U.S. patent application number 12/313903 was filed with the patent office on 2009-06-25 for heat and flame shield.
Invention is credited to Jason G. Chay, Ty G. Dawson, Gregory J. Thompson, David E. Wenstrup.
Application Number | 20090159860 12/313903 |
Document ID | / |
Family ID | 38067450 |
Filed Date | 2009-06-25 |
United States Patent
Application |
20090159860 |
Kind Code |
A1 |
Wenstrup; David E. ; et
al. |
June 25, 2009 |
Heat and flame shield
Abstract
A heat and fire resistant planar unitary shield formed of heat
and flame resistant fibers and voluminous bulking fibers. The
shield material has a heat and flame resistant zone with a majority
of the heat and flame resistant fibers, and a voluminous bulking
zone with a majority of the voluminous bulking fibers. The fibers
are distributed through the shield material in an manner that the
heat and flame resistant fibers collect closest to the outer
surface of the shield with the heat and flame resistant zone, and
the voluminous bulking fibers collect closest to the outer surface
of the shield material with the voluminous bulking zone.
Inventors: |
Wenstrup; David E.; (Greer,
SC) ; Thompson; Gregory J.; (Simpsonville, SC)
; Chay; Jason G.; (Easley, SC) ; Dawson; Ty
G.; (Spartanburg, SC) |
Correspondence
Address: |
Legal Department (M-495)
P.O. Box 1926
Spartanburg
SC
29304
US
|
Family ID: |
38067450 |
Appl. No.: |
12/313903 |
Filed: |
November 25, 2008 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11713147 |
Mar 2, 2007 |
7454817 |
|
|
12313903 |
|
|
|
|
11123337 |
May 6, 2005 |
7229938 |
|
|
11713147 |
|
|
|
|
10841148 |
May 7, 2004 |
7153794 |
|
|
11123337 |
|
|
|
|
Current U.S.
Class: |
252/608 |
Current CPC
Class: |
Y10S 428/921 20130101;
Y10T 442/3431 20150401; B60R 13/0838 20130101; D04H 1/4209
20130101; Y10T 442/69 20150401; A62C 8/06 20130101; Y10T 442/692
20150401; A47C 31/001 20130101; B32B 2307/3065 20130101; B60R 13/08
20130101; D04H 1/4374 20130101; D04H 1/54 20130101; Y10S 428/92
20130101; D04H 1/732 20130101; A47C 27/121 20130101; Y10T 442/696
20150401; B32B 5/26 20130101; D04H 1/4258 20130101; B60R 13/0815
20130101; D04H 1/4382 20130101; D04H 1/74 20130101; B32B 2307/304
20130101; Y10T 442/697 20150401 |
Class at
Publication: |
252/608 |
International
Class: |
C09K 21/02 20060101
C09K021/02 |
Claims
1. A heat and flame unitary planar shield material comprising: a
plurality of heat and flame resistant fibers and a plurality of
bulking fibers, the unitary planar shield material including a heat
and flame resistant zone extending from a heat and flame resistant
outer boundary to a heat and flame resistant inner boundary, and a
bulking zone extending from a bulking zone outer boundary to a
bulking zone inner boundary adjacent to the heat and flame
resistant inner boundary, wherein the heat and flame resistant zone
contains a portion of both the bulking fibers the heat and flame
resistant fibers with a higher portion of heat and flame resistant
fibers than bulking fibers, wherein the concentration of heat and
flame resistant fibers is greater near the heat and flame resistant
outer boundary than at the heat and flame resistant inner boundary,
and wherein the bulking zone contains a portion of both bulking
fibers and the heat and flame resistant fibers with a higher
portion of voluminous bulking fibers, wherein the concentration of
bulking fibers is greater near the bulking zone outer boundary than
at the bulking zone inner boundary.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S.
application Ser. No. 11/713,147 filed on Mar. 2, 2007, which is a
divisional of U.S. application Ser. No. 11/123,337 filed on May 6,
2005, which is a continuation-in-part of U.S. application Ser. No.
