U.S. patent application number 10/298990 was filed with the patent office on 2004-05-20 for flame-retardant nonwovens.
Invention is credited to McGuire, Sheri L., Taylor, Thomas E..
Application Number | 20040097156 10/298990 |
Document ID | / |
Family ID | 32297584 |
Filed Date | 2004-05-20 |
United States Patent
Application |
20040097156 |
Kind Code |
A1 |
McGuire, Sheri L. ; et
al. |
May 20, 2004 |
Flame-retardant nonwovens
Abstract
The present invention concerns a flame retardant (FR) nonwoven
fabric useful in household goods and particularly for mattresses.
The nonwoven fabric comprises from about 6 to 25 weight % of a low
melt binder, and least one of FR rayon fiber, FR acrylic fiber, FR
melamine fiber, or FR resin and optionally synthetic and/or natural
fiber. From this nonwoven fabric, many household goods such as
drapes, curtains, rugs, bedding and particularly mattresses may be
constructed. The present invention also contemplates a mattress
constructed from the nonwoven fabric comprising FR rayon fibers, FR
acrylic fibers, FR resin, and non FR polyester fibers, and about 6
to about 25 weight % low melt binder. The mattress from this
construction passes the California Test Bulletin 129 stringent
conditions for mattresses used in public places. Preferably the
nonwoven fabric has a batt weight of at least 5 oz./sq. yd. and
preferably between 5 oz./sq. yd. and 20 oz./sq. yd.
Inventors: |
McGuire, Sheri L.;
(O'Fallon, MO) ; Taylor, Thomas E.; (Charlotte,
NC) |
Correspondence
Address: |
DOUGHERTY, CLEMENTS & HOFER
1901 ROXBOROUGH ROAD
SUITE300
CHARLOTTE
NC
28211
US
|
Family ID: |
32297584 |
Appl. No.: |
10/298990 |
Filed: |
November 18, 2002 |
Current U.S.
Class: |
442/361 ;
428/920; 428/921; 5/698 |
Current CPC
Class: |
D04H 1/4382 20130101;
D04H 1/4258 20130101; A47C 31/001 20130101; D04H 1/64 20130101;
D04H 1/435 20130101; Y10T 442/637 20150401; D04H 1/4291
20130101 |
Class at
Publication: |
442/361 ;
428/920; 428/921; 005/698 |
International
Class: |
D04H 001/00; D04H
005/00 |
Claims
What is claimed is:
1) A nonwoven article produced from about 6 to about 25 weight %
low melt binder; at least one of FR rayon fiber, FR acrylic fiber,
FR melamine fiber, or FR resin; and optionally nonbonding synthetic
or natural fiber, wherein said nonwoven article has a weight of at
least 5 oz./sq. yd.
2) The nonwoven article of claim 1, wherein said nonbonding
synthetic fiber is rayon, polyester, or a mixture thereof.
3) The nonwoven article of claim 1, wherein article is produced
from at least two of FR rayon fiber, FR acrylic fiber, FR melamine
fiber, or FR resin.
4) The nonwoven article of claim 1, wherein said low melt binder is
a bicomponent fiber or a low melting fiber.
5) The nonwoven article of claim 4, wherein said bicomponent fiber
has a polyester component, and a polyolefin or copolyester
component.
6) The nonwoven article of claim 4, wherein said low melting fiber
is copolyester or polyolefin fiber.
7) The nonwoven article of claim 1, wherein said FR resin is a
phosphorus compound, red phosphorus, or phosphorus compatible with
said nonbonding synthetic fiber.
8) The nonwoven article of claim 1, having about 50 weight % rayon,
about 35 weight % polyester, and about 15 weight % bicomponent
fiber, totaling 100 weight %, and about 21 weight % FR resin, based
on said 100 weight %.
9) The nonwoven article of claim 1, having about 30 weight % FR
acrylic, about 25 weight % FR melamine, about 30 weight % rayon,
and about 15 weight % bicomponent fiber, totaling 100 weight %, and
about 14 weight % FR resin, based on said 100 weight %.
10) The nonwoven article of claim 1, having about 30 weight % FR
acrylic, about 25 weight % FR melamine, about 30 weight % rayon,
and about 15 weight % bicomponent fiber, totaling 100 weight %, and
about 20 weight % FR resin, based on said 100 weight %.
