group consisting of FR fibers, binder fibers and mixtures thereof.
  • the present invention further provides a flame resistant fabric, manufactured from a blend of fibers comprising amorphous silica fibers; and at least one fiber selected from the group consisting of FR fibers, binder fibers and mixtures thereof.
  • a process for protecting materials in a product from fire and heat comprises assembling a flame resistant fabric adjacent to at least one component that comprises a material susceptible to damage due to exposure to fire and heat, occasioned by exposure to open flames.
  • fiber blends containing amorphous silica show improved char strength when formed into non-woven fabric, compared to non-woven fabric not containing amorphous silica.
  • the char strength to weight ratio of non- woven fabric containing amorphous silica is also improved, when compared to non-woven fabric containing other fibers conventionally used to improve char strength, such as para-aramid fibers and melamine fibers.
  • the drawing figure is a perspective view exploded to show assembly of a tuft button test apparatus.
  • Practice of the present invention includes two types of fiber blends: a first, comprising amorphous silica fibers and at least one type of FR fiber and a second, comprising amorphous silica fibers and at least one type of binder fiber.
  • the fiber blends can then be used to form fabrics, both nonwovens and woven fabrics, for a variety of uses.
  • any amorphous silica fiber that improves the char strength when added to a fiber blend may be used.
  • the term "silica” refers to silicon dioxide which occurs naturally in a variety of crystalline and amorphous forms. Silica is considered to be crystalline when the basic structure of the molecule (silicon tetrahedra arranged such that each oxygen atom is common to two tetrahedral) is repeated and symmetrical. Silica is considered to be amorphous if the molecule lacks crystalline structure. The SiO 2 molecule is randomly linked, forming no repeating pattern. Crystalline silica is not desired because of the associated health effects related to fragmentation of its brittle crystalline structure into fragments of respirable size.
  • the amorphous silica fiber is a high-content silica fiber having a silica (SiO 2 ) content of at least about 90 percent by weight, based upon the total weight of the high silica fiber.
  • the high silica fibers have a silica content of at least 95 percent by weight, and in other embodiments, the high silica fibers have a silica content of at least 98 percent by weight.
  • the high silica fibers may contain about 98 percent by weight silica, with the balance predominantly containing alumina.
  • the amount of halogen in the high silica fiber is de minimus, less than 120 parts per million by weight.
  • the silica fibers are substantially amorphous. While the fibers may contain some crystalline material, a substantial amount of crystallinity is not desired. Suitable silica fiber is commercially available, for example from Polotsk- Steklovokno, Ecuador.
  • the starting material composition for the high silica fibers is : from about 72 to about 77% SiO 2 , from about 2.5 to about 3.5% Al 2 O 3 , from about 20 to about 25% Na 2 O, from about 0.01 to about 1.0% CoO and from about 0.01 to about 0.5% SO 3 , all percents by weight, based upon the total weight of the composition.
  • the composition may be melted at about 1480 ⁇ 10°C to form a continuous fiber.
  • This fiber may then be leached using hot sulfuric acid having a concentration of 2N at a temperature of about 98 ⁇ 2° C with a dwell time of about 60 minutes.
  • the fiber may then be rinsed with tap water until the pH is about 3-5.
  • the resulting fiber has a SiO 2 content of from about 95 to about 99% ⁇ 1 percent by weight, with the remainder being predominantly Al 2 O 3 .
  • a high silica glass composition and process for making high silica fibers is described in Russian Pat. No. 2,165,393 (the '393 patent), the disclosure of which is hereby incorporated by reference herein.
  • the high silica fibers of the '393 patent are described as having a lower coefficient of variation in the strength of the basic filaments, which gives the possibility to stabilize the strength characteristics of the resultant fiber, especially at exposure to high temperature.
  • the following description of high silica fibers is taken from the '393 patent for exemplary purposes and should not be construed to limit the present invention.
  • a precursor glass composition may include SiO 2 , Al 2 O 3 and Na 2 O, as well as CoO and SO 3 in the following proportions (percent mass):
  • the glass may further contain at least one oxide from the group CaO, MgO, ZrO 2 , TiO 2 , Fe 2 O 3 in the following quantities (percent mass):
  • a resultant, high-temperature silica fiber from the glass composition about would then include SiO 2 and Al 2 O 3 , but also would contain Na 2 O, CoO and SO 3 in the following proportions (percent mass) :
  • the silica fiber may also contain at least one oxide from the group CaO, MgO 3 TiO 2 , Fe 2 O 3 , ZrO 2 in the following quantities (percent mass) :
  • the silica fibers are substantially free of any metal oxide coating.
  • Diameter of the silica fibers may range from about 5.6 microns to about
  • Length of the silica fibers may range from about 50 millimeters to about 125 millimeters and, in one embodiment, the length is about 75 millimeters, (shorter and longer fibers are available by adjusting the cut length of the fiber, but are not practical for needlepunch applications) .
  • One method of preparation of the silica fibers according to the aforementioned Russian patent, No. 2,165,393, as set forth in Example 1 hereinbelow, may be conducted as follows: To produce continuous filament glass fiber of the proposed composition, a vessel containing (percent mass) SiO 2 :72.39, A1 2 O 3 :2.5, Na 2 O:25, CoO:0.01, SO 3 :0.1 may be prepared. The vessel may be loaded into a furnace, and the composition melted at a temperature of about 1480 ⁇ 10 0 C. From the molten glass mass, a continuous glass fiber may be formed with a diameter of 6-9 microns at a temperature of about 1260 ⁇ 50° C using 400-hole glass-forming aggregates. The resultant fiber has been shown to have a strength of about 1030 Mpa and a surface tension of about 0.318 H/m.
  • Leaching of the continuous glass fiber may then take place using a hot sulfuric acid solution having a concentration of about 2N (about 10%) at a temperature of about 98 ⁇ 2° C. Contact time for the fiber in the solution is 60 minutes. The leaching solution, reaction products, and sizing remains are then washed away from the leached fiber with tap water until the pH is at about 3-5. Final washing of the fiber is conducted with deionized water and simultaneous dehydration.
  • Examples 2 and 3 below are analogous to that as set forth above for Example 1, but with different amounts of starting materials.
  • Table 1 presents the starting amounts for the glass as well as the amounts of materials for the resultant silica compositions.
  • Table 2 presents the characteristics of the molten product, the characteristics of processing, and the characteristics of the glass and silica fibers.