10/841,148 filed May 7, 2004, the contents of all of which are
incorporated by reference herein in their entirety.
BACKGROUND
[0002] The present invention generally relates to materials for use
in shielding from heat and/or flame, and in particular, heat and/or
flame shielding material that can be used in applications such as
hood liners for automobiles, engine compartment liners, bedding
construction, upholstery, wall padding, and the like.
[0003] Numerous industries require materials which not only deliver
heat and flame resistant properties, but can also provide volume,
opacity, moldability, and other properties in a cost effective
single substrate. Often times these barrier properties are best
accomplished by using specialty materials which generate a high
level of performance, but also introduce significant cost to the
substrate. Especially in a voluminous substrate (high z direction
thickness) even the introduction of a small percent of these
materials into the shield material can introduce a significant
level of cost to the overall substrate. For this reason composites
having specialty surface layers are often used to provide these
barrier properties. An example of a composite having specialty
surface layers would be a skin laminated to a voluminous lower cost
material. While this method effectively reduces the cost of the
high cost raw material, there are disadvantages to this method such
as additional processing steps and the potential delamination of
the skin layer.
[0004] The present invention provides an alternative to the prior
art by using a unitary heat shield material with different zones to
provide the various desired properties of the material
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] These and other features, aspects, and advantages of the
present invention will become better understood with regard to the
following description, appended claims, and accompanying drawings
where:
[0006] FIG. 1 shows an enlarged cross-section of one embodiment of
the present invention;
[0007] FIG. 2 shows an enlarged cross-sectional view of another
embodiment of the present invention;
[0008] FIG. 3 shows a diagram of a machine for performing a process
for forming the planar heat and flame resistant shield material of
the present invention;
[0009] FIG. 4 shows a magnified cross sectional view of a shield
material according to the embodiment in FIG. 1
[0010] FIG. 5 shows a perspective view of a bed utilizing the
shield material of the present invention; and,
[0011] FIG. 6 shows an enlarged partial view of the walls from the
bed in FIG. 5, and the shield material incorporated therein.
DETAILED DESCRIPTION
[0012] Referring now to the figures, and in particular to FIG. 1,
there is shown an enlarged cross-sectional view of an embodiment of
the present invention, illustrated as a planar heat and flame
shield material 100. The shield material 100 may be used in its
existing sheet form as a protective blanket or shield in operations
such as welding, high temperature manufacturing, or the like. The
shield material 100 may also be formed into parts such as
automotive hood liners, engine compartment covers, and the like.
Additionally, the shield material 100 can be incorporated with
other materials, and/or into a structure to provide the materials
and structures with additional heat and flame resistance. For
example, the shield material 100 can be incorporated into the outer
material of a bed, upholstery, wall padding, and other structures
to provide additional flame and heat resistance to those
structures. Because of the bulk associated with the shield material
100, incorporating the shield material 100 into such structures may
also provide a cost benefit by replacing any bulking material in
the structures.
[0013] As illustrated, the planar shield material 100 generally
contains heat and flame resistant fibers 101 and bulking fibers
102. The heat and flame resistant fibers 101 and the bulking fibers
102 are staple fibers that are combined to form the shield material
100. As used herein, heat and flame resistant fibers shall mean
fibers having an Limiting Oxygen Index (LOI) value of 20.95 or
greater, as determined by ISO 4589-1. Types of heat and flame
resistant fibers include, but are not limited to, fire suppressant
fibers and combustion resistant fibers. Fire suppressant fibers are
fibers that meet the LOI by consuming in a manner that tends to
suppress the heat source. In one method of suppressing a fire, the
fire suppressant fiber emits a gaseous product during consumption,
such as a halogentated gas. Examples of fiber suppressant fibers
includes modacrylic, PVC, fibers with a halogenated topical
treatment, and the like. Combustion resistant fibers are fibers
that meet the LOI by resisting consumption when exposed to heat.
