U.S. patent application number 10/607739 was filed with the patent office on 2004-01-01 for fire resistant corespun yarn and fabric comprising same.
This patent application is currently assigned to McKinnon-Land, LLC. Invention is credited to Land, Frank J..
Application Number | 20040002272 10/607739 |
Document ID | / |
Family ID | 23609232 |
Filed Date | 2004-01-01 |
United States Patent
Application |
20040002272 |
Kind Code |
A1 |
Land, Frank J. |
January 1, 2004 |
Fire resistant corespun yarn and fabric comprising same
Abstract
Provided is a fire resistant corespun yarn. The yarn includes a
core of a high temperature resistant continuous filament comprising
fiberglass and a low temperature synthetic continuous filament
selected from nylon, polyester, polyethylene and polyolefin, the
core being two-plied. A first sheath of blended staple fibers
surrounds the core. The fibers include modacrylic fibers and
melamine fibers. A second sheath of staple fibers surrounds the
first corespun yarn. This double corespun yarn may be woven and
knit in fine, non-plied or plied form and extends the range of
fineness of fabrics below heretofore achievable limits. Also
provided is a fire resistant fabric which includes a fire resistant
fabric substrate formed from the fire resistant corespun yarn, as
well as a product upholstered with the fire resistant fabric.
Inventors: |
Land, Frank J.; (Freeport,
NY) |
Correspondence
Address: |
Burns, Doane, Swecker & Mathis, L.L.P.
P.O. Box 1404
Alexandria
VA
22313-1404
US
|
Assignee: |
McKinnon-Land, LLC
|
Family ID: |
23609232 |
Appl. No.: |
10/607739 |
Filed: |
June 27, 2003 |
Related U.S. Patent Documents
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Application
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Filing Date |
Patent Number |
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10607739 |
Jun 27, 2003 |
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09948720 |
Sep 10, 2001 |
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6606846 |
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09948720 |
Sep 10, 2001 |
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09624772 |
Jul 25, 2000 |
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6287690 |
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09624772 |
Jul 25, 2000 |
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09406732 |
Sep 28, 1999 |
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6146759 |
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Current U.S.
Class: |
442/190 ;
428/365; 442/301; 442/302; 442/308; 57/210; 57/229; 57/230 |
Current CPC
Class: |
Y10T 428/2915 20150115;
D10B 2321/101 20130101; Y10T 428/2929 20150115; Y10T 428/2964
20150115; Y10T 442/3073 20150401; D02G 3/443 20130101; Y10T 442/425
20150401; D02G 3/38 20130101; D02G 3/185 20130101; D02G 3/36
20130101; Y10T 428/2913 20150115; Y10T 428/2924 20150115; Y10T
442/3984 20150401; D10B 2331/021 20130101; D03D 15/513 20210101;
Y10T 428/2936 20150115; Y10T 442/3976 20150401; D02G 3/182
20130101 |
Class at
Publication: |
442/190 ;
442/301; 442/302; 442/308; 428/365; 57/210; 57/229; 57/230 |
International
Class: |
D04B 021/14; D02G
003/02; D07B 001/06; D04H 001/00; D03D 015/12 |
Claims
What is claimed is:
1. A fire resistant corespun yarn, comprising: a core of a high
temperature resistant continuous filament comprising fiberglass; a
first sheath of blended staple fibers surrounding the core, the
fibers comprising modacrylic fibers and melamine fibers; and a
second sheath of staple fibers surrounding the first corespun
yarn.
2. The fire resistant corespun yarn according to claim 1, wherein
the core has a multi-ply structure.
3. The fire resistant corespun yarn according to claim 2, wherein
the multi-ply structure comprises a low temperature resistant
continuous filament synthetic fiber selected from the group
consisting of polyethylene, nylon, polyester and polyolefin,
two-plied with the fiberglass filament.