11) The nonwoven article of claim 1, having about 30 weight % FR
acrylic, about 25 weight % FR melamine, about 30 weight % FR rayon,
and about 15 weight % bicomponent fiber, totaling 100 weight %, and
about 15 weight % FR resin, based on said 100 weight %.
12) The nonwoven article of claim 1, having about 30 weight % FR
acrylic, about 25 weight % polyester, about 30 weight % FR rayon,
and about 15 weight % bicomponent fiber, totaling 100 weight %, and
about 14 weight % FR resin, based on said 100 weight %.
13) The nonwoven article of claim 1, having about 80 weight %
rayon, about 20 weight % bicomponent fiber, totaling 100 weight %,
and about 24 weight % FR resin based on said 100 weight %.
14) The nonwoven article of claim 1, having about 40 weight % FR
acrylic, about 40 weight % FR melamine, and about 20 weight %
bicomponent fiber, totaling 100 weight %.
15) The nonwoven article of claim 1, having about 40 weight % FR
rayon, about 45 weight % polyester, and about 15 weight %
bicomponent fiber, totaling 100 weight %.
16) The nonwoven article of claim 1, having about 30 weight % FR
acrylic, about 25 weight % FR melamine, about 30 weight % FR rayon,
and about 15 weight % bicomponent fiber, totaling 100 weight %.
17) The nonwoven article of claim 1, having about 30 weight % FR
acrylic, about 30 weight % FR rayon, about 25 weight % polyester,
and about 15 weight % bicomponent fiber, totaling 100 weight %.
18) The nonwoven article of claim 1, wherein said natural fiber is
flax or kenaf.
19) A nonwoven article produced from: a low melt binder; at least
two of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR
resin; and optionally a nonbonding synthetic fiber, wherein said
nonwoven article has a weight of at least 5 oz./sq. yd.
20) A nonwoven article produced from: about 6 to about 25 weight %
low melt binder; at least two of FR rayon fiber, FR acrylic fiber,
FR melamine fiber, or FR resin; and a nonbonding synthetic or
natural fiber, wherein said nonwoven article has a weight of at
least 5 oz./sq. yd.
21) A nonwoven article produced from synthetic fiber, natural
fibers and about 6 to about 25 weight % low melt binder, and an FR
resin, wherein said nonwoven article has a weight of at least 5
oz./sq. yd.
22) The nonwoven article of claim 21, wherein said synthetic fiber
is rayon, polyester, or a mixture thereof.
23) The nonwoven article of claim 21, wherein said synthetic fiber
is from about 15 weight % to about 55 weight % of said article.
24) The nonwoven article of claim 21, wherein said natural fiber is
flax, kenaf, or a mixture of these.
25) The nonwoven article of claim 21, wherein said natural fiber is
from about 40 weight % to about 60 weight % of said article.
26) The nonwoven article of claim 21, wherein said low melt binder
is a bicomponent fiber or a low melting fiber.
27) The nonwoven article of claim 26, wherein said bicomponent
fiber has a polyester component, and a polyolefin or copolyester
component.
28) The nonwoven article of claim 26, wherein said low melting
fiber is copolyester or polyolefin fiber.
29) A mattress, said mattress having a nonwoven batt comprising
about 6 to about 25 weight % low melt binder, and at least one of
FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin,
wherein said nonwoven batt has a weight of at least 5 oz./sq.
yd.
30) The mattress of claim 29, wherein said mattress has FR rayon
fibers, FR acrylic fibers, FR resin, and non FR polyester fibers.
Description
BACKGROUND OF THE INVENTION
[0001] 1) FIELD OF THE INVENTION
[0002] The present invention concerns a flame-retardant (FR)
nonwoven fabric that can be employed in many applications,
particularly in household goods such as stuffing for comforters,
pillows, or furniture; backing for curtains and rugs; and
especially for mattress fabrics. The nonwoven fabric comprises from
about 6 to 25 weight percent of a low melt binder (a bicomponent
fiber or low-melting fiber) and at least one of FR rayon fiber, FR
acrylic fiber, FR melamine fiber, or FR resin; and optionally
non-bonding, non FR synthetic fiber and/or natural fiber. Nonwoven
fabric prepared from these components, possessing a batt weight of
greater than about 5 oz./sq. yd. is capable of passing stringent
flame-resistant tests.