  • Table 3 provides strength characteristics of the silica materials after exposure to 1000° C. [35] Tables 1- 3 also provide data confirming the introduction of cobalt and
  • SO 3 into the glass composition increases the heterogeneity of the glass mass, lowers its surface tension, decreases the fragility of the fiber during processing and also increases the stability of the technical characteristics of the silica fiber and resultant materials based on this fiber.
  • Tables 4 and 5 show various glass fiber compositions from which it can be seen that the silica fibers taught by the Russian Pat. No. 2,165,393 differ from all other glass fiber types by the presence of trace amounts of CoO and SO 3 .
  • TABLE 4 VARIOUS GLASS FIBER COMPOSITIONS FOR PRODUCING HIGH SILICA FIBERS
  • the additive fibers will be discussed next.
  • the present invention includes two embodiments, one employing flame resistant (FR) fibers and another employing binder fibers.
  • FR flame resistant
  • sica fiber shall be understood to mean those fibers containing amorphous (as opposed to crystalline) silica.
  • the amount of silica fiber in the fiber blend can vary, depending upon the other fibers used.
  • the amount of silica fiber in the blend is from about 5 to about 65 weight percent, based upon the total weight of the blend.
  • the amount of silica fiber in the blend is from about 15 to about 50 weight percent.
  • the amount of silica fiber in the blend is from about 20 to about 30 weight percent.
  • the remaining fibers in the blend include the necessary" amount of non-amorphous fibers, namely the FR fibers, to equal 100 weight percent.
  • FR fibers are known in the art.
  • the FR fibers employed in the fabrics of the present invention may be an inherent flame resistant fiber or a fiber (natural or synthetic) that is coated with an FR resin.
  • the inherent flame resistant fibers are not coated, but have an FR component incorporated within the structural chemistry of the fiber.
  • the term FR fiber, as used herein, includes both the inherent flame resistant fibers as well as fibers that are not inherently flame resistant, but are coated with FR resins. Accordingly, by way of example, a polypropylene fiber coated with an FR resin would be an FR polypropylene fiber.
  • Suitable inherently flame resistant fibers include polymer fibers having a phosphorus-containing group, an amine, a modified aluminosilicate, or a halogen- containing group.
  • Examples of inherently flame resistant fibers include melamines, meta-aramids, para-aramids, polybenzimidazole, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novoloids, poly(p-phenylene benzobisoxazoles), poly (p-phenylenebenzothiazoles), polyphenylene sulfides, flame retardant viscose rayons; (e.
  • Melamines include those sold under the tradenames Basofil by McKinnon-Land-Moran LLC.
  • Meta-aramids include poly (m-phenylene isophthalamide), for example sold under the tradenames NOMEX® by E.I. Du Pont de Nemours and Co., TEIJINCONEX ® and CONEX® by Teijin Limited and FENYLENE® by Russian State Complex.
  • Para-aramids include poly (p-phenylene terephthalamide), for example sold under the tradename KEVLAR® by E.I.
  • Du Pont de Nemours and Co. and poly (diphenylether para-aramid), for example sold under the tradename TECHNORA ® by Teijin Limited, and under the tradenames TWARON ® by Acordis and FENYLENE ST ® ( Russian State Complex).
  • Polyimides include those sold under the tradenames P-84® by Inspec Fibers and KAPTON® by E.I. Du Pont de Nemours and Co.
  • Polyamideimides include for example those sold under the tradename KERMEL® by Rhone-Poulenc.
  • Partially oxidized polyacrylonitriles include, for example, those sold under the tradenames FORTAFIL OPF® by Fortafil Fibers Inc., AVOX® by Textron Inc., PYRON® by Zoltek Corp., PANOX ® by SGLtechnik, THORNEL® by American Fibers and Fabrics and PYROMEX® by Toho Rayon Corp.
  • Novoloids include, for example, phenol-formaldehyde novolac, such as that sold under the tradename KYNOL® by Gun Ei Chemical Industry Go.
  • Poly (p-phenylene benzobisoxazole) (PBO) is sold under the tradename ZYLON ® by Toyobo Co.
  • Poly (p-phenylene benzothiazole) is also known as PBT.
  • Polyphenylene sulfide (PPS) includes those sold under the tradenames RYTON® by American Fibers and Fabrics, TORAY PPS® by Toray Industries Inc., FORTRON® by Kureha Chemical Industry Co. and PROCON® by Toyobo Co.
  • Flame retardant viscose rayons include, for example, those sold under the tradenames LENZING FR ® by Lenzing A. G. and VISIL® by Sateri Oy Finland.
  • Polyetheretherketones (PEEK) include, for example, that sold under the tradename ZYEX® by Zyex Ltd.
  • Polyketones (PEK) include, for example, that sold under the tradename ULTRAPEK® by BASF.
  • Polyetherimides (PEI) include, for example, that sold under the tradename ULTEM ® by General Electric Co.
  • Modacrylic fibers are made from copolymers of acrylonitrile and other materials such as vinyl chloride, vinylidene chloride or vinyl bromide.
  • Modacrylic fibers used in this invention are manufactured by Kaneka under the product names KANECARON PBX and PROTEX-M, PROTEX-G, PROTEX-S and PROTEX-PBX. The latter products contain at least 75% of acrylonitile - vinylidene chloride copolymer. SEF PLUS by Solutia is a modacrylic fiber as well with flame retardant properties.
  • FR fibers suitable for use in the blend of the present invention include polyester with phosphalane such as that sold under the trademark TREVIRA CS ® fiber or AVORA® PLUS FIBER by KoSa.
  • chloropolymeric fibers such as those sold under the tradenames THERMOVYL® L9S & ZCS, FIRBRAVYL® L9F, RETRACTYL ® L9R, ISOVYL® MPS by Rhovyl S. A., PIVIACID®, Thueringische, VICLON ® by Kureha Chemical Industry Co., TEVIRON ® by Teijin Ltd., ENVILON® by Toyo Chemical Co., VICRON®, SARAN® by Pittsfield Weaving, KREHALON® by Kureha Chemical Industry Co., OMNI-SARAN® by Fibrasomni, S.A. de C.V., and combinations thereof.
  • Fluoropolymeric fibers such as polytetrafluoroethylene (PTFE), poly(ethylene- chlorotrifluoroethylene (E-CTFE), polyvinylidene fluoride (PVDF), polyperfluoroalkoxy (PFA), and polyfluorinated ethylene-propylene (FEP) and combinations thereof are also useful.
  • PTFE polytetrafluoroethylene
  • E-CTFE poly(ethylene- chlorotrifluoroethylene
  • PVDF polyvinylidene fluoride
  • PFA polyperfluoroalkoxy
  • FEP polyfluorinated ethylene-propylene
  • Natural or synthetic fibers coated with an FR resin are also useful in the fiber blend of the present invention.