4. The fire resistant corespun yarn according to claim 1, wherein
the second sheath staple fibers are of a material selected from the
group consisting of cotton, wool, nylon, polyester, polyolefin,
rayon, acrylic, silk, mohair, cellulose acetate, and blends
thereof.
5. The fire resistant corespun yarn according to claim 4 wherein
the second sheath staple fibers are cotton or polyolefin
fibers.
6. The fire resistant corespun yarn according to claim 5, wherein
the core is from about 15 to 35% by weight based on the total
weight of the corespun yarn, and the second sheath is from about 35
to 80% by weight based on the total weight of the corespun
yarn.
7. The fire resistant corespun yarn according to claim 6, wherein
the core is about 25% by weight based on the total weight of the
corespun yarn, and the second sheath is about 50% by weight based
on the total weight of the corespun yarn.
8. The fire resistant corespun yarn according to claim 1, wherein
the size of the corespun yarn is from about 30/1 to 1/1
conventional cotton count.
9. The fire resistant corespun yarn according to claim 1, wherein
the modacrylic fibers and melamine fibers are present in the first
sheath of blended staple fibers in an amount of from about 50 to
90% by weight and from about 10 to 50% by weight, respectively,
based on the total weight of the first sheath.
10. A fire resistant corespun yarn, comprising: a two-plied core of
a high temperature resistant continuous filament comprising
fiberglass and a low temperature resistant continuous filament
synthetic fiber selected from the group consisting of polyethylene,
nylon, polyester and polyolefin; a first sheath of blended staple
fibers surrounding the core, the fibers comprising modacrylic
fibers and melamine fibers; and a second sheath of staple fibers
surrounding the first corespun yarn, wherein the core is from about
15 to 35% by weight based on the total weight of the corespun yarn,
and the second sheath is from about 35 to 80% by weight based on
the total weight of the corespun yarn.
11. A fire resistant fabric, comprising: a fire resistant fabric
substrate, the substrate comprising: a fire resistant corespun
yarn, the yarn comprising: a core of a high temperature resistant
continuous filament comprising fiberglass; a first sheath of
blended staple fibers surrounding the core, the fibers comprising
modacrylic fibers and melamine fibers; and a second sheath of
staple fibers surrounding the first corespun yarn.
12. The fire resistant fabric according to claim 11, wherein the
core further comprises a low temperature resistant continuous
filament synthetic fiber selected from the group consisting of
polyethylene, nylon, polyester and polyolefin, two-plied with the
fiberglass filament.
13. The fire resistant fabric according to claim 11, wherein the
second sheath staple fibers are of a material selected from the
group consisting of cotton, wool, nylon, polyester, polyolefin,
rayon, acrylic, silk, mohair, cellulose acetate, and blends
thereof.
14. The fire resistant fabric according to claim 13, wherein the
core is from about 15 to 35% by weight based on the total weight of
the corespun yarn, and the second sheath is from about 35 to 80% by
weight based on the total weight of the corespun yarn.
15. The fire resistant fabric according to claim 11, wherein the
fabric is free of a fire resistant coating.
16. A product upholstered with the fire resistant fabric of claim
11.
17. The product of claim 16, wherein the fabric is free of a fire
resistant coating.
18. The product of claim 16, wherein the product is a composite
chair, a mattress or a panel fabric furniture system.
19. The product of claim 16, wherein the fabric is free of a
barrier fabric.
20. The product of claim 16, wherein upon exposure of the fabric to
flame, the first sheath is effective to partially burn and char
around the core, thereby preventing rupture and creating oxygen
depletion to the product below the fabric.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a fire resistant yarn and to a
method of preparing a fire resistant yarn. The invention also
relates to a fabric which includes the fire resistant yarn. The
invention has particular applicability in the formation of fire
resistant fabrics for applications such as upholstery, mattress and
pillow ticking, bed spreads, pillow covers, draperies or cubicle
curtains, wallcoverings, window treatments and baby clothing.