[0003] 2) Prior Art
[0004] Flame-retardant or flame-resistant materials (FR) are well
known to those skilled in the textile art. Such materials can be
woven or nonwoven, knitted, or laminates with other materials such
that they pass various textile flame resistant or flame retardant
tests such as California TB 117 & TB 133 for upholstery; NFPA
701 for curtains and drapes; and California Test Bulletin 129 dated
October, 1992 concerning flammability tests procedure for
mattresses for use in public buildings. This last test is the most
stringent test for household goods known in the world.
[0005] Various FR fibers are well known to those skilled in the
art. FR fibers based on polyester, rayon, melamine, nylon, acrylic
and polyolefin fibers such as polyethylene, or polypropylene
fibers, are known and commercially available.
[0006] U.S. Pat. No. 6,214,058 issued to Kent et al. on Apr. 10,
2001 describes fabrics made from melamine fibers that may or may
not be flame resistant fabrics. This reference describes a process
for dyeing melamine fabrics including blends of melamine and
natural fibers (such as wool or cotton) or other synthetic fibers
such as rayon or polyester. As a passing comment it mentions that
the melamine fiber may be FR.
[0007] U.S. Pat. No. 6,297,178 issued to Berbner et al. on Oct. 2,
2001 discloses flameproof fabrics based on FR melamine fibers and
FR rayon fibers. The melamine and rayon fibers are made FR by
coating the fiber with aluminum.
[0008] In spite of the above-mentioned patents and numerous other
nonwoven FR fabrics, there is still a need in the industry to
create inexpensive nonwoven FR articles that pass the stringent
guidelines for the California Technical Bulletin 129 testing as
well as other tests for upholstery, curtains and drapes. Moreover,
there is a need in the industry to produce such a nonwoven article
from materials that are relatively inexpensive, and have light batt
weights.
[0009] Generally, the California Technical Bulletin 129 test for
mattresses states that the mattress must char, but not burn through
for a minimum of three minutes based on certain conditions such as
the position of the flame, the temperature of the flame, the source
of fuel being used, etc. Furthermore, after one hour (57 minutes
after the flame source has been extinguished) of burning the test
is terminated and certain conditions must be met, as more fully set
forth herein.
SUMMARY OF THE INVENTION
[0010] The present invention relates to nonwoven fabric which is
capable of passing the California Technical Bulletin 129 test when
the nonwoven article is employed in a mattress, as well as other
tests employed for other household goods like draperies.
[0011] The nonwoven fabric/article of the present invention may be
produced from a combination of FR synthetic fibers and/or from all
natural fibers. In each case, the nonwoven article is bonded
together by means of a low melt binder. The low melt binder may be
bicomponent fiber or low melting fiber. Additionally, the nonwoven
article has at least one of FR rayon fibers, FR acrylic fibers, FR
melamine fibers, or FR resin.
[0012] In the broadest sense, the present invention relates to a
nonwoven article produced from about 6 to about 25 weight percent
low melt binder; at least one of FR rayon fiber, FR acrylic fiber,
FR melamine fiber, or FR resin; and optionally non binding, non FR
synthetic fiber and/or natural fibers.
[0013] In the broadest sense, the present invention also comprises
a nonwoven article produced from a low melt binder, at least 2 FR
fibers of the group of FR rayon, FR acrylic, or FR melamine, and
optionally a non-binding synthetic fiber.
[0014] In the broadest sense, the present invention also concerns a
nonwoven article produced from about 6 to about 25 weight percent
low melt binder, at least 2 FR materials selected from the class of
FR rayon fibers, FR acrylic, FR melamine fiber, or FR resin; and a
non bonding synthetic fiber.
[0015] In the broadest sense, the present invention also concerns a
nonwoven article produced from synthetic fiber, natural fibers and
FR resin, and about 6 to about 25 weight percent of a low melt
binder.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The nonwoven article of the present invention is produced
from materials generally known to those skilled in the art,
however, before the present invention those materials have not been
assembled into a nonwoven article like that of the present
invention.
