U.S. patent application number 10/262133 was filed with the patent office on 2004-04-01 for flame blocking liner materials.
Invention is credited to Hale-Blackstone, Kate, Mason, Charles R..
Application Number | 20040062912 10/262133 |
Document ID | / |
Family ID | 32030141 |
Filed Date | 2004-04-01 |
United States Patent
Application |
20040062912 |
Kind Code |
A1 |
Mason, Charles R. ; et
al. |
April 1, 2004 |
Flame blocking liner materials
Abstract
A fire blocking non-woven needlepunched textile structure,
comprising a first fiber component containing polyacrylonitrile
copolymer with a halogen containing monomer and a second fiber
component. The second fiber component is selected such that it
supports the first fiber component during burning, optionally
including an inorganic filler as a coating for the first and second
fiber components. In alternative embodiment, the present invention
provides a fire blocking non-woven textile structure containing the
above first and second fiber components, blended with a third
binder fiber component in the form of a vertically lapped nonwoven
structure.
Inventors: |
Mason, Charles R.; (Nashua,
NH) ; Hale-Blackstone, Kate; (Lawrence, MA) |
Correspondence
Address: |
Steven J. Grossman
Grossman, Tucker, Perreault & Pfleger, PLLC
55 South Commercial Street
Manchester
NH
03101
US
|
Family ID: |
32030141 |
Appl. No.: |
10/262133 |
Filed: |
October 1, 2002 |
Current U.S.
Class: |
428/139 ;
428/146; 428/219; 428/311.51; 428/311.71; 442/139; 442/146;
442/362; 442/364; 442/365; 442/402; 442/405 |
Current CPC
Class: |
Y10T 428/249965
20150401; Y10T 442/2656 20150401; D04H 1/43835 20200501; Y10T
442/682 20150401; Y10T 428/249964 20150401; D04H 1/4266 20130101;
Y10T 442/642 20150401; Y10T 442/2713 20150401; D04H 1/4258
20130101; D04H 1/43 20130101; Y10T 442/638 20150401; Y10T 442/641
20150401; D04H 1/46 20130101; D04H 1/43832 20200501; D04H 1/43828
20200501; Y10T 428/24397 20150115; Y10T 428/24339 20150115; Y10T
442/686 20150401 |
Class at
Publication: |
428/139 ;
428/146; 428/219; 428/311.51; 428/311.71; 442/139; 442/146;
442/362; 442/364; 442/365; 442/402; 442/405 |
International
Class: |
D04H 001/00 |
Claims
What is claimed is:
1. A fire blocking non-woven needle-punched textile structure,
comprising a first fiber component containing polyacrylonitrile
copolymer with a halogen containing monomer and a second fiber
component, wherein said second fiber component supports said first
fiber component during burning, optionally including an inorganic
filler as a coating for said first and second fiber components.
2. The fire blocking non-woven textile structure of claim 1,
wherein said second fiber component is selected from a viscose
fiber containing silicic acid and/or a melamine/formaldehyde
polymer.
3. The fire blocking non-woven textile structure of claim 1,
wherein said halogen containing monomer is poly(vinyl chloride)
and/or poly(vinylidine chloride).
4. The fire blocking non-woven textile structure of claim 1,
wherein said polyacrylonitrile copolymer contains
Sb.sub.2O.sub.3.
5. The fire blocking non-woven textile structure of claim 1 wherein
said polyacrylonitrile copolymer is present at a level of 50-80%
(wt).
6. The fire blocking non-woven textile structure of claim 1 wherein
said textile has a basis weight of 100-500 g/m.sup.2.
7. The fire blocking non-woven textile structure of claim 1 wherein
said vermiculate is present at a level of about 20-40
g/m.sup.2.
8. The fire blocking non-woven textile structure of claim 1 wherein
the inorganic filler is selected from the group consisting of
vermiculate, graphite, fumed silica or silica dioxide, or titanium
dioxide.
9. A fire blocking non-woven textile structure, in the form of
vertical lapped batting, comprising a first fiber component
containing polyacrylonitrile copolymer with a halogen containing
monomer and a second fiber component, wherein said second fiber
component comprises a viscose fiber containing silicic acid and/or
a melamine-formaldehyde polymer, and a third fiber component
comprising a binder fiber having the capability to melt bond the
other fibers in the nonwoven structure and wherein said first and
second components are melt bonded together by said binder
fiber.
10. The fire blocking material of claim 9 wherein said
polyacrylonitrile copolymer is present at a level of about 50-70%
(wt.), said second fiber component is present at a level of about
10-20% (wt.) and said binder fiber is present at a level of about
15-30% (wt.).
11. The fire blocking material of claim 10 wherein said
polyacrylonitrile copolymer is present at a level of about 60-65%
(wt.), said second fiber component is present at a level of about
15-20% (wt.) and said binder fiber is present at a level of about
15-25% (wt.).
