U.S. patent application number 12/540049 was filed with the patent office on 2009-12-03 for composite upholstery fabric panels with enlarged graphite intumescent particles.
This patent application is currently assigned to Precision Fabrics Group, Inc.. Invention is credited to Zareh Mikaelian.
Application Number | 20090297821 12/540049 |
Document ID | / |
Family ID | 38685707 |
Filed Date | 2009-12-03 |
United States Patent
Application |
20090297821 |
Kind Code |
A1 |
Mikaelian; Zareh |
December 3, 2009 |
COMPOSITE UPHOLSTERY FABRIC PANELS WITH ENLARGED GRAPHITE
INTUMESCENT PARTICLES
Abstract
Fabric layers and composite articles that incorporate
graphite-containing coatings that do not stain are provided. A
fabric layer for use as a flame and heat blocking component of an
upholstered article includes intumescent graphite particles that
are configured to swell and char in the presence of flame so as to
form a barrier to flame, hot gases and heat for a predetermined
period of time. The graphite particles have a size greater than
about 150 microns which prevents the particles from being drawn to
a surface of an upholstered article during sewing and quilting
operations.
Inventors: |
Mikaelian; Zareh;
(Greensboro, NC) |
Correspondence
Address: |
Needham James Boddie, II;Meyers Bigel Sibley & Sajovec, P.A.
P.O. Box 37428
Raleigh
NC
27627
US
|
Assignee: |
Precision Fabrics Group,
Inc.
|
Family ID: |
38685707 |
Appl. No.: |
12/540049 |
Filed: |
August 12, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11431384 |
May 10, 2006 |
|
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12540049 |
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Current U.S.
Class: |
428/304.4 ;
428/323 |
Current CPC
Class: |
Y10T 442/20 20150401;
Y10T 428/249953 20150401; Y10T 428/249921 20150401; B32B 5/26
20130101; Y10T 442/2631 20150401; Y10T 428/25 20150115; B32B 5/16
20130101 |
Class at
Publication: |
428/304.4 ;
428/323 |
International
Class: |
B05D 1/00 20060101
B05D001/00; B32B 5/16 20060101 B32B005/16; B32B 3/26 20060101
B32B003/26 |
Claims
1-11. (canceled)
12. A method of producing a flame blocking article, comprising:
providing a substrate having a surface; and applying a coating
having flame blocking material onto the substrate surface, wherein
the flame blocking material comprises intumescent graphite
particles having a size greater than or equal to 150 microns,
wherein the intumescent graphite particles swell and char in the
presence of a flame so as to form a barrier to flame, hot gases,
and heat for a predetermined period of time.
13. The method of claim 12, wherein the graphite particles have an
average size of from 250 to 350 microns, and wherein less than one
percent (1%) of the graphite particles have a size less than 150
microns.
14. The method of claim 12, wherein the coating comprises a
polymeric binder and acid-treated expandable graphite particles,
and wherein the graphite particles have sizes in the range from 150
microns to 1000 microns.
15. The method of claim 12, wherein applying a coating onto the
substrate surface comprises applying the coating as a foam
coating.
16. The method of claim 12, wherein applying a coating onto the
substrate surface comprises applying the coating as a paste
coating.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to textiles and,
more particularly, to fire resistant textile products.
BACKGROUND OF THE INVENTION
[0002] Various textiles used in the clothing, furnishings and
industrial fabrics industries are fire-unstable, i.e., they burn or
melt or otherwise heat-degrade when in contact with flame or heat.
For example, woven, knitted, and non-woven constructions of cotton,
viscose, rayon, synthetics such as polyester, natural/synthetic
blends and wool may burn or melt in the presence of flame or
heat.
[0003] The application of flame retardant treatments to textiles,
nonwovens, papers, and the like, is well known. Flame retardant
fabrics may be treated in such a way that they do not ignite, or
support combustion, or they may be treated to provide "flame
blocking" properties. Flame blocking materials not only do not
support combustion, but also can function to protect objects that
are flammable or that can be damaged by fire.
[0004] Flame blocking materials can have many forms. For example,
flame blocking materials may be composed of non-combustible
materials like asbestos, glass, metal, or may be composed of
organic materials like para-aramid, melamine, polybenzimidazole, or
other materials that have resistance to flame and heat, or may be
composed of combustible materials that are treated chemically to
resist fire and heat. An intumescent material will tend to char,
swell, and form a barrier to flame, hot gases, and conductive heat
transfer. Exemplary intumescent materials include, but are not
limited to, melamine, pentaerythritol, fluorocarbon, graphite,
bentonite, clay, phosphated or borated melamine, ammonium
polyphosphate polyols and the like.
