U.S. patent application number 10/714132 was filed with the patent office on 2004-06-03 for needlepunch flame-retardant nonwovens.
Invention is credited to McGuire, Sheri L., Taylor, Thomas E..
Application Number | 20040106347 10/714132 |
Document ID | / |
Family ID | 36651689 |
Filed Date | 2004-06-03 |
United States Patent
Application |
20040106347 |
Kind Code |
A1 |
McGuire, Sheri L. ; et
al. |
June 3, 2004 |
Needlepunch 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 at least one of FR rayon fiber, FR
acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin
fiber, or FR resin coated fiber and optionally synthetic and/or
natural fiber mechanically bound together by a needlepunch process.
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 fiber, FR
acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin
fiber, or FR resin coated fiber. The mattress from this
construction passes the California Test Bulletin 603 stringent
conditions for mattresses used in residential places. Preferably
the nonwoven fabric has a batt weight of at least 2.25 oz./sq. yd.
and preferably between 2.25 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: |
36651689 |
Appl. No.: |
10/714132 |
Filed: |
November 14, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10714132 |
Nov 14, 2003 |
|
|
|
10298990 |
Nov 18, 2002 |
|
|
|
Current U.S.
Class: |
442/361 ;
428/920; 428/921; 5/698 |
Current CPC
Class: |
A47C 27/122 20130101;
D04H 1/587 20130101; Y10T 442/637 20150401; D04H 1/43835 20200501;
D04H 1/64 20130101; D04H 1/4258 20130101; D04H 1/4382 20130101;
D04H 1/435 20130101; D04H 1/4291 20130101; D04H 1/4266 20130101;
A47C 31/001 20130101 |
Class at
Publication: |
442/361 ;
428/920; 428/921; 005/698 |
International
Class: |
D04H 001/00; D04H
003/00 |
Claims
What is claimed is:
1) A nonwoven needlepunched article produced from at least one of
the group consisting of FR rayon fiber, FR acrylic fiber, FR
melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR
resin coated fiber; and optionally nonbonding synthetic or natural
fiber, wherein said nonwoven article has a weight of at least 2.25
oz. /sq. yd.
2) The nonwoven article of claim 1, further comprising a nonbonding
synthetic fiber is selected from the group consisting of rayon,
polyester, or a mixture thereof.
3) The nonwoven article of claim 1, wherein article is produced
from at least two of the group consisting of FR rayon fiber, FR
acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin
fiber, or FR resin coated fiber.
4) The nonwoven article of claim 1, wherein said FR resin is
selected from the group consisting of phosphorus, phosphorus
compound(s), red phosphorus, esters of phosphorus, and phosphorus
complexes; amine compounds, boric acid, bromide, urea-formaldehyde
compound(s), phosphate-urea compound(s), ammonium sulphate, or
halogen based compounds compatible with said nonbonding synthetic
fiber.
5) The nonwoven article of claim 1, wherein said synthetic fiber
comprises from about 10 to about 70 weight % of said article, said
synthetic fiber further comprising polyester, and wherein the sum
of said FR rayon fiber, said FR acrylic fiber, said FR melamine
fiber, said FR polyester fiber, said FR polyolefin fiber, and said
FR resin coated fiber comprises from about 25 to about 90 weight %
of said article.
6) The nonwoven article of claim 1, having about 50 weight % rayon,
about 50 weight % polyester, totaling 100 weight %, and about 20
weight % FR resin, based on said 100 weight %.
7) 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 % polyester totaling 100 weight %, and about 20
weight % FR resin, based on said 100 weight %.
8) The nonwoven article of claim 1, having about 30 weight % FR
rayon, 30 weight % FR acrylic, about 25 weight % FR melamine, about
15 weight % polyester, totaling 100 weight %, and about 20 weight %
FR resin, based on said 100 weight %.
9) The nonwoven article of claim 1, having about 30 weight % FR
rayon, 30 weight % FR acrylic, and about 40 weight % polyester,
totaling 100 weight %, and about 20 weight % FR resin, based on
said 100 weight %.
10) The nonwoven article of claim 1, having about 80 weight %
rayon, and about 20 weight % polyester, totaling 100 weight %, and
about 20 weight % FR resin, based on said 100 weight %.
11) The nonwoven article of claim 1, having about 40 weight % FR
acrylic, about 40 weight % FR melamine, and about 20 weight %
polyester, totaling 100 weight %.