  • Suitable fibers coated with an FR resin include those where the resin contains one or more of phosphorus, phosphorus compounds, red phosphorus, esters of phosphorus, and phosphorus complexes; amine compounds, boric acid, bromide, urea-formaldehyde compounds, phosphate-urea compounds, ammonium sulfate, or halogen based compounds.
  • Non-resin coatings like metallic coating are not generally employed for the present invention, because they tend to flake-off after continuous use of the product.
  • Suitable commercially available FR resins are sold under the trade names GUARDEX FR®, and FFR® by Glotex Chemicals in Spartanburg, S. C.
  • the manner in which the resin is coated onto the fiber is not particularly limited.
  • the FR resin is a liquid product that can be applied as a spray.
  • the FR resin is a solid that may be applied as a hot melt product to the fibers, or as a solid powder that is then melted into the fibers.
  • the FR resin is applied to the fibers in an amount of from about 6 to about 25 weight %, based upon the total weight of the coated fibers.
  • the amount of coated FR fiber in the blend can vary, but is from about 35 to about 95 weight percent, based upon the total weight of the blend. In one embodiment, the amount of coated FR fiber in the blend is from about 40 to about 90 weight percent. In another embodiment, the amount of coated FR fiber in the blend is from about 45 to about 85 weight percent.
  • the denier of the FR fibers is from about 1.5 to about 15 dpf (denier per filament).
  • the foregoing listing of FR fibers is not to be construed as a limiting the practice invention but instead to illustrate the fact that any FR fiber known can be employed with an amorphous silica fiber and utilized in the practice of the present invention.
  • fiber types includes multifilament and monofilament yarns, having a variety of cross-sections and shapes as well as fibrillated yarns, typically manufactured from slit films or tapes.
  • the fiber blend of the present invention may further contain one or more non-FR fibers.
  • the non-FR fibers may be synthetic or natural fibers.
  • Suitable non-FR synthetic fibers include polyester such as polyethylene terephthalate (PET); cellulosics, such as rayon and/or lyocell; nylon; polyolefm such as polypropylene fibers; acrylic; melamine and combinations thereof.
  • the lyocell fibers are a generic classification for solvent-spun cellulosic fibers. These fibers are commercially available under the name TENCEL®. Natural fibers include flax, kenaf, hemp, cotton and wool. In one embodiment, non-FR fibers are employed to enhance certain characteristics such as loft, resilience or springiness, tensile strength, and thermal retention.
  • the fiber blend includes amorphous silica fiber and at least one type of FR fiber. Therefore, the present invention is embodied by a fiber blend that contains amorphous silica fiber, an FR fiber, optionally additional FR fibers, and optionally one or more non-FR fibers.
  • the fiber blend includes: modacrylic fiber; a cellulosic fiber, lyocell, and amorphous silica fiber.
  • the fiber blend further includes more than one type of FR fiber.
  • the fiber blend includes amorphous silica fiber, modacrylic fiber, and VISIL.
  • the fiber blend includes modacrylic fiber, FR rayon fiber, and amorphous silica fiber.
  • the fiber blend includes modacrylic fibers, VISIL
  • FR viscose rayon fibers FR viscose rayon fibers
  • amorphous silica fibers FR polypropylene fibers.
  • the amounts of each component can vary; however, advantageous char strength is obtained when a needlepunched fabric is prepared from a blend containing about 40 weight percent modacrylic, about 40 weight percent VISIL, about 15 weight percent amorphous silica, and about 5 weight percent FR polypropylene fibers.
  • the fibers of the present invention can be used to manufacture fabrics, where FR properties are desired or would be useful.
  • any type of fabric, produced from fibers, such as non-woven fabrics; woven fabrics, both open and closed weave; knitted fabrics and various laminates can be made using the fibers of the present invention.
  • the manufacture of such fabrics is not limited to a particular method or apparatus.
  • woven fabrics it is possible to employ amorphous silica fibers in the machine direction or the cross machine direction, alternating with one or more of the FR fibers.
  • the fibers can be alternated in the machine direction and woven with either an amorphous or an FR fiber in the cross machine direction.
  • woven fabrics according to the present invention can comprise the compositions stated above for the blend of amorphous and FR fibers.
  • the non-woven fabric of the present invention may be produced by mechanically interlocking the fibers of a web. The mechanical interlocking can be achieved through a needlepunch operation. Needlepunch methods of preparing non- woven fabric are known in the art.
  • the nonwoven fabric sometimes called a batt, may be constructed as follows: the fiber blend may be weighed and then dry laid/air laid onto a moving conveyor belt. The speed of the conveyor belt can be adjusted to provide the desired batt weight. Multiple layers of batts are fed through a needle loom where barbed needles are driven through the layers to provide entanglement.
  • nonwoven fabrics There are several other known methods for producing nonwoven fabrics including hydroentanglement (spunlace), thermal bonding (calendering and/or though-air), latex bonding or adhesive bonding processes.
  • the spunlace method is similar to needlepunch except waterjets are used to entangle the fibers instead of needles.
  • Thermal bonding requires either some type if thermoplastic fiber or powder to act as a binder. It is to be appreciated that all forms of nonwovens can be made with the FR fiber blends of the present invention to produce barrier fabrics having FR properties. Accordingly, reference to nonwoven fabrics herein includes all forms of manufacture.
  • Suitable non-woven fabrics of the present invention have a batt weight greater than about 2.25 oz./sq. yd. (osy). In one embodiment, the batt weight ranges from about 2.25 osy to about 20 osy. In another embodiment, the batt weight is about 3.5 osy. In one embodiment, the fibers are carded. Then the conveyor belt moves to an area where spray-on material may optionally be added to the nonwoven batt. For example, the FR resin may be sprayed onto the nonwoven batt as a latex. In one embodiment, the conveyor belt is foraminous, and the excess latex spray material drips through the belt and may be collected for reuse later.
  • the fiber blend is transported to a dryer or oven.
  • the fibers may be transported by conveyer belt to the needlepunch loom where the fibers of the batt are mechanically oriented and interlocked to form a non-woven fabric.
  • the non-woven FR fabric is useful as a barrier fabric for bedding materials and bed clothing.
  • the fabric is also useful in upholstery and drapery applications where flame resistance is desired. Another use for such fabrics is as hot gas filtration fabrics. Additionally, fabrics other than non-wovens can be made from the fibers of the present invention, where an FR fabric is desired.