[0005] Intumescent coatings are described in Intumescent Coating
Systems, Their Development and Chemistry by H. L. Vandersall, J.
Fire & Flammability, Vol. 2 (April 1971), pp. 97-140, which is
incorporated herein by reference in its entirety. The application
of an intumescent material to textiles is usually carried out by
conventional techniques, such as knife coating, roll coating, spray
coating, calendering, transfer coating or screen printing.
[0006] U.S. Pat. No. 5,645,926 to Horrocks et al. describes a
flexible fire and heat resistant material comprising an intimate
mixture of organic intumescent filler and organic fibres adapted to
char intensely within the temperature range of 200.degree. C. to
500.degree. C.
[0007] U.S. Pat. No. 4,923,729 to Porter et al. describes a method
for increasing heat dissipation from the smolder or open flame site
of an upholstered article by interposing a fire barrier material
between the outer upholstery fabric and the filler or padding
materials. The fire barrier material is formed by coating a fibrous
substance, such as glass fibers, carbon fibers, and the like with a
latex containing a finely divided heat conductive metal.
[0008] U.S. Pat. No. 5,830,319 to Landin describes a flexible fire
barrier felt and a method of producing the fire barrier felt. The
felt includes: at least about 10 weight percent (wt-%) of an
organic polymeric binder; at least about 5 wt-% of organic fibers
having pendant hydroxyl groups (preferably cellulosic fibers); and
at least about 10 wt-% of a heat absorbing compound; wherein the
felt contains at least about 0.3 wt-% of phosphorus, as provided by
a phosphorus-containing compound.
[0009] U.S. Pat. No. 5,070,119 to Nugent, Jr. et al. describes an
intumescent curable composition which contains as a resinous binder
a flexible polyepoxide resin. The intumescent curable composition
is usually in the form of a thick material such as a mastic and is
spray applied to a substrate.
[0010] U.S. Pat. No. 6,153,668 to Gestner et al. describes a method
of making a fire barrier material comprising the steps of (a)
providing components comprising at least about 25 wt-% binder, at
least about 10 wt-% intumescent compound, and at least about 5 wt-%
organic fibers comprising an organic material having pendant
hydroxyl groups, based on a total dry weight of the fire barrier
material; (b) combining the components to form a mixture; (c)
foaming the mixture; (d) placing the foamed mixture onto a
substrate; and (e) drying the foamed mixture for a time sufficient
to form the fire barrier material, wherein the fire barrier
material has a density ranging from greater than zero to about 0.35
g/cm.sup.3. Once the mixture has been formed into a foam-like
material, it is placed or applied onto a substrate, for example, by
casting, pouring, or spreading. Placing or applying the mixture
onto a substrate can be accomplished by casting the mixture onto a
substrate and then pressing it to a desired thickness by means of a
platen press, or it can be poured or cast into a mold lined with a
release liner.
[0011] U.S. Pat. No. 6,265,082 to Dunham et al. describes a fire
retardant composition consisting of a cured film, wherein the film
is formed from a film-forming composition comprising a curable
resin and at least one fire retardant, the fire retardant being
included in an amount from about 5 to about 95 percent by weight
based on the weight of the cured film, and wherein, when the film
is adhered to a flexible substrate, the film substantially does not
alter the hand of the flexible substrate.
[0012] U.S. Pat. No. 4,806,185 to Porter et al. describes a method
for increasing heat dissipation from the smolder or open flame site
of an upholstered article. The upholstered article comprises an
outer fabric that houses and contains filler materials such as
padding. The method involves interposing a fire barrier material
between the decorative outer upholstery fabric and the filler
materials. The barrier material completely envelops the filler
material and can be woven or nonwoven and is made of coated fibrous
substances, such as glass fibers, carbon fibers, polyaramid,
polybenzimidazole, polymeta-phenylene diamine isophthalate, and
combinations thereof. The coating consists of a latex of enhanced
thermal conductivity containing a finely divided heat conductive
metal such as aluminum, copper, nickel, and mixtures thereof, with
the proviso that the outer upholstered fabric has a porosity rating
of less than 10 cubic feet of air per minute per square foot,
measured at a pressure of one-half inch of water. The amount of
heat conductive metal can vary from about 4 to 20%, and preferably
about 8 to 10% by weight of the coating composition. The fire
barrier fabric can also function as an effective fire barrier with
for example, bedspreads, quilts or mattress ticking, and the like.