12) The nonwoven article of claim 1, having about 40 weight % FR
rayon, about 60 weight % polyester, totaling 100 weight %.
13) The nonwoven article of claim 1, having about 30 weight % FR
rayon, about 30 weight % FR acrylic, about 25 weight % FR melamine,
about 15 weight % polyester, totaling 100 weight %.
14) The nonwoven article of claim 1, having about 40 weight % FR
rayon, about 30 weight % FR acrylic, and about 30 weight % PET,
totaling 100 weight
15) The nonwoven article of claim 2, having about 50 weight %
polyester, about 25 weight % flax, about 25 weight % kenaf,
totaling 100 weight %, and about 20 weight % FR resin, based on
said 100 weight %.
16) The nonwoven article of claim 1, having about 55 weight % FR
rayon, and about 45 weight % polyester, totaling 100 weight %.
17) The nonwoven article of claim 1, having about 40 weight % FR
rayon, about 30 weight % polyester, and about 30 weight % FR
polyester, totaling 100 weight %.
18) The nonwoven article of claim 1, wherein said natural fiber is
flax or kenaf.
19) The nonwoven article of claim 17, wherein said FR rayon is
Visil.RTM. fiber.
20) The nonwoven article of claim 17, wherein said FR rayon is
coated with 15 wt. % add-on with an FR resin.
21) A nonwoven needlepunched article produced from synthetic fiber,
natural fibers, and an FR resin, wherein said nonwoven article has
a weight of at least 2.25 oz./ sq. yd.
22) The nonwoven article of claim 21, wherein said synthetic fiber
is selected from the group comprising 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) A mattress, said mattress having a nonwoven batt comprising at
least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber,
FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber,
wherein said nonwoven batt has a weight of at least 2.25 oz./ sq.
yd.
27) The mattress of claim 26, wherein said mattress has FR rayon
fibers, FR acrylic fibers, FR resin, FR polyester, and non FR
polyester fibers.
Description
[0001] This application is a Continuation-In-Part of my co-pending
U.S. patent application Ser. No. 10/298,990 filed Nov. 18,
2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention concerns a flame-retardant (FR)
nonwoven fabric that can be employed in many applications,
particularly in household goods such as a fabric FR layer for
comforters, pillows, or furniture; backing for curtains and rugs;
and especially for mattress fabrics. The nonwoven fabric comprises
at least one of FR rayon fiber, FR acrylic fiber, FR melamine
fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated
fiber; and optionally non-bonding, non-FR synthetic fiber and/or
natural fiber, all of which are mechanically bonded together
through a needlepunch process. Nonwoven fabric prepared from these
components, possessing a batt weight of greater than about
2.25oz./sq. yd. is capable of passing stringent flame-resistant
tests.
[0004] 2. Prior Art
[0005] Flame-retardant or flame-resistant (FR) materials 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 603 dated
Nov. 4, 2003 concerning a flammability test procedure for
residential mattress/box spring sets.
[0006] Generally, the California Technical Bulletin 603 test for
mattresses states that the mattress must not release too great a
quantity of energy for a given exposure to a flame, based on
certain conditions such as the position of the flame, the
temperature of the flame, the source of fuel being used, etc.
Furthermore, 30 minutes after the flame source has been initiated
the test is terminated and certain conditions must be met, as more
fully set forth herein.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] PCT application WO 03/023108 filed Sep. 11, 2002 in the name
of Mater and Handermann discloses a highloft FR material composed
of FR rayon or FR melamine that are inherently FR. Additionally the
application also discloses and requires the use of modacrylic
fibers. These materials have no coating thereon.
[0011] 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 603 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.
[0012] The present invention relates to nonwoven fabric that is
capable of passing the California Technical Bulletin 603 test when
the nonwoven article is employed in a mattress, as well as other
tests employed for other household goods like bed clothing and
furniture.
[0013] 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 created by
mechanically interlocking the fibers of a web. The mechanical
interlocking is achieved through a needlepunch operation.
Additionally, the nonwoven article has at least one of FR rayon
fibers, FR acrylic fibers, FR melamine fibers, FR polyester fiber,
FR polyolefin fiber, or FR resin coated fiber.