12. The fire blocking material of claim 9 wherein said textile has
a basis weight of 100-500 g/m.sup.2.
13. The fire blocking material of claim 9 wherein said binder fiber
comprises one or a plurality of polymer components.
14. The fire blocking material of claim 9 wherein said binder fiber
comprises a sheath/core, side by side, or monofiliment
configuration.
Description
FIELD OF THE INVENTION
[0001] This invention relates to fire resistant needle punched
materials and to their methods of preparation. The invention has
particular utility in the formation of fire blocking fabric as a
liner under upholstery fabric and mattress ticking. The invention
also has utility for the production of fire resistant vertical
lapped batting material.
BACKGROUND OF THE INVENTION
[0002] As noted in U.S. Pat. No. 6,287,690, it is well known in the
textile industry to produce fire resistant fabrics for use as
upholstery, mattress ticking, panel fabric, etc., using yarn formed
of natural or synthetic fibers, and then treating the fabric with
fire retardant chemicals. Conventional fire retarding chemicals
include halogen-based and/or phosphorous-based chemicals. Such
treated fabrics reportedly are heavier than similar types of
non-fire retardant fabrics, and are said to have a more limited
wear life.
[0003] Not surprisingly, therefore, one can uncover numerous
disclosures aimed at modifying the burning characteristics of fiber
materials. For example, in U.S. Pat. No. 4,600,606 a method of
flame retarding textile and related fibrous materials is reported,
which relies upon the use of a water-insoluble, non-phosphorous
containing brominated aromatic or cycloaliphatic compounds along
with a metal oxide. U.S. Pat. No. 4,026,808 reports on the use of a
phosphorous containing N-hydroxy-methyl amide and
tetrakis(hydroxymethyl) phosphonium chloride. U.S. Pat. No.
3,955,032 confirms the use of chlorinated-cyclopentadieno
compounds, chlorobrominated-cyclpentadieno compounds, either alone
or in combination with metal oxides.
[0004] U.S. Pat. No. 4,702,861 describes a flame retardant
composition for application as an aqueous working dispersion onto
surfaces of combustible materials. Upon exposure to elevated
temperatures and/or flame, the formulation reportedly creates a
substantially continuous protective film generally encapsulating
and/or enveloping the surface of the article onto which it is
applied. The film-forming materials are based upon an aqueous latex
dispersion of polyvinylchloride-acrylic copolymer together with
certain other film-forming and viscosity controlling
components.
[0005] Other disclosures which offer additional background
information include U.S. Pat. No. 4,776,854 entitled "Method for
Flameproofing Cellulosic Fibrous Materials"; U.S. Pat. No.
5,051,111 entitled "Fibrous Material"; 5,569,528 entitled "Treating
Agent for Cellulosic Textile Material and Process for Treating
Cellulosic Textile Material"; and U.S. Pat. No. 6,309,565 entitled
"Formaldehyde-Free Flame Retardant Treatment for
Cellulose-Containing Materials".
[0006] It is also worth mentioning that within the various efforts
to provide flame resistant fabric products, various polymers
themselves have emerged as substrates for use as flame resistant
fibers. For example, melamine and melamine/formaldehyde based
resinous fibers are said to display desirable heat stability,
solvent resistance, low flammability and high-wear characteristics.
One form of melamine/formaldehyde fiber is marketed under the
tradename Basofil.TM.. In addition, the aromatic polyamide family
or aramids reportedly have high strength, toughness, and thermal
stability. Aramid fibers are marketed under the tradenames
Nomex.TM. and Kevlar.TM..
[0007] Furthermore, acrylic fibers are well-known in the synthetic
fiber and fabric industries, as are the modified acrylic fibers
(modacrylic). Such modacrylics are relatively inexpensive, and have
been used in various blends with the fibers noted above to provide
fire-resistant fabric material. One particular modacrylic fiber is
sold under the tradename Protex.TM., which is available from Kaneka
Corporation, Japan.
[0008] In addition, flame retardant viscose fibers have become
available, and one particular viscose fiber is sold under the
tradename Visil.TM.. More specifically, Visil.TM. is said to
comprise a silicic acid containing viscose, with a limiting oxygen
index (i.e., the minimum concentration of oxygen necessary to
support combustion) in the range of 0.27-0.35, depending upon a
particular textile construction.