  • a template was fabricated so that the fabric could be sandwiched between the template and the existing test plate.
  • Specimens of the barrier fabric were cut into 4" by 8" (10 by 16 cm) samples and weighed. The samples were placed in a charring frame and charred by using a Bunsen burner. The frame was then mounted into the modified stiffness tester and the char strength of the sample was measured. Table 6 summarizes the results for Example Nos.4-15. As a standard, a blend comprising 40% modacrylic and 60% Visil was selected (Ex. No. 4).
  • Basofil® (abbreviated Bas); modacrylic fiber KANECARON PBX; VISIL® (abbreviated Vis); polyethylene terephthalate (abbreviated PET); and amorphous silica (abbreviated SiI).
  • Basofil® abbreviated Bas
  • modacrylic fiber KANECARON PBX abbreviated PBX
  • VISIL® abbreviated Vis
  • PET polyethylene terephthalate
  • SiI amorphous silica
  • Example 9 comprised a blend 10% Basofil fibers with PET fibers, modacrylic fiber and Visil fiber;
  • Examples 10 and 11 contained 10% and 15% PET fibers as a replacement for varying amounts of modacrylic fiber and Visil fiber;
  • Examples 13 and 14 contained 10% Basofil fibers as a replacement for varying amounts of modacrylic fiber and Visil fiber;
  • Examples 12 and 15 were prepared from fiber blends containing amorphous silica fibers, according to the present invention.
  • Examples 16-45 were prepared and tested as for Examples 4-15, except that different blends of fiber were used, as summarized in Table 7. Strength of each fabric is reported in pounds, as discussed hereinabove. The fabrics have been reported in six groups of four blends and two groups of three blends. Examples 19, 23, 27, 31, 34, 38, 41, and 45 report a base fabric and the examples immediately preceding report the addition of various types of FR fiber. Char strength, in pounds, was measured and the results have been reported by decreasing values for each group. [67] For example, FR rayon and modacrylic fibers were used to prepare
  • Example 19 denoted FR Rayon/Modacrylic Base Fabric.
  • Examples 16-18 are variations of this base fabric, because in each case one other type of FR fiber was added: para-aramid fibers were added to Example 16, melamine fibers were added to Example 17, and amorphous silica fibers were added to Example 18, according to the present invention.
  • Example 23 was prepared from FR rayon fibers and is denoted
  • Examples 20-22 were variations of this base fabric: para-aramid fibers were added to Example 20, melamine fibers were added to Example 21, and amorphous silica fibers were added to Example 22, according to the present invention.
  • Example 27 is a rayon/modaciylic base fabric
  • Example 26 were variations of this base fabric: melamine fibers were added to Example 24, para-aramid fibers were added to Example 25, and amorphous silica fibers were added to Example 26, according to the present invention.
  • Example 31 is a lyocell/modacrylic base fabric, and Examples 28-30 were variations of this base fabric: para-aramid fibers were added to Example 28, melamine fibers were added to Example 29, and amorphous silica fibers were added to Example 30, according to the present invention.
  • Example 34 is the Visil/modacrylic base fabric, and Examples 32, 33 and 35 were variations of this base fabric: para-aramid fibers were added to Example 32, amorphous silica fibers were added to Example 33, according to the present invention; and melamine fibers were added to Example 35.
  • Example 38 is a Visil base fabric, while Examples 36-37 were variations of this base fabric: melamine fibers were added to Example 36, and amorphous silica fibers were added to Example 37, according to the present invention.
  • Example 41 is a rayon base fabric, while Example 39 contains rayon and melamine, and Example 40 contains rayon and amorphous silica, according to the present invention.
  • Example 45 is a lyocell base fabric, while Example 42 contains para aramid, Example 43 contains lyocell and melamine, and Example 44 contains lyocell and amorphous silica, according to the present invention.
  • Examples 46-53 were prepared by using a needlepunch line including a
  • Example No. 46 was the base blend (8 osy) comprising 40 % modacrylic and 60 % Visil) and in the Examples following, various materials or FR fibers were employed.
  • Example 47 comprised a blend of the base blend (79 %) and leno weave carpet backing, 2.1 osy, (21%).
  • Example 48 comprised a blend of the base blend (89 %) and Conwed scrim, 1 osy, (11 %). Conwed is a very lightweight polypropylene material with the "warp" and “fill” monofilaments "welded” together at the vertices to provide a "leno type" appearance.
  • Example 49 comprised a blend of the base blend (85 %) and Basofil (melamine) (15 %).
  • Example 50 comprised a blend of the base blend (85 %) and Conex (15 %). Conex is a meta-aramid.
  • Example 51 comprised a blend of the base blend(85 %) and amorphous silica (15 %).
  • Example 52 comprised a blend of the base blend(85 %) and Kynol (phenol-formaldehyde novolac) (15 %).
  • Example 53 comprised a blend of amorphous silica (15 %), modacrylic fiber (40 %) and Visil fiber (45 %).
  • Example No. 53 represents a fabric of the present invention.
  • a tuft button simulation was designed to expose the charred fabric to stresses that it might see in an actual mattress burn, and gives a pass/fail indication of fabric strength.
  • a small test rig was constructed out of wood. Components were assembled shown in the drawing figure to form tuft button test apparatus 10. Mattress components including 4 inch foam 12, two 1 inch super-soft foams 14,16, barrier fabric 18, which was 0.5 ounces per square foot (osf), PET fiber fill 20, and a PET ticking fabric 22 were assembled as described below, and then burned under tension. [78] The components were assembled on top of upper plate 24. The foam components 12, 14 and 16, were compressed and the barrier fabric 18, fiber fill 20, and ticking 22 were wrapped around all sides of upper plate 24.
  • Lower plate 26 was positioned to sandwich fabrics 18, 20, 22 between upper plate 24 and lower plate 26.
  • a tuft button simulator 28 was welded to threaded rod 30, and rod 30 was pushed through all of the mattress components, and through aligned holes 32, 34 in upper and lower plates 24, 26.
  • Wing nut 36 was fastened to rod 30 to apply tension to the assembly and draw tuft button simulator 28 down into the foam.
  • a TB 603 top burner 28 was placed in the center of tuft button simulator
  • Ex No 48 used the 8osy fabric in a composite with a 2.1 osy leno weave secondary carpet backing fabric. Likewise, it cracked within 20 seconds, and was withdrawn as a possible solution. Similarly, Ex No 48 used a polypropylene scrim, very light in wt (about 1 osy) that had a "leno-weave look" to it. Though it was not a woven fabric, the vertices of the "warp" and "fill” monofilaments were fused together. This sample also cracked well under 1 minute.