[0003] 2. Description of the Related Art
[0004] It is well known in the textile industry to produce fire
resistant fabrics for use as upholstery, mattress ticking, panel
fabric and the like, using yarn formed of natural or synthetic
fibers, and then treating the fabric with fire retarding chemicals.
Conventional fire retarding chemicals include halogen-based and/or
phosphorus-based chemicals. Unfortunately, such treated fabric is
heavier than similar types of non-fire retardant fabrics, and
further has a limited wear life. Also, this type of fabric
typically melts or forms brittle chars which break away when the
fabric is burned, and exposes the foam of a composite chair,
mattress or panel fabric system. The exposed foam then acts as a
fuel source.
[0005] It is also known to form fire resistant fabrics of fire
resistant, relatively heavy weight yarns in which a low temperature
resistant fiber is ring spun around a core of continuous filament
fiberglass. However, this type of ring spun yarn has torque
imparted thereto during the spinning process and is very lively.
Because of the lively nature of the yarn, it is necessary to ply
AS.congruent. and AZ.congruent. ring spun yarns together so that
the torque and liveliness in the yarn is balanced in order to
satisfactorily weave or knit the yarn into the fabric, without
experiencing problems of tangles occurring in the yarn during the
knitting or weaving process. This plying of the "S" and "Z" yarns
together results in a composite yarn which is so large that it
cannot be used in the formation of fine textured, lightweight
fabrics. In some instances, the fiberglass filaments in the core
protrude through the natural fiber sheath. It is believed that the
problem of protruding core fibers is associated with the twist,
torque and liveliness being imparted to the fiberglass core during
the ring spinning process.
[0006] It is the current practice to produce coated upholstery
fabrics by weaving or knitting a substrate or scrim of a cotton or
cotton and polyester blend yarn. This scrim is then coated with a
layered structure of thermoplastic polyvinyl halide composition,
such as polyvinyl chloride (PVC). This coated upholstery fabric has
very little, if any, fire resistance and no flame barrier
properties. In addition to the coating chemical having a limited
shelf life, the chemical coatings are disadvantageous in that they
pose a safety hazard in case of contact with skin.
SUMMARY OF THE INVENTION
[0007] To overcome or conspicuously ameliorate the disadvantages of
the related art, it is an object of the present invention to
provide a novel fire resistant corespun yarn. As used herein, the
term "fire resistant" means that when, in the form of a woven or a
knitted fabric composed entirely of the yarn, it satisfies the
requirements of the standard Technical Bulletin, California 133
Test Method (Cal. 133).
[0008] It is a further object of the invention to provide a fire
resistant fabric which includes the fire resistant corespun yarn in
a fire resistant fabric substrate.
[0009] It is a further object of the invention to provide a product
upholstered with the fire resistant fabric.
[0010] The corespun yarn can advantageously be used in forming fine
textured or non-textured fire resistant decorative fabrics. Upon
exposure to flame and high heat, sheathings of staple fibers
surrounding and covering a core become charred and burnt, yet
remain in position around the core to create a thermal insulation
barrier. The char effectively can block the flow of oxygen and
other gases, preventing the fabric from igniting.
[0011] In addition, the fabrics woven or knit with the corespun
yarn of the present invention can advantageously be dyed and
printed with conventional dying and printing materials. These
fabrics are particularly suitable for forming fine textured fire
resistant flame barrier decorative fabrics for use in upholstery,
panel fabrics, mattress and pillow ticking, draperies or cubicle
curtains, wallcoverings, window treatments and baby clothing.
[0012] In accordance with a first aspect of the invention, a fire
resistant corespun yarn is provided. The corespun yarn includes a
core of a high temperature resistant continuous filament comprising
fiberglass. A first sheath of blended staple fibers surrounds the
core, the fibers including modacrylic fibers and melamine fibers. A
second sheath of staple fibers surrounds the first corespun
yarn.