[0017] Suitable FR fibers are those that can pass the various tests
set forth below, FR fibers having too little flame resistance are
not suitable for the present invention.
[0018] The FR fibers employed in the nonwoven articles of the
present invention are FR rayon, FR melamine, and FR acrylic. More
specifically, suitable FR rayon is sold under the registered
trademark "Visil" by Steri Oy and distributed by Ventex
Incorporated. Visil is permanently fire-resistant because of the
high silica content incorporated into the fiber during the
manufacturing process. It does not melt or flow when in contact
with heat or flame. The silica forms an insulating barrier to the
source of heat.
[0019] Suitable FR melamine fibers are well known in the art and
can be purchased, for example, under the trade name "BASOFIL" by
McKinnon-Land-Moran LLC. Like the FR rayon, the FR melamine fiber
does not melt or shrink away from the flame, but forms a char that
helps control the burn and shield the materials surrounded by
fabric.
[0020] Suitable FR acrylic fiber is well known to those skilled in
the art and sold under the trade name of Modacrylic.TM. distributed
by Mitsui Textile Corporation and another suitable fiber may also
be sold under the trade name CEF Plus by Solutia & Inc.
[0021] The FR resin employed is a type that has no binding
characteristics. It is simply a resin which has an FR component
therein, such as phosphorus, a phosphorus compound, red phosphorus,
esters of phosphorus, and phosphorus complexes. The FR resin may be
based on any material provided that it is compatible with the other
components mentioned herein for the nonwoven batt. Typically, the
FR resin is clear or translucent latex (where color is important,
or any color and not translucent where color is unimportant) and is
applied by spraying. A suitable commercially available FR resin is
known by the trade name GUARDEX FR made by GLOTEX Chemicals in
Spartanburg, S.C. There are several different GUARDEX FR resins and
those skilled in the art can pick and choose among them to find
that which is most compatible, taking into account such things as
cost, appearance, smell, and the effect it may have on the other
fibers in the nonwoven batt (does it make the other fibers rough,
or have a soft hand or discolor the other fibers). The FR resin may
be applied to the nonwoven batt in a range from about 6 to about 25
weight percent of the nonwoven batt. It is also within the scope of
the invention to apply the FR resin to just a portion of the fibers
before such fibers are employed in the nonwoven batt. For example,
the FR resin could be applied to the natural fibers, before they
are dry laid/air laid onto a conveyor belt. Nevertheless, when
considering the nonwoven batt as a whole, the amount of the FR
resin remains within the range of 6 to 25 wt. % of the nonwoven
batt.
[0022] The GUARDEX FR products are generally cured at about 300
degrees Fahrenheit, or preferably lower to minimize yellowing.
Although this product must be cured it has no significant binding
effect on the other fibers in the nonwoven batt. It is merely cured
to the fibers themselves so that it provides an FR characteristic
to the fibers in addition to any FR characteristics or lack thereof
of the fibers that are in the nonwoven batt.
[0023] While the above FR product (Guardex) is a liquid product
applied as a spray, other FR resin in solid form may be applied as
a hot melt product to the fibers, or as a solid powder which is
then melted into the fibers.
[0024] The FR fibers come in different deniers from approximately
1.5 to about 10 dpf (denier per filament).
[0025] The low melt binder may be either a bicomponent fiber, for
example, or a low melt polymer fiber. The low melt binder is
generally employed in a range of from about 5 to about 50 weight
percent of the nonwoven batt. The bicomponent fiber generally
contains a low melt portion and a high melt portion. Consequently,
the bicomponent fiber may be either the side-by-side type where the
low melt component is adjacent to high melt component, or the
sheath-core type wherein the high melt component is the core and
the low melt component forms the sheath. Such bicomponent fibers
are well known to those skilled in the art and may be based upon
polyolefin/polyester, copolyester/polyester, polyester/polyester,
polyolefin/polyolefin, wherein the naming convention is the low
melt component followed by the high melt component. In those types
wherein it is polyester/polyester, or polyolefin/polyolefin, the
high melt component has at least 5 and preferably 8 degrees
Fahrenheit higher melt temperature than the low melt temperature.
More specifically, for example, a polyolefin/polyolefin could be
polyethylene/polypropylene. Suitable bicomponent fibers are
preferable a 50:50 low melt portion to high melt portion. But the
present invention also contemplates a broader range of 20:80 to
80:20 for the bicomponent fiber.