[0014] In the broadest sense, the present invention relates to a
nonwoven article produced from at least one of FR rayon fibers, FR
acrylic fibers, FR melamine fibers, FR polyester fiber, FR
polyolefin fiber, or FR resin coated fiber; and optionally non
binding, non FR synthetic fiber and/or natural fibers.
[0015] In the broadest sense, the present invention also comprises
a nonwoven article produced from at least 2 FR fibers of the group
of FR rayon fibers, FR acrylic fibers, FR melamine fibers, FR
polyester fiber, FR polyolefin fiber, or FR resin coated fiber, and
optionally a non-binding synthetic fiber.
[0016] In the broadest sense, the present invention also concerns a
nonwoven article produced from at least 2 FR materials selected
from the class of FR rayon fibers, FR acrylic fibers, FR melamine
fibers, FR polyester fiber, FR polyolefin fiber, or FR resin coated
fiber, and a non-binding synthetic fiber.
[0017] In the broadest sense, the present invention also concerns a
nonwoven article produced from synthetic fiber, natural fibers, and
FR resin coated fiber.
[0018] 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.
[0019] 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. Sufficient amounts of FR
fibers must be present if the nonwoven article is to pass the
California Test Bulletin 129 and 603 tests.
[0020] The FR fibers employed in the nonwoven articles of the
present invention may be an inherent flame resistant fiber or an FR
fiber (natural or synthetic fibers) that are coated with an FR
resin. An inherently flame resistant fiber may be one whose
polymeric structure incorporates an FR component such as phosphorus
or phosphorus compounds, an amine, modified aluminosilicate, or
halogen based compounds. An especially preferred halogen based
compound is a thermoplastic polyvinyl halide composition.
Thermoplastic polyvinyl halide compositions, when exposed to a
flame, generate oxygen depleting gases that help to extinguish the
flame. Thus it is inherently flame resistant. Modacrylic fiber is a
generic name for a synthetic manufactured copolymer fiber composed
of between about 35 wt. % and 85 wt. % of acrylonitrile units
(--CH.sub.2CH(CN)--), with the remainder being thermoplastic
polyvinyl halide, such as vinyl chloride or vinylidene chloride
monomers. Suitable modacrylic fibers are sold under the trade name
of Modacrylic.TM. distributed by Mitsui Textile Corporation, Protex
sold by Kaneka, or SEF Plus by Solutia, Inc. These modacrylic
fibers are copolymers of acrylonitrile and vinyl chloride or
vinylidene chloride. Other inherently flame resistant fibers are:
a) rayon with aluminosilicate modified with silica and sold by
Sateri Oy in Finland under the trademark Visil.RTM. fiber; b) a
melamine fiber sold under the trademark Basofil.RTM. fiber by
McKinnon-Land-Moran LLC.; and c) polyester with phosphalane (organo
phosphorus compound) such as that sold under the trademark Trevira
CS.RTM. fiber or Avora.RTM. Plus fiber by KoSa. These inherent
flame resistant fibers are not coated, but have an FR component
incorporated within the synthetic material (within its structural
chemistry). Generally inherent FR 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.
[0021] The natural or synthetic fibers coated with an FR resin
contain one or more of the same type components mentioned above,
namely phosphorus, phosphorus compound(s), red phosphorus, esters
of phosphorus, and phosphorus complexes; amine compounds, boric
acid, bromide, urea-formaldehyde compound(s), phosphate-urea
compound(s), ammonium sulphate, or halogen based compounds. The
typical FR resin is clear or translucent latex and is applied by
spraying. Other non-clear FR resins are also known and are employed
where color is not important. A suitable commercially available FR
resin is sold under the trade name Guardex FR, or FFR which is
produced by Glotex Chemicals in Spartanburg, S.C. While there are
several different varieties of Guardex and Glotex FR resins, 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 other fibers in
the nonwoven batt (i.e., does it make the other fibers rough, or
have a soft hand, or discolor the other fibers, etc.). FR resin may
be applied to specific fibers in a range from about 6 to 25 weight
% of the weight of the specific fibers or the nonwoven article. For
example, the FR resin could be applied to natural or synthetic
fibers before they are dry laid/air laid onto a conveyor belt. It
is also within the scope of the present invention to purchase the
fiber already coated with the desired FR resin coating, and merely
blend them into the nonwoven fabric. The FR resin employed is a
type that has no binding characteristics. Non-resin coatings like
metallic coating are not suitable for the present invention,
because they tend to flake-off after continuous use of the
product.