[0013] In accordance with a particularly preferred embodiment of
the invention, the core has a structure which includes a low
temperature resistant continuous filament synthetic fiber selected
from the group consisting of polyethylene, nylon, polyester and
polyolefin, two-plied with the fiberglass filament.
[0014] In accordance with a further aspect of the invention, a fire
resistant corespun yarn is provided. The corespun yarn includes a
two-plied core of a high temperature resistant continuous filament
comprising fiberglass and a low temperature resistant continuous
filament synthetic fiber selected from the group consisting of
polyethylene, nylon, polyester and polyolefin. A first sheath of
blended staple fibers surrounds the core, the fibers including
modacrylic fibers and melamine fibers. A second sheath of staple
fibers surrounds the first corespun yarn. The core accounts for
from about 15 to 35% by weight based on the total weight of the
corespun yarn, and the second sheath accounts for from about 35 to
80% by weight based on the total weight of the corespun yarn.
[0015] In accordance with yet another aspect of the invention, a
fire resistant fabric is provided. The fabric includes a fire
resistant fabric substrate, which includes the fire resistant
corespun yarn.
[0016] In accordance with yet another aspect of the invention, a
product upholstered with the fire resistant fabric is provided. The
product can advantageously be free of a fire resistant coating and
of a barrier fabric.
[0017] Other objects, advantages and aspects of the present
invention will become apparent to one of ordinary skill in the art
on a review of the specification, drawings and claims appended
hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The objects and advantages of the invention will become
apparent from the following detailed description of the preferred
embodiments thereof in connection with the accompanying drawings,
in which like numerals designate like elements, and in which:
[0019] FIG. 1 is an enlarged view of a fragment of the balanced
double corespun yarn in accordance with the present invention;
[0020] FIG. 2 is a schematic diagram of an air jet spinning
apparatus of the type utilized in forming the fine denier corespun
yarn and double corespun yarn of the present invention; and
[0021] FIG. 3. is a fragmentary isometric view of a portion of a
woven fabric in accordance with invention;
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0022] Preferred embodiments of the invention will now be described
with reference to FIG. 1, which illustrates an exemplary fire
resistant multi-corespun yarn in accordance with one aspect of the
invention. While the exemplary fire resistant yarn is a balanced
double corespun yarn, it should be clear that triple or more
corespun yarns are also envisioned.
[0023] The basic structure of the yarn 100 in accordance with the
invention includes a filament core 102 completely surrounded by a
first sheath 104, and a second sheath 106 completely surrounding
the first sheath 104.
[0024] Core 102 is formed from a high temperature resistant
continuous filament fiberglass 108, two-plied with a low
temperature resistant continuous filament synthetic fiber 110. The
core 102 is preferably from about 15 to 35% by weight based on the
total weight of the corespun yarn.
[0025] Suitable continuous filament fiberglass materials for use in
the core 102 are commercially available, for example, from PPG. The
filament fiberglass 108 is preferably from about 10 to 30% by
weight of the total weight of the double corespun yarn 100.
[0026] Preferably, synthetic fiber 110 is formed of a synthetic
(i.e., man made) material selected from the group consisting of a
polyethylene, a nylon, a polyester and a polyolefin. Of these,
nylon is particularly preferred. Suitable continuous synthetic
fiber filaments are commercially available, for example, continuous
filament nylon from BASF. Synthetic fiber 110 is preferably from
about 5 to 25% by weight of the total weight of the double corespun
yarn 100. While a two-plied core structure has been exemplified, it
should be clear that other multi-plied core structures can be
used.