  • this invention is directed to a single layer nonwoven fabric useful in protecting items from fire and the related heat; and a process for protecting adjacent materials in an assembly using the fire and heat barrier fabric.
  • the nonwoven barrier is of at least about 0.45 ounces per square yard of an amorphous silica fiber and at least about 0.45 ounces per square yard of a binder fiber; the single layer nonwoven fabric having a basis weight of at least about 3.0 ounces per square yard.
  • the fiber blend by weight of the nonwoven fabric comprises about 15 to about 80 percent by weight amorphous silica fiber, about 15 to about 85 percent by weight binder fiber and may, but not necessarily, contain up to about 70 percent by weight of complimentary fibers with a reduction of the other two fibers to total 100 percent by weight without falling below the minimum amounts.
  • the amorphous silica fiber is always present in the nonwoven fabric composition and comprises at least about 15 percent by weight of the fiber blend, but no more than about 80 percent. In one embodiment the amorphous silica fiber comprises between about 35 and about 50 percent by weight of the fiber blend. As the blend percentage by weight of the silica fiber is reduced, the effectiveness of the single layer nonwoven to shield open flames and heat diminishes.
  • the blend percentage by weight of the amorphous silica is limited to no more than about 80 percent by weight in the described nonwoven to preserve the functional characteristics required of a fire and heat barrier fabric.
  • the fiber-to-fiber cohesion of the amorphous silica is such that at least about 20 percent by weight of more cohesive fibers are required for sufficient fiber web strength and fiber entanglement in the nonwoven.
  • a binder fiber is always present in the nonwoven fabric composition and comprises at least 15 percent by weight of the fiber blend. In one embodiment, the amorphous silica fiber comprises between 50 and 65 percent by weight of the fiber blend.
  • the binder fiber is necessary for the required thermal bonding of the nonwoven barrier fabric, but a multi-component binder fiber may also serve both a mechanical and a thermal role in the nonwoven fabric construction. Mechanically, at least one fiber must offer sufficient fiber-to- fiber cohesion to maintain the integrity of the fiber web and sufficient structure after thermal bonding to maintain entanglement of the fibers among the amorphous silica fibers.
  • This cohesive fiber may be a component of the binder fiber (in the case of a multi-component binder fiber) that remains intact after thermal bonding, or it may be a fiber, or fibers, additive to the amorphous silica and binder fiber in the blend.
  • the binder fiber may be a single component, low melting point fiber that strictly acts as a binding agent for the thermal bond necessary in the nonwoven.
  • Exemplary single component fibers include low-melt polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low-density polyethylene, polylactic acid, polytrimethylene terepthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified..By "sufficiently low” is meant that such thermoplastic fibers will have the lowest melting point of all the component fibers present. Some polymers will inherently have the lowest melting point while others, such as the polyesters, may need to be modified with an appropriate additive to yield a lower melting point than inherently possessed by the unmodified polymer.
  • the single-component binder fiber comprises at least 15 percent by weight of the fiber blend in the nonwoven.
  • any instance where a single-component binder fiber is used requires the addition of at least 15 percent by weight of a higher cohesion fiber for mechanical fiber interlock after thermal bonding.
  • the single-component binder fiber must have a melting temperature no less than 107° C, but the melting temperature cannot exceed a value 10° C less than the lowest melting temperature of any other structural fiber in the fiber blend of the nonwoven.
  • the maximum melt temperature of the single-component binder fiber allows for the binder fiber to melt and flow, forming a binding matrix along and between structural fibers as these fibers are left intact at a temperature lower than their melting point.
  • the minimum temperature varies by end-use application of the nonwoven fire/heat barrier and is based on a temperature higher than the maximum temperature exposure of the nonwoven barrier in subsequent assembly processes and day-to-day operational use and environs.
  • the melt temperature of the single-component binder fiber is minimized within the range to reduce the energy and time required to thermally bond the nonwoven barrier fabric.
  • Diameter of the single-component binder fiber ranges from about 20 microns to about 60 microns and in one embodiment, it is about 31 microns.
  • Length of the single-component fiber ranges from about 50 millimeters to about 125 millimeters and in one embodiment, it is about 75 millimeters, for needlepunch applications.
  • the single-component binder fiber should not act as a contributory fuel source for an open flame.
  • the binder fiber may be a multiple component, low melting point fiber that acts strictly as a binding agent for the thermal bond necessary in the nonwoven.
  • Exemplary multiple component fibers include those fibers of co-extruded polymers in combinations containing at least two of the following polymers: polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low- density polyethylene, polylactic acid, polytrimethylene terpthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified.
  • the term "sufficiently low” has the same meaning as set forth above for the single-component fibers. Similar to the single-component fibers, the multi-component fibers provide two polymers that melt to provide thermal bonding.
  • This multi-component thermal binding fiber comprises at least about 15 percent by weight of the fiber blend in the nonwoven.
  • a multi-component binder fiber acts only as a thermal binding agent, its use requires the addition of at least about 15 percent by weight of a higher cohesion fiber, but no more than about 70 percent by weight, for mechanical fiber interlock after thermal bonding.
  • This multi-component thermal binding fiber must have a melting temperature no less than 107° C, but the melting temperature cannot exceed a value 1O 0 C less than the lowest melting temperature of any other structural fiber in the fiber blend of the nonwoven.
  • the maximum melt temperature of the multi-component thermal binding fiber allows for the binder fiber to melt and flow, forming a binding matrix along and between structural fibers as these fibers are left intact at a temperature lower than their melting point.
  • the minimum temperature varies by end-use application of the nonwoven fire/heat barrier and is based on a temperature higher than the maximum temperature exposure of the nonwoven barrier in subsequent assembly processes and day-to-day operational use and environs.
  • the melt temperature of the multi-component binding fiber is minimized within the range to reduce the energy and time required to thermally bond the nonwoven barrier fabric.
  • Diameter of the multi-component binder fiber ranges from about 20 microns to about 60 microns and in one embodiment, it is about 31 microns.
  • the multi-component binder fiber should not act as a contributory fuel source for an open flame.
  • the binder fiber may be a multiple component, multi-binding (both mechanical and thermal binding functions) low melting point fiber that acts as a binding agent for the thermal bond necessary in the nonwoven and as a mechanical actor that has fiber-to-fiber cohesion sufficient to maintain entanglement of the nonwoven fiber matrix.