The outer face fabric and the fire barrier fabric can be attached
sequentially to a cushion or furniture frame. Alternatively, a
prelaminated fabric consisting of the face fabric can be adhesively
laminated to the fire barrier fabric. The fire barrier fabric can
also be sewn to an outer face fabric.
[0013] U.S. Pat. No. 4,824,709 to Tschirch describes a textile
product having a textile material and a backcoating comprised of a
polymer matrix and inorganic smoke suppressant and/or flame
retardant intumescent particles. The backcoating may also contain
an inorganic filler that further enhances the flame retardancy and
low smoke properties of the textile product. The methods of forming
the textile product include mixing the smoke suppressant and/or
flame retardant intumescent particles with the backcoating prior to
its application to the textile material or the simultaneous
spreading of the particles on the textile material with the polymer
backcoating in order to form a layer of the particles directly
adjacent to the textile material.
[0014] U.S. Pat. No. 4,216,261 to Dias describes a process for
imparting an intumescent, water repellent, fire retardant finish
that is applied by conventional coating techniques to one side of a
fabric. The treated material is then dried at temperatures in the
range 222.degree. F. to 260.degree. F.
[0015] U.S. Pat. No. 3,889,022 to Whittaker et al. describes a
flame-retardant composite article having a core of one or more
combustible materials, at least partly covered by a combination of
one or more flexible intumescent char-forming materials, and one or
more textile fibrous layers.
[0016] Expandable graphite is a particularly effective intumescent
material. Graphite to be used as an intumescent material is
conventionally treated with an acid (e.g., sulfuric, nitric, acetic
acid, etc.) which permeates the layers of the graphite structure
and causes the graphite to become expandable and form a thick
insulative layer of carbon char when exposed to flame. When a
substrate, such as a nonwoven, knit, or woven fabric, is coated
with a layer of material containing expandable graphite, the
coating will expand and form a thick char when exposed to fire,
heat, hot gases, or molten materials, and effectively block the
progress of a flame. Unfortunately, when fabrics having
graphite-containing coatings are processed into composite
upholstery articles (e.g., panels for use in mattress construction)
via sewing and/or quilting, the graphite tends to stain the
surfaces of the composite articles.
[0017] FIGS. 1A-1B illustrate a conventional composite upholstery
panel 10 having a ticking layer 12, a layer of resilient cushioning
material 14, and a backing layer 16 with a coating 18 of material
containing expandable graphite. The ticking layer 12, cushioning
material 14 and backing layer 16 are quilted together in a pattern
via thread 20. Graphite particles from the coating 18 work their
way through the cushioning material 14 and the ticking layer 12 for
example, via a quilting needle, and stain the ticking layer surface
12a adjacent to the quilting thread 20, as illustrated. The
staining is indicated generally as 22.
[0018] Graphite staining is particularly troublesome when
upholstery panels have white and other light-colored outer layers
(e.g., ticking layers). Unfortunately, light-colored ticking layers
and covers are preferred in many upholstery industries including
the bedding industry. As such, graphite is typically not used as an
intumescent material in the bedding industry.
[0019] However, because graphite is an effective intumescent
material, it would be desirable to be able to utilize graphite in
the various upholstery industries where white and other
light-colored fabrics are utilized.
SUMMARY OF THE INVENTION
[0020] In view of the above, fabric layers and composite articles
that incorporate graphite-containing coatings that do not stain are
provided. According to an embodiment of the invention, a fabric
layer for use as a flame and heat blocking component of an
upholstered article includes intumescent graphite particles that
are configured to swell and char in the presence of flame so as to
form a barrier to flame, hot gases and heat for a predetermined
period of time. The graphite particles have a size greater than
about 150 microns which prevents the particles from being drawn to
a surface of an upholstered article during sewing and quilting
operations.
[0021] According to embodiments of the present invention, a
composite upholstery panel includes a layer of ticking fabric, a
layer of resilient cushioning material, and a layer of backing
fabric having a coating of intumescent material disposed on a
surface thereof. The coating includes expandable graphite particles
greater than 150 microns in size and that resist adherence to
needles and thread and passage thereof through the layer of
cushioning material and ticking layer. The ticking layer,
cushioning layer, and backing layer are quilted together with
thread that forms spaced-apart patterns of stitches extending along
the composite upholstery panel. The graphite particles do not stain
the ticking layer and, when exposed to flame, char and swell to
form a barrier to flame, hot gases, and heat for a predetermined
period of time.