[0026] Where the low melt binder is a low melt polymer fiber, those
fibers mentioned above with respect to the low melt component of
the bicomponent fiber are also suitable low melt polymer fibers. In
other words, the low melt polymer fiber may be copolyester, or
polyolefin, such as polyethylene. Lastly, the low melt binder may
also be latex sprayed onto the nonwoven batt. In this situation,
the latex employed has a low melt temperature so that once the
latex is sprayed on to the nonwoven fiber batt, it can be cured by
means of heat (subjecting the nonwoven batt to an oven for a short
period of time sufficient to cure the latex). Such low melt binders
are well known to those skilled in the art.
[0027] It is within the scope of the present invention to provide a
low melt binder in the form of latex. Such products are well known
and commercially available. It is also known to make an FR resin in
the form of latex. Those skilled in the art recognize that it may
be desirable to combine low melt binder latex with FR resin latex
and apply such a product to the nonwoven batt by spraying.
[0028] Suitable non FR synthetic fibers can be polyester such as
polyethylene terephthalate (PET), rayon, nylon, polyolefin such as
polyethylene fibers, acrylic, melamine and combinations of these.
Other synthetic fibers not mentioned may also be employed. When non
FR synthetic fibers are employed, they give the batt certain
characteristics like loft, resilience (springiness), tensile
strength, and thermal retention, useful for household goods.
Preferred are PET and rayon fibers.
[0029] Natural fibers may also be employed in the nonwoven batts of
the present invention. Natural fibers such as flax, kenaf, hemp,
cotton and wool may be employed, depending on the properties
desired. Preferred are flax and kenaf.
[0030] Because the synthetic fibers and natural fibers are
non-binding and are not flame resistant, such fibers can be used to
dial-in desired characteristics and cost. As such it is also within
the scope of the present invention to employ a mixture of synthetic
and natural fibers.
[0031] Currently there are no regulations in effect for mattresses
for home (residential) use. However, California is considering
drafting some regulations and many industry experts say such
proposed regulations will mirror TB 129. The strictest flame
resistant test for mattresses is the state of California,
Department of Consumer Affairs, Bureau of Home Furnishings and
Thermal Insulation, Technical Bulletin 129. The purpose of this
test is to set a standard for the behavior of mattresses used in
public occupancy such as hotels, motels, dormitories, prisons, etc.
Specifically, this test measures the mattress when it is subjected
to a specific flaming ignition source under well-ventilated
conditions. Under such conditions, it should char but not support
flame for at least 3 minutes. The California burn test 129
specifies a fabric wrapped around foam with a horizontal flame at
1800 degrees Fahrenheit for 3 minutes. There can be no drips, and
the fabric must contain the foam although the foam may be melted or
partially melted. The fabric cannot let the flame reach and ignite
the foam.
[0032] The nonwoven batt may be constructed as follows. The various
combinations of fibers that can be employed in the present
invention may be weighed and then dry laid/air laid onto a moving
conveyor belt, for example. The size or thickness of a nonwoven
batt is generally measured in terms of ounces per square yard. The
speed of the conveyor belt, for example, can determine or provide
the desired batt weight. If a thick batt is required, then the
conveyor belt moves slower than for a thin batt. The weight % of
the total fibers in the batt is 100%. This doesn't include the
weight of the FR resin since it is not in fiber form. It does,
however, include the bicomponent fibers.
[0033] Suitable nonwoven fabrics of the present invention have a
batt weight greater than about 5 oz./sq. yd. Preferably the batt
weight ranges from 5 oz./sq. yd. to 20 oz./sq. yd, with the most
preferred range being 6-9 oz./sq. yd. Using a batt weight greater
than about 20 oz./sq. yd. offers no significant improvement in
performance and is more costly. If desired any rearrangement of the
fibers such as by carding occurs next. Then the conveyor belt moves
to an area where any spray-on material is added to the nonwoven
batt, for example, the FR resin sprayed onto the nonwoven batt as a
latex while the batt is still positioned on the conveyor belt. If
the conveyor belt is foraminous, the excessive latex FR resin drips
through the belt and may be collected for reuse later. Once all the
sprayed-on materials have been applied, if any, the conveyer belt
can then move the nonwoven dry laid batt to an oven for melting and
curing the low melt component of the bicomponent fiber or the low
melt polymer fiber. The residence time in the oven depends on the
fibers employed and is easily determinable by one skilled in the
art. Thereafter, the nonwoven batt is cooled so that any low melt
binder material re-solidifies thus locking the fibers employed into
a solid batt. Thereafter, the batt may be cut to any size desired
to serve as mattress fabric or other purposes such as stuffing for
comforters, pillows, and furniture.