[0022] 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.
[0023] The FR fibers come in different deniers from approximately
1.5 to about 15 dpf (denier per filament).
[0024] 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 many different
applications. Preferred are PET and rayon fibers.
[0025] 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 is cotton.
[0026] 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.
[0027] 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, 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.
[0028] Suitable nonwoven fabrics of the present invention have a
batt weight greater than about 2.25 oz./sq. yd. Preferably the batt
weight ranges from 2.25 oz./sq. yd. to 20 oz./sq. yd, with the most
preferred product being 3.5 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. After
spraying the FR resin latex, it is transported to a dryer or oven.
Once all the dried sprayed-on materials have been applied, if any,
the conveyer belt can then move the nonwoven dry laid batt to the
needlepunch loom where the fibers of the batt are mechanically
oriented and interlocked.
[0029] In another embodiment of the invention, individual fibers
are treated with the FR resin prior to the laying of the fibers
(dry laid) onto the conveyor belt. Suitable fibers that have been
pretreated with FR resins are commercially available. Utilizing the
pretreated fibers eliminates the necessity to spray on the FR
resin, and the drying time associated therewith.
[0030] The batt passes into the needlpunch loom between the bed
plate on the bottom and the stripper plate on the top. Needles that
are attached to one or more needle boards correspond to holes that
are in one or both of the bed plate and the stripper plate. The
needle board(s) moves up and down allowing the needles to pass
through the plates, into and out of the batt. As the needles
penetrate into the batt, barbs on the blade of the needle hook onto
fibers in the batt, pulling the fibers the depth of the
penetration. As the needle then moves out of the batt, the barbs
release the hooked/pulled fibers, leaving the hooked/pulled fibers
reoriented from a horizontal to a predominantly vertical position.
This causes the fibers of the batt to become entangled, which
creates the nonwoven fabric.
[0031] Generally, the more penetrations of the needles into a given
area of the batt, i.e., an increase in the puncture density, the
more dense and strong the web will become. This increase in web
density can be achieved by increasing the density of the needles in
the needle board, decreasing the rate of material feed, increasing
the frequency of punching, or similarly changing other operational
production parameters that would be obvious to one skilled in the
art. The depth of penetration by the needles into the batt has a
similar effect on the strength and density of the nonwoven fabric.
With an increase in the depth of penetration, a greater number of
barbs along the needle blade are employed, resulting in greater
entanglement of the fibers within the batt, and therefore a
stronger, denser web. The now entangled and interlocked batt is
pulled through the loom with the aid of draw rolls and wound onto
tubes. The nonwoven batt may be used as an outer wrap in
conjunction with other stuffing materials. In this arrangement, the
nonwoven web provides a flame resistant barrier around a typically
non-flame resistant filling.
[0032] Currently there are test standards in effect for mattresses
for home (residential) use known as California Technical Bulletin
603 with an implementation date of 2005. The purpose of this test
is to provide a means of determining the burning behavior of
mattress/foundation sets intended for residential use by measuring
specific fire test responses when the test specimen, a mattress
plus foundation, is subjected to a specified flaming ignition
source under well-ventilated conditions.
GENERAL PROCEDURES
[0033] 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 1.5-15 as mentioned previously. Also, the
weight of the fiber batt as well as a pilot burn test designed to
mimic the California TB 603 testing protocol is set forth in the
examples.
[0034] Additionally, some sample where tested under the California
TB 603 test that requires the test specimen to be conditioned for
24 hours at above 54.quadrature.F and below 70% relative humidity.
It was then placed on a steel frame, on a load cell platform along
the far side of the test room. A pair of propane burners was placed
on the top panel and border as specified in the test protocol. The
computer data acquisition system was started, and the burners were
ignited and allowed to burn for 70 seconds (top) and 50 seconds
(border). The test was allowed to proceed until either all
combustion ceased, or 30 mins passes.
[0035] The most important fire test response characteristic
measured in this test is the rate of heat release, which quantifies
the energy generated by the fire. The specimen does not meet the
test requirements if any of the following criteria are
exceeded:
[0036] 1. Maximum rate of heat release of 200 KW.
[0037] 2. Total heat release of 25 MJ in the first 10 minutes.