[0027] First sheath 104 is a medium to high temperature staple
fiber blended sheath. The fiber blend comprises two or more
different types of synthetic fibers which include blended
modacrylic and melamine staple fibers surrounding the two-plied
core 102. Modacrylic fiber is a stable fiber which chars and
expands when exposed to open flame, while melamine fiber is a high
temperature resistant, unstable brittle fiber. The modacrylic fiber
acts as a carrying agent for the melamine fiber which, when
blended, creates a stable/flexible high temperature resistant
material. Suitable modacrylics are sold under the tradenames
Protex7 (M) or Protex7 (S), while melamine fiber is commercially
available from BASF under the tradename Basofil7.
[0028] In the fiber blend, the modacrylic staple fibers preferably
account for from about 50 to 90% by weight of the total weight of
the first sheath, while the melamine fibers preferably account for
from about 10 to 50% by weight of the total weight of the first
sheath. The first sheath 104 is preferably from about 10 to 40% by
weight of the total weight of the double corespun yarn 100.
[0029] Second sheath 106 is a low to medium temperature chopped
staple fiber sheath surrounding the core 102 and first sheath 104
(i.e., the first core spun yarn) to create the product double
sheath corespun yarn 100. The low to medium temperature resistant
staple fibers of the second sheath 106 are preferably selected from
a variety of different types of either natural (e.g., vegetable,
mineral or animal) or synthetic fibers, such as cotton, wool,
nylon, polyester, polyolefin, rayon, acrylic, silk, mohair,
cellulose acetate, or blends of such fibers. Of these, the
preferred low to medium temperature resistant staple fibers are
cotton or polyolefin. The second sheath 106 is preferably from
about 35% to 80% of the total weight of the double corespun yarn
100.
[0030] The two-plied continuous fiberglass and synthetic filaments
108, 110 of the core 102 extend generally longitudinally in an
axial direction of the double corespun yarn 100. The majority of
the staple fibers of the first sheath 104 and of the second sheath
106 extend around core 102 in a slightly spiraled direction. A
minor portion, for example, from about 35 to 80%, of the staple
fibers of each of the sheaths form a binding wrapper spirally
around the majority of the staple fibers, as indicated at 112, in a
direction opposite the majority of staple fibers. The first sheath
104 hence surrounds and completely covers the two-plied core 102,
and the second sheath 106 surrounds and completely covers the first
sheath 104. The outer surface of the double corespun yarn has the
appearance and general characteristics of the low to medium
temperature resistant fibers forming the second sheath 106.
[0031] The size of the product yarn will vary depending on the
final application of the yarn and the particular fabric
characteristics desired, but is preferably within the range of from
about 30/1 to 1/1 conventional cotton count, preferably from about
21/1 to 10/1 conventional cotton count.
[0032] The product multi-corespun yarn is balanced and has very
little if any torque or liveliness. This characteristic allows the
yarn to be woven or knitted in single end manner without the need
for two ends to be plied to balance the torque. As a result, fine
textured fabrics can be formed having heat resistant properties
which have not been possible to date.
[0033] A method for forming the double corespun yarn 100 in
accordance with the invention will now be described with reference
to FIG. 2. As pointed out above, the double corespun yarn 100 of
the present invention is preferably produced on an air jet spinning
apparatus 200 of the type illustrated. Such an apparatus is
commercially available, for example, from Murata of America, Inc.,
and is described in the literature. See, e.g., U.S. Pat. Nos.
5,540,980, 4,718,225, 4,551,887 and 4,497,167, the entire contents
of which patents are incorporated herein by reference.
[0034] The air jet spinning apparatus 200 includes an entrance
trumpet 202 into which a sliver of medium to high temperature
resistant staple fibers 204 is fed. Staple fibers 204 are then
passed through a set of paired drafting rolls 206. A continuous
filament fiberglass and low temperature continuous filament
synthetic two-plied core 102 is fed between the last of the paired
drafting rolls 206 and onto the top of the staple fibers 204.