  • Exemplary multiple component, multi-binding component fibers include those fibers of co-extruded polymers in combinations containing at least two of the following polymers: polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low-density polyethylene, polylactic acid, polytrimethylene terpthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified.
  • the term "sufficiently low” has the same meaning as set forth above for the single-component fibers.
  • the multi-component, multi-binding fibers provide a polymer that melts to provide thermal bonding; however, the second polymer does not melt and provides the mechanical function for fiber entanglement.
  • This latter difference is a distinction between the multi-component fibers and the multi-component multi-binding fibers.
  • the multi-component multi-binding fibers must contain at least one component comprised of a lower-melt binding agent and a higher melt point component that remains intact after exposure to heat in the thermal bonding stage. This latter difference is a distinction between the multi-component fibers and the multi-component, multi-binding fibers.
  • the multi-component multi-binding fiber comprises at least 15 percent by weight of the fiber blend in the nonwoven.
  • any case where a multi-component multi-binding fiber is used does not necessarily require the addition of another higher cohesion fiber for mechanical fiber interlock after thermal bonding provided all described criteria are met.
  • Diameter of the multi-component multi-binding fiber ranges from about
  • the multi-component multi-binding fiber should not act as a contributory fuel source for an open flame and may, in fact, be flame resistant. [99]
  • the multi-component, multi-binding fibers may be any of several different fiber configurations ⁇ e.g.
  • a minimum of about 10 percent, but no more than about 90 percent, by weight of the individual fiber acts as the thermal binding agent and must have a melting temperature no less than about 107° C, but no more than about 150° C. In another embodiment the melting temperature is about 110° C.
  • the previously described core fiber comprises a minimum of about 10 percent, but no more than about 90 percent, by weight of the individual fiber and must have a melting temperature no less than about 115° C.
  • a useful binder fiber is a core/sheath bi-component configuration comprised of a polyethylene terephthalate (PET) core and a lower melt temperature PET sheath wherein the sheath is about 60 percent by weight of the individual fiber and the core is the remaining 40 percent.
  • the sheath acts as the thermal binding agent forming the outer surface of the binder fiber and has a melting temperature of about 110° C and the core has a melting temperature of about 130° C.
  • PET polyethylene terephthalate
  • core has a melting temperature of about 130° C.
  • core/sheath bi-component binder fiber is available from Huvis Corporation in Korea.
  • core/sheath bi-component binder fiber comprises between 50 and 65 percent by weight of the fiber blend in the nonwoven barrier.
  • multi-component multi-binding fibers that may also be employed include those fibers of co-extruded polymers in combinations containing at least two of the following polymers: polyethylene terephthalate, polypropylene, polyethylene, low-density polyethylene, linear low-density polyethylene, polylactic acid, polytrimethylene terepthalate, polycyclohexanediol terephthalate, polyethylene terephthalate glycol, nylon 6, nylon 6,6, nylon 11, nylon 12, polymethyl pentene and other thermoplastic polymers that have sufficiently low melting points, whether inherent or modified, or any natural cellulosic fibers (cotton, flax, ramie, jute, kenaf, hemp, and the like) or protein fibers (wool, cashmere, camel hair, mohair, other animal hair, silk, and the like) coated or joined together with any of the aforementioned thermoplastic polymers.
  • multi-component multi-binding fibers must contain more than one component comprised of a lower-melt binding agent and a higher melt point component that remains intact after exposure to heat in the thermal bonding stage, similar to the multi-component, multi-binding fibers described hereinabove.
  • the binding agent may be any synthetic fiber with a melting temperature within the aforementioned range that does act as a contributory fuel source for an open flame.
  • the remaining core portion may be any synthetic or natural fiber with a melting temperature no less than 115° C, does not act as a contributory fuel source for an open flame, and has fiber-to-fiber cohesion sufficient to maintain fiber web integrity and hold entanglement among fibers after needling.
  • a fiber must have a minimum Limiting Oxygen Index (LOI) of at least about 21 to be considered a non-contributory fuel source.
  • LOI is a relative measure of flammability that is determined by igniting a sample in an oxygen/nitrogen atmosphere and then adjusting the oxygen content to the minimum amount required to sustain steady burning. The higher the value, the less flammable a material is considered.
  • [O 2 (cone)] and [N 2 ] are the minimum oxygen concentration in the inflow gases required to pass the "minimum burning length"' criterion and the nitrogen concentration in the inflow gases respectively. If the inflow gases are maintained at constant pressure then the denominator of the equation is constant since any reduction in the partial pressure (concentration) of oxygen is balanced by a corresponding increase in the partial pressure (concentration) of nitrogen. Limiting oxygen index is more commonly reported as a percentage rather than fraction. [104] Since air comprises about 20.95% oxygen by volume, any material with a limiting oxygen index less than this will burn easily in air.
  • binder fibers commercially available for practice of the present invention include the following specialty single polymer fibers, all of which are available from Fiber Innovations Technology (FIT) of Johnson City, Tennessee, the product code of each being provided in parentheses: PETG binder fiber (undrawn) (T-135), PETG binder fiber (drawn) (T-137), PCT (T-180), FR (flame resistant) PET (T-190) and FR PET for yarn spinning (T-191).
  • FIT Fiber Innovations Technology
  • binder fibers include the following concentric sheath/core bi-component fibers, also available from FIT and having the product code set forth in parentheses: 110 0 C "melt" CoPET/PET (T-201), 185°C melt CoPET/PET (T-202), Dawn Grey version of T-201 (T-203), Black version of T-202 (T-204), 13O 0 C melt CoPET/PET (T-207), 15O 0 C melt high crystallinity CoPET/PET (T-215), Black version of T-215 (T-225), PCT/PP (T-230), PCT/PET (T-231), PETG/PET (T-235), 185°C, high Tg coPET/PET (T-236), HDPE/PET (T-250), HDPE/PP (FDA food contact) (T-251), LLDPE/PET (T- 252), PP/PET (T-260), Nylon 6/ nylon 6,6 (T-270
  • PET Polyethylene terephthalate
  • Tm 110 0 C
  • coPET coPET
  • Tm 125°C
  • coPET coPET
  • Tm 18O 0 C 3 coPET
  • Tm 200 0 C
  • PLA polylactic add
  • Tm 130 0 C 3 PLA
  • Tm 150°C 3 PLA
  • Tm 17O 0 C
  • PTT polytrimethylene terephthalate
  • PETG PET glycol
  • HDPE high density- polyethylene
  • PP polypropylene, PE/PP copolymer
  • PMP polymethyl pentene
  • polyester binder fibers may be used in some instances.