EXAMPLES
[0038] 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 1-5 and 11, where an FR resin was
employed via saturation method, it was applied to individual fibers
before they were laid onto the moving conveyor. The nonwoven fiber
batt was transported via the conveyor belt to a card, then to a
needlepunch loom where the individual fibers were mechanically
entangled through the needling process to create the interlocked
web.
[0039] These various nonwoven batts, at various weights, were then
subjected to Western Nonwovens bench scale test. In the test the
nonwoven fabric was wrapped once around the foam. A flame was
applied directly to the nonwoven fabric for at least 600 seconds
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.
[0040] In all samples where FR resin was employed (Samples 1-5, 11
and 12) GUARDEX FR resin was used. All Samples containing an FR
rayon employed Visil.RTM. fiber as the FR rayon. The FR resin is
based on the total weight of the fibers employed to make up the
nonwoven batt, except Sample 11 where the FR resin was employed
only on the rayon. In all samples, the nonwoven web was interlocked
together using needlepunch techniques generally known in the
art.
[0041] When FR components, including but not limited to FR rayon
fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR
polyolefin fiber, or FR resin coated fiber, are employed in the
nonwoven batt they should be present in a concentration from about
25 to about 90 weight %, and preferably from about 30 to about 85
weight %. Synthetic fibers, which can be polyester and in
particular PET fibers, are present from about 10 to about 70 weight
%, and preferably from about 15 to about 65 weight % when employed
in the nonwoven batt.
[0042] In all Samples except 12, the nonwoven batt was constructed
of PET and varying amounts of FR rayon, FR acrylic, and/or FR
melamine. Each batt had a final weight of about 9.0 oz/yd.sup.2.
The batt was then wrapped around a piece of foam and subjected to a
burn test as described above. Each batt was subjected to a burn
time test of over 600 seconds. All of the test samples maintained
their structural integrity for at least the time indicated, and the
flame did not reach the foam.
[0043] Sample 9 was also made up into twin-size mattresses and
submitted for California TB 603 testing. Sample 9 was tested at
9oz/yd.sup.2 in a 1-sided, pillow top design; and also a 2 sided
bed. Sample 9 successfully passed in both bed constructions.
[0044] Sample 12 contains natural fibers - flax and kenaf, and
synthetic PET fiber. These fibers are made into a batt and all the
fibers were coated with an FR resin. The amount of FR resin was 20
wt. % based on the weight of the natural and synthetic fibers. The
FR resin spray coated on the fibers was GuardEx FFR from Glo-Tex.
This batt was not tested.
[0045] Lastly, the nonwoven batt from Sample 13 was constructed
from Visil.RTM. fiber and PET fiber. It was constructed into a twin
size mattress in compliance with and as described in California
Technical Bulletin 603. The batt's weight was 5.85oz/yd.sup.2. The
mattress was then subjected to the full Flammability Test Procedure
for Residential Mattresses that is described in TB 603. As
indicated, a flame was applied directly to the mattress's upper
surface (70 seconds) and side surface (50 seconds) utilizing a pair
of propane burners. The structural integrity of the mattress was
noted thereafter for a period of 30 minutes. The flame did not
penetrate the nonwoven ticking employed around the mattress. There
was no appreciable heat release during the burn time testing.
Sample 13 was tested at 5.85 oz./sq.yd. in a two-sided twin bed
construction. The mattress successfully passed TB 603.
[0046] All key data and results, if any, are summarized in Table
1.
1TABLE 1 FR FR FR FR FR Batt Burn Time Sample Rayon Acrylic
Melamine Rayon PET PET Flax Kenaf Resin Weight Test 1 50 50 20% 2
30 25 30 15 20% 3 30 30 25 15 20% 4 30 30 40 20% 5 80 20 20% 6 40
40 20 7 40 60 9.0 oz/yd.sup.2 600 + sec. 8 30 30 25 15 9.0
oz/yd.sup.2 600 + sec. 9 40 30 30 9.0 oz/yd.sup.2 600 + sec. &
TB603 10 40 30 30 9.0 and 600 + sec. 11.25 oz/yd.sup.2 & TB603
11 40 30 30 15% on 9.0 oz/yd.sup.2 rayon only 12 50 25 25 20% 13 55
45 5.85 and 600 + sec. & 9.0 oz/yd.sup.2 TB603 Note: Samples
1-6, 11 and 12 have not been tested.
[0047] 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.
* * * * *