Examples of combustion resistant fibers include silica impregnated
rayon such as rayon sold under the mark VISIL.RTM., partially
oxidized polyacrylonitrile, polyaramid, para-aramid, carbon,
meta-aramid, melamine and the like. Bulking fibers are fibers that
provide volume to the heat shield material. Examples of bulking
fibers would include fibers with high denier per filament (one
denier per filament or larger), high crimp fibers, hollow-fill
fibers, and the like.
[0014] In one embodiment, the heat and flame resistant fibers 101
and the bulking fibers 102 are air-laid with a binder fiber 105.
Binder fibers are fibers that form some type of adhesion or bond
with the other fibers. Binder fibers can include fibers that are
heat activated. An additional benefit of using a binder fiber 105
in the shield material 100 that is heat activated, is that the
shield material 100 can be subsequently molded to part shapes for
use in automotive hood liners, engine compartment covers, etc.
Examples of heat activated binder fibers are fibers that can melt
at lower temperatures, such as low melt fibers, core and sheath
fibers with a lower sheath melting temperature, and the like. In
one embodiment, the binder fibers are a polyester core and sheath
fiber with a low melt temperature sheath.
[0015] Still referring to FIG. 1, the heat and flame resistant
fibers 101 are concentrated in a heat and flame resistant zone 110
of the planar shield material 100, and the bulking fibers 102 are
concentrated in a voluminous bulking zone 120 of the planar shield
material 100. The heat and flame resistant zone 110 provides the
shield material 100 with the primary heat and flame resistant
attributes. The voluminous bulking zone 120 provides the shield
material 100 with the desired z-direction thickness which extends
horizontally from the planar dimension of the shield material 100.
In the embodiment illustrated in FIG. 1, the heat and flame
resistant zone 110 is smaller in the z-direction than the
voluminous bulking zone 120.
[0016] Referring still to FIG. 1, the heat and flame resistant zone
110 has an outer boundary 111 located at the outer surface of the
shield material 100, and an inner boundary 112 located adjacent to
the voluminous bulking zone 120. The voluminous bulking zone 120
has an outer boundary 121 located at the outer surface of the
shield material 100 and an inner boundary 122 located adjacent to
the heat and flame resistant zone 110. The shield material 100 is a
unitary material, and the boundaries of the two zones do not
represent the delineation of layers, but areas within the unitary
material. Because the shield material 100 is a unitary material,
and the heat and flame resistant zone 110 and the voluminous
bulking zone 120 are not discrete separate layers joined together,
various individual fibers will occur in both the heat and flame
resistant zone 110 and the voluminous bulking zone 120. Although
FIG. 1 illustrates the heat and flame resistant zone 110 being a
smaller thickness than the voluminous bulking zone 120, the
relative thickness of the two zones can have a substantially
different than as shown.
[0017] Referring still to FIG. 1, the heat and flame resistant zone
110 contains both the heat and flame resistant fibers 101 and the
bulking fibers 102. However, the heat and flame resistant zone 110
primarily contains the heat and flame resistant fibers 101.
Additionally, the distribution of the fibers in the heat and flame
resistant zone 110 is such that the concentration of the heat and
flame resistant fibers 101 is greater at the outer boundary 111 of
the heat and flame resistant zone 110 than the inner boundary 112
of that zone. Also, as illustrated, it is preferred that the
concentration of the heat and flame resistant fibers 101 decreases
in a gradient along the z-axis from the outer boundary 111 of the
heat and flame resistant zone 110 to the inner boundary 112 of that
zone.