[0035] The two-plied core 102 and staple fibers 204 then pass
through a first fluid swirling airjet nozzle 210, and a second
fluid swirling air jet nozzle 212, thereby forming a first corespun
yarn 214. The first and second air jet nozzles 210, 212 are
constructed to produce swirling fluid flows in opposite directions,
as indicated by the arrows. The action of first air jet nozzle 210
causes the staple fibers 204 to be wrapped or spiraled around the
two-plied core 102 in a first direction. The oppositely operating
air jet nozzles 210, 212 causes a minor portion, for example, from
about 5 to 20%, of the staple fibers to separate and wind around
the unseparated staple fibers in a direction opposite the majority
fiber spiral. The wound staple fibers maintain the first sheath 104
in close contact surrounding and covering the two-plied core 102.
The first corespun yarn 214 is then drawn from the second nozzle
212 by a delivery roll assembly 216 and is wound onto a take-up
package (not shown).
[0036] The same air jet spinning apparatus can be utilized to apply
the second sheath 106 to the first corespun yarn 214 in the same
manner described above, thereby forming the double corespun yarn
100. In this instance, the low to medium temperature resistant
staple fibers of the second sheath 106 are fed through the entrance
trumpet 202, and the first corespun yarn 214 is passed through the
set of paired drafting rolls 206. The same spiraling action
achieved for the first sheath is obtained for the second sheath
staple fibers around the first sheath by way of the oppositely
operating air jet nozzles 210, 212. The second corespun yarn is
then drawn from the second nozzle 212 by the delivery roll assembly
216 and is wound onto the take-up package.
[0037] Since the formation of the present yarn on an air jet
spinning apparatus does not impart excessive liveliness and torque
to the two-plied fiberglass/synthetic core, no problems are
experienced with loose and broken ends of the fiberglass/synthetic
core protruding outwardly through the first sheath and or the
second sheath in the yarn and the fabrics produced therefrom. Since
it is possible to produce woven and knitted fabrics utilizing
single ends of double corespun yarn, the double corespun yarn can
be woven into fine textured fabrics with the double corespun yarn
being in the range of from about 30/1 to 1/1 conventional cotton
count. This extends the range of fineness of the fabrics which can
be produced relative to the types of fabrics heretofore possible to
produce by utilizing only double corespun yarns of the prior
art.
[0038] The flame resistant multi-corespun yarns described above can
advantageously be used in forming fine textured fire resistant
barrier decorative fabrics for numerous applications, such as
upholstery, mattress and pillow ticking, bed spreads, pillow
covers, draperies or cubicle curtains, wallcoverings, window
treatments and baby clothing. FIG. 3 illustrates an enlarged view
of a portion of an exemplary woven decorative fabric 300 in a two
up, one down, right-hand twill weave design. In this exemplified
embodiment, the above-described flame retardant multi-corespun yarn
is employed for warp yarns A. The material for the filling yarn can
be the same or different from that of the warp yarn, depending on
the second sheathing material. For purposes of illustration, an
open weave is shown to demonstrate the manner in which the warp
yarns A and the filling yarns B are interwoven. However, the actual
fabric can be tightly woven. For example, the weave can include
from about 10 to 200 warp yarns per inch and from about 10 to 90
filling yarns per inch.
[0039] While FIG. 3 illustrates a two up, one down, right-hand
twill weave design, the described multi-corespun yarns can be
employed in any number of designs. For example, the fabric can be
woven into various jacquard and doubly woven styles.
[0040] Fabrics formed with the described yarns have the feel and
surface characteristics of similar types of upholstery fabrics
formed of 100% polyolefin fibers while having the desirable fire
resistant and flame barrier characteristics not present in
upholstery fabric formed entirely of polyolefin fibers. In this
regard, the fabrics formed in accordance with the invention meet
various standard tests designed to test the fire resistancy of
fabrics. For example, one standard test for measuring the fire
resistant characteristics of fabrics is Technical Bulletin,
California 133 Test Method (Cal. 133), the entire contents of which
are herein incorporated by reference. According to this test, a
composite manufactured chair upholstered with a fabric to be tested
is exposed to an 80 second inverted rectangular Bunsen burner
flame. Fabrics employing the above-described fire resistant
multi-spun yarns having gone through this test remain flexible and
intact, exhibiting no brittleness, melting, or fabric shrinkage.