  • polyester binder fibers include those available from Wellman, Inc. of Fort Mill, South Carolina, under various type names such as 209, H1305, H1295, H1432, M1440, M1429, M1427, M1425, M1428, and M1431.
  • the nonwoven fabric composition may comprise up to 70 percent by weight of other fibers, Le., complimentary fibers, considered to be a non-contributory fuel source.
  • any embodiment comprised of a thermal-only binder fiber such as a single component binder fiber containing a low melt polymer, requires the addition of at least 15 percent by weight of a higher cohesion fiber to provide mechanical fiber interlock after thermal bonding.
  • One embodiment of the present invention comprises between about 35 and 50 percent by weight of the amorphous silica, between 50 and 65 percent by weight of the binder fiber, wherein the binder fibers is of a core/sheath bi-component configuration comprised of a polyethylene terephthalate (PET) core and a lower melt temperature PET sheath, and between 5 and 10 percent by weight of a complimentary fiber such as a solution dyed (pigmented) PET fiber for color in the single layer nonwoven fire and heat barrier fabric.
  • PET polyethylene terephthalate
  • a complimentary fiber such as a solution dyed (pigmented) PET fiber for color in the single layer nonwoven fire and heat barrier fabric.
  • any such fibers employed will have limited application in the production of flame resistant fabrics or fabrics resistant to fire and heat.
  • This invention also relates to the method of producing the single layer nonwoven fabric through slight mechanical entanglement of a web of the fibers and further thermal bonding to reduce physical property directional bias, maintain fuller length of individual fibers, encapsulate and contain individual fibers, and to reduce density per area of the nonwoven fabric without significantly diminishing the integrity of the fabric.
  • the nonwoven fabric may be constructed as follows. The various combinations of fibers that can be employed in the present invention may be weighed and dry or wet formed into a fiber web. The web may be formed by any of several different methods:
  • Bales of each fiber type are fed into the process where the clumps and bundles of fibers are separated (opened).
  • the opened fibers of each type are weighed in process and are fed together into a blended web laydown calculated by percent fiber type weight of the total.
  • This web laydown is then fed into a card which uses rotating cylinders with fine teeth to orient the fibers into parallel arrays.
  • This carded web is then transferred directly to the bonding process or is crosslapped onto a conveyor moving at a right angle allowing layering of carded web to increase web width, web weight and/or cross-directional strength before moving on to the bonding process.
  • Bales of each fiber type are fed into the process where the clumps and bundles of fibers are separated (opened).
  • the opened fibers of each type are weighed in process and are fed together into a blended web laydown calculated by percent fiber type weight of the total.
  • This web laydown is formed by suspending the fibers in the air and then collecting them as a batt on a screen that separates the fibers from the air.
  • This web is then transferred directly to the bonding process or is crosslapped onto a conveyor moving at a right angle allowing layering of carded web to increase web width and/or web weight before moving on to the bonding process.
  • a useful method of web formation is the dry-laid carded process.
  • the useful fabric formation is mechanical fiber entanglement by needlepunching the web and then thermal bonding through the application of heat above the melting temperature of the binder, but below the melting temperature of the structural fibers that mechanically bind the fabric through entanglement.
  • one embodiment is a nonwoven fabric with mechanically entangled fibers that are then heat bonded
  • woven fabrics it is possible to employ amorphous silica fibers in the machine direction or the cross machine direction, alternating with one or more of the FR or the binder fibers.
  • the fibers can be alternated in the machine direction and woven with either an amorphous or an FR or a binder fiber in the cross machine direction.
  • woven fabrics according to the present invention can comprise the compositions stated above for the blend of amorphous silica and FR fibers as well as amorphous silica and binder fibers.
  • the particular weave construction for open weave fabrics is not a limitation of the present invention and thus, all ranges of end counts in both the machine and cross machine directions are included.
  • Ply/Cord Yarns a) Twisting together two or more single yarns of different types into a resultant ply yarn. b) Twisting together two or more ply yarns of different types into a resultant cord yarn.
  • Core-Spun/Wrapped Yarns a) A central core of a continuous yarn or filament around which another type fiber is wrapped or twisted, resulting in a continuous yarn with one fiber type as the core and another type making up the exterior layer.
  • the warp yams may be of one type and the weft yarns of another type.
  • Yarns of different fiber types may be combined in the warp at some interval.
  • Yarns of different fiber types may be combined in the weft at some interval.
  • This invention relates to a fabric useful in protecting items, or products, such as mattresses, from fire and the related heat; a process for producing the fabric; and a process for protecting materials in a product by using the fire and heat barrier fabric.
  • One such process for protecting materials in a product using the fire and heat barrier is by ultrasonically bonding or ultrasonically welding the barrier fabric directly to at least one component that is also present in the product.
  • Such a component comprises a material that is susceptible to damage due to fire and heat, occasioned by exposure to open flames and therefore, requires barrier protection.
  • Ultrasonic bonding is well known in the art, but the ability directly incorporate a fire and heat barrier into a sub-assembly is novel. Ultrasonic bonding uses ultrasonic energy to join layers of thermoplastic materials. High speed ultrasonic vibrations result in welds between thermoplastics fusing the materials together. This fusing, or welding, requires similar thermoplastic materials to form the bond. [119] As an example, many traditional mattress constructions are covered by a surface assembly of a high-loft fiber batt between an outside layer of ticking fabric and an inner layer of a lightweight fabric (typically spunbond) to hold the backstitch of the needle-and-thread quilted assembly.
  • the quilted assembly forms a surface that is both soft and visually appealing due to the lofty quilted pattern. Because the high- loft fiber batt is conventionally PET, and because both the outer ticking layer and the inner structural layer are available in PET or a majority-blend PET, these and similar assemblies, or products, e.g., furnishings, transportation seats and surfaces, bed clothing and the like, are sometimes quilted by ultrasonic bonding means, rather than by the traditional needle-and-thread sew quilting.
  • blends and resultant fabrics of the present invention are such that they allow for the ultrasonically bonded quilting of an assembly containing a flame and thermal barrier.
  • those blends comprising at least 40 percent by weight PET, or other suitable thermoplastic, are suitable for ultrasonic bonding to other materials containing a minimum of 40 percent of the same or similar thermoplastic.
  • One embodiment is for the flame and thermal barrier fabric to comprise a minimum of 50 percent PET by weight, and the other layers of the assembly contain at least 50 percent by weight of PET or similar thermoplastic.
  • Assemblies for mattress construction may be produced in any number of configurations (no inner layer is necessary) such as the following:
  • the flame and thermal barrier fabric may be ultrasonically bonded to the outer ticking layer at points across the full width and along the length of the assembly.