[0009] Finally, it is worth noting that various manufacturers have
produced and sold fireresistant fabric material. They are as
follows: 1. E.R. Carpenter's "Fire Stop.TM.", which relies upon
Basofil.TM./modacrylic high loft batting; 2. Chiquola Industrial
Fabric's "FireGuard.TM." which relies upon core spun flame
retardant yarns into woven or knit form; 3. ChemTick Coated Fabrics
"Flame Safe.TM." which relies upon core spun yarn in woven
configuration with flame retardant treatment; 4. Elk Corporation's
"VersaShield.TM." which relies upon a woven fiberglass base with a
soft foam like coating on one side; 5. Jones Fiber Products, Inc.'s
"T-Bond.TM." which relates to a flame retardant treatment of cotton
batting; 6. Legett & Platt's "Pyro-Gon.TM." which is a batting
of a blend of Pyron (panox) fibers with other fibers; 7. MLM, LLC's
"Allesandra" which is a core spun flame retardant yarn in woven
form; 8. Tex Tech's various blends of Basofil.TM. and Nomex.TM.,
Kevlarm and PBI in the form of needlepunched felts; and 9. Ventex's
"Integrity 30.TM.", SpunGold.TM. and AKTIV.TM. which collectively
relate to various products of knits and nonwoven battings that may
include Basofil.TM., panox, Kevlarm or Nomex.TM..
[0010] It is therefore an object of the present invention to expand
upon the technology directed at the manufacture of flame retardant
materials, and develop a fire resistant needle punched material
that can serve, among other things, as a protective liner material.
More specifically, it is an object of the present invention to
develop new types of needle punched materials that rely upon a
foundation component of a modified acrylic type fiber that is based
upon a copolymer of polyacrylonitrile and a halogen based monomer
to provide an inexpensive fire blocking composition.
[0011] It is also an object of the present invention to provide a
fire-resistant material which relies upon a needle punched
non-woven manufacture of two principal components, wherein one
component is selected to provide non-burning characteristics, and a
second component is selected to support and maintain the first
component in place during burning as well as to provide non-burning
characteristics, thereby resulting in a synergistic composition
that reduces the burn rate in a given liner application.
SUMMARY OF THE INVENTION
[0012] In a first embodiment, the present invention comprises a
fire blocking non-woven needlepunched textile structure, comprising
a first fiber component containing polyacrylonitrile copolymer with
a halogen containing monomer and a second fiber component, wherein
said second fiber component supports said first fiber component
during burning, optionally including inorganic filler as a coating
for said first and second fiber components.
[0013] In a second embodiment, the invention herein comprises a
fire blocking non-woven textile structure, in the form of vertical
lapped batting, comprising a first fiber component containing
polyacrylonitrile copolymer with a halogen containing monomer and a
second fiber component, wherein said second fiber component
comprises a viscose fiber containing silicic acid and/or a
melamine-formaldehyde polymer, and a third fiber component
comprising a binder fiber having the capability to melt bond said
first and second components wherein said first and second
components are melt bonded together by said binder fiber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] In the first embodiment, the fire resistant non-woven
material of the present invention, which can be used as a
protective liner material, is preferably manufactured from a
needle-punched combination of modacrylic fiber with a second fiber
component which may comprise a viscose fiber containing silicic
acid and or a melamine/formaldehyde polymer. Optionally, and as
described in more detail below, an inorganic filler such as
vermiculate may be included as a coating. Other inorganic fillers
include those selected from the group consisting of graphite, fumed
silica or silica dioxide, or titanium dioxide, and mixtures
thereof.
[0015] It should be noted that at least one factor contributing to
the performance of this first embodiment, as a unique fire
resistant non-woven material, is the modacrylic fiber. When the
modacrylic is activated by heat, it apparently assists in the
displacement of oxygen thereby reducing heat release and burn rate.
Furthermore, the vermiculate coating may then serve to disperse the
heat across the needlepunch fabric. However, the invention herein
is not limited to any particular theorized functionality of the
individual components and relies upon the various combinations that
are ultimately described in the appended claims.
[0016] The modacrylic fiber is preferably based upon a
polyacrylonitrile copolymer with a halogen containing comonomer,
and the halogen containing comonomer is preferably poly(vinyl
chloride) or poly(vinylidine chloride). A preferred modacrylic
fiber is available form Kaneka Corporation, under the tradename
Protex.TM.. In a most preferred embodiment, the modacrylic employed
herein is sold under the tradename Protex.TM. M, at a specific
gravity of 1.45-1.60 with a fiber denier of 2.2 dtex.times.38 mm.
Protex.TM. M is described as having the following chemical
components: acrylonitrile, vinylidine chloride copolymer, antimony
oxide. A preferred viscose fiber containing silicic acid is sold
under the tradename Visil.TM., available from Sateri Oy Inc. The
Visil fiber is type AP 33 3.5 dtex.times.50 mm. It is composed of
65-75% regenerated cellulose, 25-35% silicic acid, and 2-5%
aluminum hydroxide. A preferred melamine/formaldehyde fiber
component is sold under the tradename Basofil.TM., available from
McKinnon-Land-Moran, LLC.