Additional tests which the formed fabrics meet include the proposed
Consumers Product Safety Commission (CPSC) Proposed Flammability
Code, the Component Testing on Chair Contents (Britain, France,
Germany and Japan) and the Component Testing on Manufactured Chair
(Britain, France, Germany and Japan).
[0041] When fabrics which have been formed of the balanced double
corespun yarn of the present invention are exposed to flame and
high heat, the first and second sheaths 104, 106 of staple fibers
surrounding and covering the core are charred and burned but remain
in position around the two-ply fiberglass/synthetic core 102 to
create a thermal insulation barrier. The fiberglass core and part
of the first sheath 104 of the modacrylic/melamine fiber blend
remain intact after the organic staple fiber materials from the
second sheath 106 have burned. They form a lattice upon which the
char remains, thereby blocking flow of oxygen and other gases
through the fabric while providing a structure which maintains the
integrity of the fabric after the organic materials of the staple
fiber first and second sheaths have been burned and charred. Unlike
known fabrics, chemical treatment of the sheath or fabric fibers is
not required because the composite multi-corespun yarn is
inherently flame resistant. Non-flame retardant coatings may,
however, be applied to the surface or backing of the fabric to form
a more dimensionally stable fabric depending on the end product use
or composite fabric and product application.
[0042] Fabrics woven or knit of the double corespun yarn of the
present invention may be dyed and printed with conventional dying
and printing materials and methods since the outer surface
characteristics of the yarn and the fabric formed thereof are
determined by the second sheath of low to medium temperature
resistant staple fibers surrounding the first sheath and covering
the core.
[0043] This ability to dye the fabrics is quite surprising to
persons skilled in the art given that the fiberglass cores in known
fabrics are known to explode during the dye process. This explosion
phenomena is believed to be due to excessive heating of the
fiberglass core together with the diffusion of sodium into and
reaction with the fiberglass core during the dye process. In this
regard, the dye process is typically conducted under relatively
high temperatures (e.g., 60 to 70EC), and the dye chemical is known
to pass through the sheathing to the core of known fabrics. Because
of this problem, conventional fabrics are limited in post-treatment
coloration to various printing processes. The modacrylic/melamine
fibers of the first sheath are believed to significantly diffuse
the fiberglass/synthetic two-plied core. Additionally, the first
sheath is believed to dissipate heat such that the fiberglass
filament is not overheated.
[0044] The following non-limiting examples are set forth to further
demonstrate the formation of multi-corespun yarns produced in
accordance with the present invention. These examples also
demonstrate that fire resistant fabrics can be formed from these
multi-corespun yarns.
EXAMPLES
Example 1
[0045] A continuous filament fiberglass was two-plied with a
continuous nylon fiber to form a core for the yarn. The fiberglass
of the core was ECD 225 1/0 (equivalent to 198 denier) sold by PPG,
and the nylon was 20 denier 8 filament (equivalent to a 172
conventional cotton count) from BASF. The core fiber materials had
a weight such that the core accounted for 25% by weight of the
overall double spun yarn weight. The two-plied core was fed between
the paired drafting rolls 206 of the air jet spinning apparatus
illustrated in FIG. 2. At the same time, a blended sliver of medium
to high temperature resistant modacrylic (Protex7 (M))/melamine
(BASF Basofil7) fibers was fed into the entrance end of the
entrance trumpet 202 to form a first corespun yarn. The blended
modacrylic/melamine sliver had a weight of 45 grains per yard, and
a modacrylic/melamine fiber blend of 50/50% by weight, which was
obtained by a Truetzschler multi-blending, carding and drawing
process. The modacrylic/melamine fibers had a weight such that the
first sheath accounted for 25% by weight of the overall double spun
yarn weight. The first corespun yarn had a conventional cotton yarn
count of 20.