  • the flame and thermal barrier fabric may be ultrasonically bonded to the outer ticking layer at points only along the assembly edges.
  • layer (s) of high-loft batt may be added between the flame and thermal barrier fabric and the ticking before bonding as described in 1, hereinabove.
  • layer(s) of high-loft batt may be added between the flame and thermal barrier fabric and the ticking before bonding as described in 2, hereinabove.
  • Variations of configuration 3 offering the same or similar effect are possible by layering the flame and thermal barrier fabric directly to the ticking layer and the high-loft batt is layered to the inside before ultrasonically bonding as described in 1, hereinabove.
  • Variations of configuration 4 offering the same or similar effect are possible by layering the flame and thermal barrier fabric directly to the ticking layer and the high-loft batt is layered to the inside before ultrasonically bonding as described in 2, hereinabove.
  • Another product used in mattress construction is the border fabric, or side fabric material.
  • satisfactory border assemblies for mattresses and/or box springs may be produced in any of the above configurations using full width roll-good materials up to approximately 120-inches in width (theoretically the width is unlimited because the ultrasonic horns and anvils may be arranged in a modular format, but practically, the width is limited to currently available widths of roll-good ticking and high-loft batt as well as currently available supporting equipment).
  • the body quilt pattern is ultrasonically bonded using a series of wide horns applied across the width of a patterned cylinder anvil.
  • the typical width of a border assembly ranges from about 9 inches to about 14 inches (or more). These individual widths may be ultrasonically slit and the edges ultrasonically sealed with a stitch pattern (or other pattern) using an in-line or off-line series of horns and slitter/sealing anvils.
  • Fabrics of the present invention are particularly useful for mattress borders because the need for comfort is not present, as it is in the tops and bottoms of mattresses, the panels, which will incorporate batting to give the panel softness and loft. Accordingly, in the borders, the FR fabric is readily assembled to the ticking, as by ultrasonic welding, to form that product, which can be thought of a sub- assembly of the complete product, the mattress.
  • An example process setup for ultrasonic sealing would employ 1.IkW power supplies to 9-inch horns in series across the width of a cylinder anvil patterned to the quilting design desired in the body of the assembly. After the layers are fed from and unwound into this portion of the process, additional layers may be introduced if desired before flowing through a series of one inch diameter horns spaced at the desired widths of the border assemblies to be simultaneously slit and sealed (if desired) using a 1.IkW power supply to each horn. Process variables such as pressure, speed, amplitude, power boosters and loadings differ based on the types of materials used and the mass.
  • barrier fabrics comprising 40 percent of amorphous silica, provided acceptable protection, as compared to the incumbent products.
  • Examples 66 and67 did show higher percent mass loss, this was attributable to the lower mass per unit area (4.9 and 4.7) compared to the other fabrics.
  • Example 73 showed both a greater maximum temperature and mass loss, which was due to the presence of the 8 percent PP fiber, a complimentary fiber which may be a fuel source, i.e., not a "non-contributory" fuel source, added to provide a colored, or pigmented, fabric.
  • FR fabrics of the present invention in various items include the following: 1. Bedding - barrier beneath ticking or exposed on the bottom of one-sided mattresses or on the top and/or bottom of the box springs. Borders, as discussed above, are also products that benefit by the presence of the barrier.
  • the present invention therefore, includes any of the foregoing products produced by the process of the present invention.
  • amorphous silica fibers is highly effective in providing FR blends and fabrics.
  • the invention can be practiced by combining amorphous silica fibers with at least one other flame resistant fiber, or a binder fiber but is necessarily limited thereto.
  • the fiber blends of the present invention can be utilized to manufacture flame resistant fabrics for a variety of purposes including, but not limited to barrier fabrics for upholstery, bedding and bed clothing applications. Moreover, the fabrics are not limited to non-woven types.

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PCT/US2005/043173 2004-11-30 2005-11-30 Flame resistant fiber blends, fire and heat barrier fabrics and related processes WO2007061423A2 (en)

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ES05858690T ES2385391T3 (es) 2004-11-30 2005-11-30 Combinaciones de fibras resistentes a la llama
AU2005338024A AU2005338024B2 (en) 2004-11-30 2005-11-30 Flame resistant fiber blends, fire and heat barrier fabrics and related process
KR1020077015059A KR101341293B1 (ko) 2004-11-30 2005-11-30 내연성 섬유 블렌드, 불 및 열 장벽 직물 및 관련 공정
CA2589863A CA2589863C (en) 2004-11-30 2005-11-30 Flame resistant fiber blends, fire and heat barrier fabrics and related processes
AT05858690T ATE552368T1 (de) 2004-11-30 2005-11-30 Flammwidrige fasermischungen
EP05858690A EP1861524B1 (en) 2004-11-30 2005-11-30 Flame resistant fiber blends
BRPI0516642A BRPI0516642B1 (pt) 2004-11-30 2005-11-30 misturas de fibra resistente à chama (fr)
CN2005800463661A CN101263253B (zh) 2004-11-30 2005-11-30 阻燃纤维混合物，火和热阻隔织物和相关方法
DK05858690.0T DK1861524T3 (da) 2004-11-30 2005-11-30 Flammebestandige fiberblandinger
JP2007546712A JP5312794B2 (ja) 2004-11-30 2005-11-30 難燃性繊維混紡、防火遮熱布、および関連する方法
IL183618A IL183618A (en) 2004-11-30 2007-05-31 Fire-resistant fiber blends, fire and heat-blocking fabrics and associated processes

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EP1861524B1 (en) 2012-04-04
EP1861524A2 (en) 2007-12-05
AU2005338024B2 (en) 2011-07-21
IL183618A0 (en) 2009-02-11
ATE552368T1 (de) 2012-04-15
ES2385391T3 (es) 2012-07-24
JP5312794B2 (ja) 2013-10-09
DK1861524T3 (da) 2012-05-29
KR20070100262A (ko) 2007-10-10
CA2589863A1 (en) 2007-05-31
BRPI0516642A (pt) 2008-09-16
WO2007061423A3 (en) 2007-12-06
IL183618A (en) 2014-01-30
JP2008522056A (ja) 2008-06-26
AU2005338024A8 (en) 2008-12-18
EP1861524A4 (en) 2010-05-19
KR101341293B1 (ko) 2013-12-12
BRPI0516642B1 (pt) 2016-08-30
CA2589863C (en) 2014-08-19
AU2005338024A1 (en) 2007-06-21

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