[0018] Still referring to FIG. 1, the voluminous bulking zone 120
contains both the heat and flame resistant fibers 101 and the
bulking fibers 102. However, the voluminous bulking zone 120
primarily contains the bulking fibers 102. Additionally, the
distribution of the fibers in the voluminous bulking zone 120 is
such that the concentration of the bulking fibers 102 is greater at
the outer boundary 121 of the voluminous bulking zone 120 than the
inner boundary 122 of that zone. Also, as illustrated, it is
preferred that the concentration of the bulking fibers 102
decreases in a gradient along the z-axis from the outer boundary
121 of the voluminous bulking zone 120 to the inner boundary 122 of
that zone.
[0019] Referring now to FIG. 2, there is shown an enlarged
cross-sectional view of another embodiment of the present
invention, illustrated as a heat and flame shield material 200. As
illustrated, the shield material 200 generally contains heat and
flame resistant fibers 201 and bulking fibers 202. The heat and
flame resistant fibers 201 and the bulking fibers 202 are staple
fibers that are combined to form the shield material 200. In one
embodiment, the heat and flame resistant fibers 201 and the bulking
fibers 202 are air-laid with a binder fiber 205. When the binder
fiber 205 is a heat activated binder fiber, the combination of
fibers is heated to activate the binder fiber 205 for bonding
together the fibers of the shield material 200. An additional
benefit of using a heat activated binder fiber as the binder fiber
205 in the shield material 200 is that the shield material 200 can
be subsequently molded to part shapes for use in automotive hood
liners, engine compartment covers, etc.
[0020] Still referring to FIG. 2, the heat and flame resistant
fibers 201 are concentrated in a heat and flame resistant zone 210
of the shield material 200, and the bulking fibers 202 are
concentrated in a voluminous bulking zone 220 of the shield
material 200. The heat and flame resistant zone 210 provides the
shield material 200 with the primary heat and flame resistant
attributes of the shield material 200. The voluminous bulking zone
220 provides the shield material 200 with the desired z-direction
thickness. In the embodiment illustrated in FIG. 2, the heat and
flame resistant zone 210 is smaller in the z-direction than the
voluminous bulking zone 220.
[0021] Referring still to FIG. 2, the heat and flame resistant zone
210 has an outer boundary 211 located at the outer surface of the
shield material 200, and an inner boundary 212 located adjacent to
the voluminous bulking zone 220. The voluminous bulking zone 220
has an outer boundary 221 located at the outer surface of the
shield material 200 and an inner boundary 222 located adjacent to
the heat and flame resistant zone 210. The shield material 200 is a
unitary material, and the boundaries of the two zones do not
represent the delineation of layers, but areas within the unitary
material. Because the shield material 200 is a unitary material,
and the heat and flame resistant zone 210 and the voluminous
bulking zone 220 are not discrete separate layers joined together,
various individual fibers will occur in both the heat and flame
resistant zone 210 and the voluminous bulking zone 220. Although
FIG. 2 illustrates the heat and flame resistant zone 210 being a
smaller thickness than the voluminous bulking zone 220, the
relative thickness of the two zones can have a substantially
different than as shown.
[0022] Still referring to FIG. 2, the heat and flame resistant zone
210 contains both the heat and flame resistant fibers 201 and the
bulking fibers 202. However, the heat and flame resistant zone 210
primarily contains the heat and flame resistant fibers 201.
Additionally, the distribution of the fibers in the heat and flame
resistant zone 210 is such that the concentration of the heat and
flame resistant fibers 201 is greater at the outer boundary 211 of
the heat and flame resistant zone 210 than the inner boundary 212
of that zone. Also, as illustrated, it is preferred that the
concentration of the heat and flame resistant fibers 201 decreases
in a gradient along the z-axis from the outer boundary 211 of the
heat and flame resistant zone 210 to the inner boundary 212 of that
zone.