General Procedures
[0034] Various fiber components, some FR fibers and some synthetic
fibers (primarily employed for increasing physical properties of
the nonwoven batt) are set forth in the various examples having a
range of dpf between 1.5-10 as mentioned previously. Also, the
weight of the fiber batt as well as the burn test according to
California's Technical Bulletin 129, measured in seconds is set
forth in the examples.
[0035] More specifically, for Example 3 the specimen consisted of a
twin size, innerspring mattress and foundation set. The specimen
was covered with a white/off-white colored ticking material. The
construction of the mattress is well described in TB 129.
[0036] The test specimen, after conditioning to 73.degree. and 50%
R.H. was placed on a steel frame, on a load cell platform along the
far side of the test room. The specified propane burner was placed
centrally and parallel to the bottom horizontal surface of the
mattress 1 inch from the vertical side panel of the mattress. The
computer data acquisition system was started, then the burner was
ignited and allowed to burn for 180 seconds. The test was continued
until either all combustion ceased, or one hour passed.
[0037] The specimen does not meet the test requirements if any of
the following criteria are exceeded:
[0038] 1. Weight loss of 3 lbs or greater in the first 10
minutes.
[0039] 2. Maximum rate of heat release of 100 KW.
[0040] 3. Total heat release of 25 MJ in the first 10 minutes.
EXAMPLE 1
[0041] Various combinations of FR fibers with other synthetic or
natural fibers such as rayon, PET, flax and kenaf were produced.
The various fibers were dry laid onto a moving conveyor belt as is
known in the art. For Samples 1-6 and 11, where an FR resin was
employed, it was sprayed on to the nonwoven fiber batt. The
nonwoven fiber batt was transported via the conveyor belt to an
oven such that the low melt component melts. Then the fibers were
transported to a cooling area where the low melt component of the
low melt binder re-solidified thus locking the various fibers into
a unitary structure as a batt. These various nonwoven batts, at
various weights, were then subjected to a burn time test similar to
the California Technical Bulletin 129. In the test the nonwoven
fabric was wrapped once around the foam. A flame was applied
directly to the nonwoven fabric for at least 300 secs. and the
structural integrity was noted. All of the test samples maintained
their structural integrity for at least the time indicated, and the
flame did not reach the foam. The burn time is listed in seconds.
The batt weight is listed in ounces per square yard.
[0042] In all samples where FR resin was employed (Samples 1-6 and
11), GUARDEX FR resin was used. The FR resin, because it is sprayed
on, is based on the total weight of the fibers that are employed to
make up the nonwoven batt. In all samples, a bicomponent fiber
comprising a low melt sheath component of copolyester and a high
melt component of PET was employed. In Samples 2, 4, and 9 the FR
acrylic employed was 7 dpf (denier per filament). In Sample 7 the
dpf of the FR acrylic was 5, and in Samples 3, 5, and 10 the dpf
was 2. The dpf of the FR rayon in Samples 4 and 9 was 3.5. In
Sample 8 it was 5 dpf, and in Samples 5 and 10 it was 8 dpf. The
nonwoven batt construction and results are set forth below in Table
1.
1TABLE 1 FR FR FR FR Batt weight Burntime Sample Rayon Acrylic
Melamine Rayon PET Resin* Bico (oz/yd.sup.2) (seconds) 1 50 35 (21)
15 8.67 605 2 30 25 30 (14) 15 8.5 623 3 30 25 30 (20) 15 8.6 941 4
30 30 25 (15) 15 8.9 **1200 5 30 30 25 (14) 15 8 **1200 6 80 (24)
20 9.5 600 7 40 40 20 5.9 307 8 40 45 15 5.1 451 9 30 30 25 15 8.9
**360 10 30 30 25 15 8 **360 11 25% Flax; 25% Kenaf 35 (20)*** 15
11.7 **360 *Weight % based on weight of all other components. **The
burn time was terminated because it had more than passed the test.