[0046] A second sheath material consisted of a 100% polyolefin
sliver having a weight of 45 grains per yard and a denier of 532.
The polyolefin fibers had a weight such that the second sheath
accounted for 50% by weight of the overall yarn weight. These
fibers were fed into the entrance end of the entrance trumpet 202.
At the same time, the first corespun yarn having a weight necessary
to account for 50% by weight of the overall double spun yarn weight
was fed between the paired drafting rolls 206. A double corespun
yarn was thereby formed. The double corespun yarn achieved by this
air jet process had a 10/1 conventional cotton count.
Example 2
[0047] A continuous filament fiberglass was two-plied with a
continuous nylon fiber to form a core for the yarn. The fiberglass
of the core was ECD 450 1/0 (equivalent to 98 denier) sold by PPG,
and the nylon was 20 denier 8 filament (equivalent to a 172
conventional cotton count) from BASF. The core fiber materials had
a weight such that the core accounted for 25% by weight of the
overall double spun yarn weight. The two-plied core was fed between
the paired drafting rolls 206 of the air jet spinning apparatus
illustrated in FIG. 2. At the same time, a blended sliver of medium
to high temperature resistant modacrylic (Protex7 (M))/melamine
(BASF Basofil7) fibers was fed into the entrance end of the
entrance trumpet 202 to form a first corespun yarn. The blended
modacrylic/melamine sliver had a weight of 45 grains per yard, and
a modacrylic/melamine fiber blend of 50/50% by weight, which was
obtained by a Truetzschler multi-blending, carding and drawing
process. The modacrylic/melamine fibers had a weight such that the
first sheath accounted for 25% by weight of the overall double spun
yarn weight. The first corespun yarn had a conventional cotton yarn
count of 30.
[0048] A second sheath material consisted of a 100% polyolefin
sliver having a weight of 45 grains per yard and a denier of 532.
The polyolefin fibers had a weight such that the second sheath
accounted for 50% by weight of the overall yarn weight. These
fibers were fed into the entrance end of the entrance trumpet 202.
At the same time, the first corespun yarn having a weight necessary
to account for 50% by weight of the overall double spun yarn weight
was fed between the paired drafting rolls 206. A double corespun
yarn was thereby formed. The double corespun yarn achieved by this
air jet process had a 15/1 conventional cotton count.
Example 3
[0049] The double corespun samples resulting from Examples 1 and 2
were each employed as the filling yarn in the woven process to form
a respective fabric sample as illustrated in FIG. 3. The fabrics
had 90 warp yarns per inch and 40 filling yarns per inch. The
double corespun yarn had a 10/1 conventional cotton count in the
filling and a 15/1 conventional cotton count in the warp to form an
8.5 ounce per square yard, two up, one down, right-hand twill weave
fabric.
[0050] The fabrics were subjected to the standard test described in
Technical Bulletin, California 133 Test Method (Cal. 133). The
fabrics were each found to remain flexible and intact, exhibiting
no brittleness, melting, or fabric shrinkage. The second sheath of
polyolefin fibers was burnt and charred. However, the charred
portions remained in position surrounding the core and the first
sheath. These results indicate that the two-plied core and first
sheath effectively provide a thermal insulation barrier and limited
movement of vapor through the fabric, while, in addition, the
fiberglass/synthetic core and the first sheath modacrylic/melamine
blend also provide a grid system, matrix or lattice which prevents
rupture of the upholstery fabric and penetration of the flame
through the upholstery fabric and onto the material of which the
chair was formed.
[0051] While the invention has been described in detail with
reference to specific embodiments thereof, it will be apparent to
one skilled in the art that various changes and modifications can
be made, and equivalents employed, without departing from the scope
of the appended claims.
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