[0023] Referring still to FIG. 2, the bulking fibers 202 of the
shield material 200 comprise first bulking fibers 203 and second
bulking fibers 204. In one embodiment, the first bulking fibers
have a higher denier per filament, and/or mass per fiber, than the
heat and flame resistant fibers 201, and the second bulking fibers
204 have a higher denier per filament, and/or mass per fiber, than
the first bulking fiber 203 and the heat and flame resistant fibers
201. Also, the voluminous bulking zone 220 is divided into a first
bulking zone 230 and a second bulking zone 240. The first bulking
zone 230 has an outer boundary 231 located adjacent to the heat and
flame resistant zone 210 and inner boundary 232 located adjacent to
the second bulking zone 240. The second bulking zone 240 has an
outer boundary 241 located adjacent to the outer surface of the
shield material 200 and an inner boundary 242 located adjacent to
the first bulking zone 230. As previously stated, the shield
material 200 is a unitary material, and as such, the boundaries of
the two bulking zones do not represent the delineation of layers,
but areas with in the unitary material. Because the shield material
200 is a unitary material, and the first bulking zone 230 and the
second bulking zone 240 are not discrete separate layers joined
together, various individual bulking fibers will occur in both the
first bulking zone and the second bulking zone 240. Although FIG. 2
illustrates the heat and flame resistant zone 210 being a smaller
thickness than the voluminous bulking zone 220, the relative
thickness of the two zones can have a substantially different than
as shown.
[0024] Still referring to FIG. 2, the first bulking zone 230
contains both the first bulking fibers 203 and the second bulking
fibers 204. However, the first bulking zone 230 will contain more
of the first bulking fibers 203 than the second bulking fibers 204.
The distribution of the fibers in the first bulking zone 230 is
such that the concentration of the first bulking fibers 203
increases in a gradient along the z direction from the outer
boundary 231 of the first bulking zone 230 to a first bulking fiber
concentration plane 235 located between the inner boundary 232 and
the outer boundary of the first bulking zone. Also, as illustrated,
it is preferred that the concentration of the first bulking fibers
203 decreases in a gradient along the z-axis from the first bulking
fiber concentration plane 235 to the inner boundary 232 of that
zone.
[0025] Referring still to FIG. 2, the second bulking zone 240
contains both the first bulking fibers 203 and the second bulking
fibers 204. However, the second bulking zone 240 will contain more
of the second bulking fibers 204 than the first bulking fibers 203.
The distribution of the fibers in the second bulking zone 230 is
such that the concentration of the second bulking fibers 204 is
greater at the outer boundary 241 of the second bulking zone 240
than the inner boundary 242 of that zone. Also, as illustrated, it
is preferred that the concentration of the second bulking fibers
204 decreases in a gradient along the z-axis from the outer
boundary 241 of the second bulking zone 240 to the inner boundary
242 of that zone.
[0026] Still referring to FIG. 2, the first bulking zone 230 will
also contain heat and flame resistant fibers 201. However, the
first bulking zone 230 will contain more of the first bulking
fibers 203 than the heat and flame resistant fibers 201. The heat
and flame resistant zone 210 can have some amount of the second
bulking fiber 204; however, the amount of second bulking fiber 204
in the heat and flame resistant zone 210 is significantly lower
than the first bulking fibers 203. The second bulking zone 240 can
also have some amount of the heat and flame resistant fibers 201;
however, the amount of the heat and flame resistant fibers 201 in
the second bulking zone 240, if any, is significantly lower than
the first bulking fibers 203. An advantage of using the two
distinct bulking fibers 203/204 (FIG. 2) over using a single
bulking fiber 102 (FIG. 1), is that for the same respective weights
of heat and flame resistant fibers 101/201 and voluminous bulking
fibers 102/202, a shield material 200 having two types of bulking
fibers 203 and 204 will have fewer heat and flame resistant fibers
201 located in the voluminous bulking zone 120/220 than a shield
material 100 having only one type of bulking fiber 102.
[0027] Referring now to FIGS. 1 and 2, it is contemplated that the
shield material 100/200 can include additional fibers that create
additional zones extending outward from the bulking zone 120/220.