In all other instances the burn time test was permitted to go to
completion (i.e. where the flame burned through the nonwoven
material such that it could no longer contain the liquefied foam.).
***the weight % is based on the weight of the natural fibers
only.
EXAMPLE 2
[0043] Example 2 was a repeat of Samples 1, 5, 6, & 8-10 and
their corresponding burn time test, except in Samples 1 and 5 the
amount of bicomponent employed was 20% by weight, while the amount
of PET employed was 5 weight percent less. In each instance, the
burn time in second was stopped at 600 seconds. 600 seconds is more
than 3 times longer than what is required by California Technical
Bulletin 129. The results are set forth in Table 2 below.
2TABLE 2 FR FR FR FR Batt weight Burntime Sample Rayon Acrylic
Melamine Rayon PET Resin* Bico (oz/yd.sup.2) (seconds) 1 50 15 (21)
20 8.67 **600 5 30 30 15 (14) 20 8 **600 6 80 (24) 20 9.5 **600 8
40 45 15 5.1 **600 9 30 30 25 15 8.9 **600 10 30 30 25 15 8
**600
[0044] While this result is consistent for samples 1 and 6, the
retest of sample 8 gave a slightly stronger result.
EXAMPLE 3
[0045] A nonwoven batt similar to Sample 5 was made, except 20% by
weight FR resin was sprayed onto the batt (instead of 14% by
weight, as in Sample 5). The batt weight was 5.85 oz./sq. yd.
(instead of 8 oz./sq. yd., as in Sample 5). A twin size mattress
was constructed as described in the General Procedures and more
specifically in TB 129. This mattress was subjected to the full
Flammability Test Procedure for Mattresses for Use in Public
Buildings specified in the General Procedures and more specifically
in TB 129. The test results are reported below.
[0046] The ambient temperature was 75.degree. F. with a relative
humidity of 50%. After the test, the specimen was removed from the
test room and was damaged in the following manner:
[0047] Ticking Material: 40% consumed.
[0048] Internal Components: 50% consumed.
[0049] Barrier Material: Intact.
[0050] Foundation: 65% consumed.
[0051] The results of the test were as follows:
[0052] Peak Rate of Heat Release=40.60 KW
[0053] Total Heat Release=8.60 MJ
[0054] Weight Loss in First 10 Minutes=0.5 lb.
3 Time (Min:Sec) Observations 0.00 The test was started. 0:05 The
ticking material began to char. 0:08 The ticking material ignited.
0:45 The flames began to propagate across the top panel. 3:00 The
propane test burner was turned off. 3:30 The flames began to
propagate across the front side of foundation. 8:30 Flaming drops
began to fall from the left handle of the mattress. 10:10 Flaming
drops ceased from the left handle. 14:50 Flaming drops began to
fall from the right handle. 23:15 The flames reached the left front
corner of the mattress. 45:42 The flames began to decrease on the
left corner of the mattress. 50:00 The flames reached the right
front corner of the mattress. 53:49 The flames reached the right
rear corner of the mattress. 57:30 Flaming drops began to fall from
the left rear corner of the mattress. 60:00 Test
terminated/specimen extinguished.
[0055] A weight loss of 3 pounds or more in the first 10 minutes is
a test failure. For this Example, the result of 0.5 pounds is
excellent. A test failure also occurs if the maximum rate of heat
released exceeds 100 KW. For this Example, the result of 40.60 KW
is excellent. A test failure occurs if the total heat release is 25
MJ or more in the first 10 minutes. For this Example the result was
8.60 MJ. This was excellent.
[0056] Thus, it is apparent that there has been provided, in
accordance with the invention, a nonwoven fabric that fully
satisfies the objects, aims, and advantages set forth above. While
the invention has been described in conjunction with specific
embodiments thereof, it is evident that many alternatives,
modifications, and variations will be apparent to those skilled in
the art in light of the foregoing description. According, it is
intended to embrace all such alternatives, modifications, and
variations as fall within the spirit and broad scope of the
invention.
* * * * *