[0017] Preferably, the non-woven material will also have a basis
weight of 100-500 g/m.sup.2, including all increments therebetween
at 1 g/m.sup.2 variation.
[0018] The above referenced fire blocking non-woven textile
therefore may preferably contain the modacrylic polymer component
(e.g., polyacrylonitrile copolymer with poly(vinylidine chloride))
at levels of about 50-80% (wt.), and correspondingly, the second
fiber component which supports the modacrylic component may be
present at about 20-50% (wt.). In a particularly preferred
embodiment, the modacrylic component is present at about 80% (wt.)
and the second fiber component is preferably a viscose fiber
containing silicic acid and/or a melamine/formaldehyde polymer
which is present at about 20% (wt.). In the context of all of these
preferred ranges, it should be understood that within the broad
scope of this invention, all increments therebetween are included,
at 1% (wt) variation.
[0019] While not being bound by any particular theory, it has been
observed that in the context of the above needle punched non-woven
structure, the second fiber component serves to support the first
fiber component during burning. By "support" it is meant that the
second fiber maintains the first fiber component in place thereby
reducing the tendency of the first fiber component to undergo
shrinkage during burning, which shrinkage will sacrifice
considerably the fire blocking performance. Accordingly, the
combination of the first and second fiber components, through the
needle punching operation, allows for the development of an
relatively inexpensive fire blocking composition which can be
readily applied as a fire blocking fabric liner under upholstery
fabric and mattress ticking, thereby protecting the more flammable
interior components of such products from igniting and
participating in the burning process.
[0020] In addition, and again, without being bound by any
particular theory of operation, it is also believed that the
selective use of the modacrylic fibers herein, that preferably rely
upon a copolymer of polyacrylonitrile and a poly(vinylidine
chloride) copolymer structure, releases hydrochloric gas during the
burning process. It is believed that the hydrochloric gas then
assists in controlling the burn rate, providing another overall
synergistic feature with respect to the above disclosed strategic
selection of the individual components. Also, when combustion
temperatures exceed 600.degree. F., oxyhalides are formed which
take up the free radicals formed in the vapor phase.
[0021] Furthermore, as noted above, it is preferable that the above
non-woven include an inorganic filler, e.g. vermiculite as a
coating component. Vermiculate is reference to one of the mica
groups that are used as granular fillers, and comprise a
crystalline layer silicate material. However, some of the silicon
atoms are replaced with aluminum, producing a negative charge that
is neutralized by the interlayer cations, mostly magnesium. The
vermiculite particles are of a planer structure consisting of
platelets that have a minimum 400:1 xy plane to z plane ratio.
Preferably, the level of vermiculate herein, as a coating in the
non-woven, is about 20-40 g/m.sup.2, including all increments
therebetween at 1.0 g/m.sup.2 variation.
[0022] In accordance with the above embodiment, the fire blocking
non-woven material is preferably of a thickness of: 1.5-25 mm,
including all increments therebetween at 1.0 mm variation.
[0023] In a second preferred embodiment, the above non-woven
textile is further modified, in the sense that the concentration of
the first and second fiber components are reduced in favor of the
use of a binder polymer fiber. Such binder polymer fiber has the
capability to melt bond with the first and second fiber components.
The preferred binder fiber is 4d.times.2" from either Nan Ya or Sam
Yang in Korea with the outer layer having a melting point of
150.degree. C. which melting point is lower than the melting point
of the inner layer of this particular binder fiber material.
Furthermore, in this embodiment the first component modacrylic
fiber is first blended with the second fiber component (viscose
fiber containing silicic acid and/or melamine/formaldehyde polymer)
as well as the bicomponent polymer fiber noted above. The three
fibers are blended together, formed into a web which is then
vertically lapped and then bonded in a hot air oven as the final
process. The binder fiber outer layer melts and flows onto the
other fibers which bonds the structure together.
[0024] Elaborating upon the above, and in the broad context of the
present invention, the binder fibers of the present invention may
include one or plurality of polymer components. In addition, the
binder fiber may be in the form of a sheath/core, side by side, or
monofiliment configuration.
[0025] In accordance with the above, the modacrylic fiber component
is present at a level of about 50-70% (wt.), the second fiber
component is present at a level of about 10-20% (wt.) and the
binder fiber is present at a level of about 10-30% (wt.). Again, as
noted above, in should be understood that in the context of the
present invention, all increments therebetween are included at 1%
(wt) variation. Furthermore, such composition preferably is
prepared at a basis weight of 100-500 g/m.sup.2, and at all 1.0
g/m.sup.2 increments.
[0026] While the invention has been described in detail with
reference to specific preferred embodiments, it will be appreciated
that various changes and modifications can be made, and equivalents
employed, without departing from the scope of the following
claims.
* * * * *