In such embodiments, the outer boundary 121/221/241 of the bulking
zone 120/220 will not be adjacent to the exterior of the shield
material 100/200, but will be disposed in the interior of the
shield material 100/200. The additional zones will also have an
area of transition in the concentration of the bulking fibers
102/204 to the additional fibers, similar to the transition of the
first bulking fibers 203 to the second bulking fibers 204 in the
shield material 200. Multiple additional zones can be created with
multiple additional fibers, resulting in many additional zones. In
the outer most additional zone, the fibers creating that outer most
additional zone will be concentrated at the exterior of the shield
material 100/200 similar to the bulking fibers 102 and 204 as shown
in FIGS. 1 and 2.
[0028] Referring now to FIG. 3, there is shown a diagram of a
particular piece of equipment 300 for the process to form the
planar unitary heat and flame shield from FIGS. 1 and 2. A
commercially available piece of equipment that has been found
satisfactory in this process to form the claimed invention is the
"K-12 HIGH-LOFT RANDOM CARD" by Fehrer AG, in Linz, Austria. The
heat and flame resistant fibers 101/201 and the voluminous bulking
fibers 102/202 are opened and blended in the appropriate
proportions and enter an air chamber 310. In an embodiment using
the binder fibers 105/205, the binder fibers 105/205 are also
opened and blended with the heat and flame resistant fibers 101/201
and the bulking fibers 102/202 prior to introduction into the air
chamber 310. In an embodiment where the voluminous bulking fibers
202 contain multiple types of bulking fibers 203/204, those
multiple types of bulking fibers 203/204 are also opened and
blended in the appropriate portions with the other fibers before
introduction into the air chamber 310. The air chamber 310 suspends
the blended fibers in air, and are expelled for delivery to an air
lay machine that uses a cylinder 320. The cylinder 320 rotates and
slings the blended fibers towards a collection belt 330. The
spinning rotation of the cylinder 320 slings the heavier fibers a
further distance along the collection belt 330 than it slings the
lighter fibers. As a result, the mat of fibers collected on the
collection belt 330 will have a greater concentration of the
lighter fibers adjacent to the collection belt 330, and a greater
concentration of the heavier fibers further away from the
collection belt 330. In general, the larger the difference in
denier between the fibers, the greater the gradient will be in the
distribution of the fibers.
[0029] In the embodiment of the shield 100 illustrated in FIG. 1,
the heat and flame resistant fibers 101 are lighter than the
voluminous bulking fibers 102. Therefore, in the process
illustrated in FIG. 3, the heat and flame resistant fibers 101
collect in greater concentration near the collection belt 330, and
the voluminous bulking fibers 102 collect in greater concentration
away from the collection belt 330. It is this distribution by the
equipment 300 that creates the heat and flame resistant zone 110
and the voluminous bulking zone 120 of the planar unitary shield
material 100.
[0030] In the embodiment of the shield 200 illustrated in FIG. 2,
the heat and flame resistant fibers 201 are lighter than the
voluminous bulking fibers 202. Therefore, in the process
illustrated in FIG. 3, the heat and flame resistant fibers 201
collect in greater concentration near the collection belt 330, and
the voluminous bulking fibers 202 collect in greater concentration
away from the collection belt 330. It is this distribution by the
equipment 300 that creates the heat and flame resistant zone 210
and the voluminous bulking zone 220 of the planar unitary shield
material 200. Additionally, the first bulking fibers 203 of the
voluminous bulking fibers 220 are lighter than the second bulking
fibers 204. Therefore, in the process illustrated in FIG. 3, the
first bulking fibers 203 are collected in greater concentration
nearer the collection belt 330 than the second bulking fibers 204.
It is this distribution that creates the first bulking zone 230 and
the second bulking zone 240 of the voluminous bulking zone 220 of
the planar unitary shield material 200.
[0031] In formation of the shield material 100/200, the combined
percentage of heat and flame resistant fibers can range from about
10% by total weight, to about 90% by total weight. The combined
percentage of bulking fibers in the shield material 100/200 can
range from about 80% by total weight, to about 5% by total weight.
An optimum amount of binder fibers in the shield material 100/200
can range from about 10% by total weight to about 40% by total
weight. It has been found that a high loft shield material provides
a desirable product for quilting with other materials to use in
applications such as mattress borders and panels. The combination
of bulking fibers with the heat and flame resistant fibers in the
present process reduces costs by reducing steps and gives better
performance than combining two separate layers of the materials for
criteria such as de-lamination. Additionally, the performance of
the shield material appears to have better flame resistance for the
same cost, and a lower cost for similar performance.
[0032] In a first example of the present invention, planar unitary
heat and flame resistant shield material was formed from a blend of
four fibers including: [0033] 1) 4% by weight of a heat and flame
resistant fiber being 2 dpf partially oxidized polyacrylonitrile
[0034] 2) 25% by weight of a first bulking fiber being 6 dpf
polyester [0035] 3) 41% by weight of a second bulking fiber being
15 dpf polyester, and [0036] 4) 30% by weight of a low melt binder
fiber being 4 dpf core sheath polyester with a lower melting
temperature sheath. The fibers were opened, blended and formed into
a shield material using a "K-12 HIGH-LOFT RANDOM CARD" by Fehrer
AG. The shield had a weight per square yard of about 16-32 ounces
and a thickness in the range of about 12-37 mm. In the resulting
shield material, the heat and flame resistant fibers in the heat
and flame resistant zone comprised at least 70% of the total fibers
in that zone, and the heat and flame resistant fibers in the
voluminous bulking zone were less than about 2% of the total fibers
in that zone.
[0037] In a second example of the present invention, planar unitary
heat and flame resistant shield material was formed from a blend of
four fibers including: [0038] 1) 40% by weight of a heat and flame
resistant fiber being about 3.2 dpf Visil.RTM. [0039] 2) 20% by
weight of about 2 dpf modacrylic (Kanecaron.TM.) [0040] 3) 20% by
weight of a bulking fiber being 15 dpf polyester, and [0041] 4) 20%
by weight of a low melt binder fiber being 4 dpf core sheath
polyester with a lower melting temperature sheath. The fibers were
opened, blended and formed into a shield material using the "K-12
HIGH-LOFT RANDOM CARD" by Fehrer AG. The shield had a weight per
square yard of about 8 ounces and a thickness in the range of about
25 mm. In the resulting shield material, the heat and flame
resistant fibers in the heat and flame resistant zone comprised at
least 60% of the total fibers in that zone, and the heat and flame
resistant fibers in the voluminous bulking zone were less than
about 40% of the total fibers in that zone. In an alternate version
of the second example, the low melt binder fiber was a 10 dpf core
sheath polyester with a lower melting temperature sheath.
[0042] In a third example of the present invention, planar unitary
heat and flame resistant shield material was formed from a blend of
four fibers including: [0043] 1) 30% by weight of a heat and flame
resistant fiber being about 3.2 dpf Visil.RTM. [0044] 2) 30% by
weight of about 2 dpf modacrylic (Kanecaron.TM.) [0045] 3) 20% by
weight of a bulking fiber being 15 dpf polyester, and [0046] 4) 20%
by weight of a low melt binder fiber being 4 dpf core sheath
polyester with a lower melting temperature sheath.
[0047] The fibers were opened, blended and formed into a shield
material using the "K-12 HIGH-LOFT RANDOM CARD" by Fehrer AG. The
shield had a weight per square yard of about 8 ounces and a
thickness in the range of about 25 mm. In the resulting shield
material, the heat and flame resistant fibers in the heat and flame
resistant zone comprised at least 60% of the total fibers in that
zone, and the heat and flame resistant fibers in the voluminous
bulking zone were less than about 40% of the total fibers in that
zone.
[0048] In a fourth example of the present invention, planar unitary
heat and flame resistant shield material was formed from a blend of
four fibers including: [0049] 1) 40% by weight of a heat and flame
resistant fiber being about 3.2 dpf Visil.RTM. [0050] 2) 40% by
weight of about 2 dpf modacrylic (Kanecaron.TM.) [0051] 3) 15% by
weight of a bulking fiber being 15 dpf polyester, and [0052] 4) 5%
by weight of a low melt binder fiber being 4 dpf core sheath
polyester with a lower melting temperature sheath.
[0053] The fibers were opened, blended and formed into a shield
material using the "K-12 HIGH-LOFT RANDOM CARD" by Fehrer AG. The
shield had a weight per square yard of about 10 ounces and a
thickness in the range of about 25 mm. In the resulting shield
material, the heat and flame resistant fibers in the heat and flame
resistant zone comprised at least 60% of the total fibers in that
zone, and the heat and flame resistant fibers in the voluminous
bulking zone were less than about 40% of the total fibers in that
zone.
[0054] In a fifth example of the present invention, planar unitary
heat and flame resistant shield material was formed from a blend of
four fibers including: [0055] 1) 50% by weight of a heat and flame
resistant fiber being 2 dpf panox [0056] 2) 30% by weight of a
bulking fiber being 15 dpf polyester, and [0057] 4) 20% by weight
of a low melt binder fiber being 4 dpf core sheath polyester with a
lower melting temperature sheath.
[0058] The fibers were opened, blended and formed into a shield
material using the "K-12 HIGH-LOFT RANDOM CARD" by Fehrer AG. The
shield had a weight per square yard of about 6 ounces and a
thickness in the range of about 25 mm. In the resulting shield
material, the heat and flame resistant fibers in the heat and flame
resistant zone comprised at least 60% of the total fibers in that
zone, and the heat and flame resistant fibers in the voluminous
bulking zone were less than about 40% of the total fibers in that
zone.
[0059] Referring now to FIG. 4, there is shown an enlarged cross
sectional view of an embodiment of the shield material 100 from
FIG. 1 formed according to the method disclosed with reference to
FIG. 3. FIG. 4 illustrates the heat and flame resistant zone above
the bulking zone. As can be seen, the fibers have an orientation
with the mode of the angle being at approximately 30 degrees, which
is most pronounced in the bulking zone. The angle of the fibers are
a result of the manufacturing process, and give the shield material
a stiffness and resiliency. The mode of the angle for the fibers
can vary from about 5 degrees to about 80 degrees towards the
horizontal z-direction from the planar dimensions of the shield
material 100.
[0060] Referring now to FIG. 5, there is shown a mattress
incorporating the shield material 100/200. The mattress 500
includes a first side 511, an opposing second side 512, and at
least one of side walls 521, 522, 523, and 524 connecting the first
side 511 and the second side 512. Illustrated in FIG. 6 is a
partial cutaway view of a wall 600 used for the sides 511, 512, or
walls 521, 522, 523, and 524 of the mattress 500 in FIG. 5. As
illustrated, the wall 600 includes an exterior ticking material
610, a shield material 620, a support material 630, and a backing
material 640. The shield material 100/200 described above in
reference to FIGS. 1-4, can be used as the shield material 620 in
the wall 600 and is preferably oriented with the heat and flame
resistant zone nearest to the exterior ticking material 610. The
support material 630 is a resilient material such as foam,
nonwoven, or the like. The backing material 640 is a flexible
material such as a woven, knitted, or nonwoven textile.
[0061] Although the present invention has been described in
considerable detail with reference to certain preferred versions
thereof, other versions are possible. For example, an additional
layer of material such as a nonwoven can be added to the outside
surface or the inside surface of the present invention for
additional purposes. Therefore, the spirit and scope of the
appended claims should not be limited to the description of the
preferred versions contained herein.
* * * * *