[0022] Possible uses of composite panels and fabrics according to
embodiments of the present invention include, but are not limited
to, fabrics, clothing, mattresses, upholstered or leather-covered
furniture, and commercial/transportation seating (e.g., airplane
seating, train seating, auditorium seating, etc.).
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings, which form a part of the
specification, illustrate key embodiments of the present invention.
The drawings and description together serve to fully explain the
invention.
[0024] FIG. 1A is a plan view of a composite upholstery panel
having a backing layer, cushioning layer and ticking layer quilted
together, and wherein graphite particles from a coating on the
backing layer have stained the surface of the ticking layer.
[0025] FIG. 1B is a cross-sectional view of the composite
upholstery panel of FIG. 1A taken along lines 1B-1B.
[0026] FIG. 2 is an enlarged cross sectional view of the composite
upholstery panel of FIG. 1A which illustrates graphite particles
being drawn up through the cushioning layer by the needle and
thread and being deposited on and adjacent to the surface of the
ticking layer.
[0027] FIG. 3A is a plan view of a composite upholstery panel,
according to some embodiments of the present invention, having a
backing layer, cushioning layer and ticking layer quilted together,
and wherein a coating including large, expandable graphite
particles is disposed on the backing layer.
[0028] FIG. 3B is a cross-sectional view of the composite
upholstery panel of FIG. 3A taken along lines 3B-3B.
[0029] FIG. 4 is an enlarged cross sectional view of the composite
upholstery panel of FIG. 3A which illustrates no graphite particles
being drawn up through the cushioning layer via the quilting needle
and thread.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention now is described more fully
hereinafter with reference to the accompanying drawings, in which
preferred embodiments of the invention are shown. This invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein; rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0031] Like numbers refer to like elements throughout. In the
figures, the thickness of certain lines, layers, components,
elements or features may be exaggerated for clarity. Broken lines
illustrate optional features or operations unless specified
otherwise. All publications, patent applications, patents, and
other references mentioned herein are incorporated herein by
reference in their entireties.
[0032] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. As
used herein, the term "and/or" includes any and all combinations of
one or more of the associated listed items. As used herein, phrases
such as "between X and Y" and "between about X and Y" should be
interpreted to include X and Y. As used herein, phrases such as
"between about X and Y" mean "between about X and about Y." As used
herein, phrases such as "from about X to Y" mean "from about X to
about Y."
[0033] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is is consistent with their
meaning in the context of the specification and relevant art and
should not be interpreted in an idealized or overly formal sense
unless expressly so defined herein. Well-known functions or
constructions may not be described in detail for brevity and/or
clarity.
[0034] It will be understood that when an element is referred to as
being "on", "attached" to, "connected" to, "coupled" with,
"contacting", etc., another element, it can be directly on,
attached to, connected to, coupled with or contacting the other
element or intervening elements may also be present. In contrast,
when an element is referred to as being, for example, "directly
on", "directly attached" to, "directly connected" to, "directly
coupled" with or "directly contacting" another element, there are
no intervening elements present. It will also be appreciated by
those of skill in the art that references to a structure or feature
that is disposed "adjacent" another feature may have portions that
overlap or underlie the adjacent feature.
[0035] Spatially relative terms, such as "under", "below", "lower",
"over", "upper" and the like, may be used herein for ease of
description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. It
will be understood that the spatially relative terms are intended
to encompass different orientations of the device in use or
operation in addition to the orientation depicted in the figures.
For example, if the device in the figures is inverted, elements
described as "under" or "beneath" other elements or features would
then be oriented "over" the other elements or features. Thus, the
exemplary term "under" can encompass both an orientation of "over"
and "under". The device may be otherwise oriented (rotated 90
degrees or at other orientations) and the spatially relative
descriptors used herein interpreted accordingly. Similarly, the
terms "upwardly", "downwardly", "vertical", "horizontal" and the
like are used herein for the purpose of explanation only unless
specifically indicated otherwise.
[0036] It will be understood that, although the terms "first",
"second", etc. may be used herein to describe various elements,
components, regions, layers and/or sections, these elements,
components, regions, layers and/or sections should not be limited
by these terms. These terms are only used to distinguish one
element, component, region, layer or section from another element,
component, region, layer or section. Thus, a "first" element,
component, region, layer or section discussed below could also be
termed a "second" element, component, region, layer or section
without departing from the teachings of the present invention. The
sequence of operations (or steps) is not limited to the order
presented in the claims or figures unless specifically indicated
otherwise.
[0037] Applicant has unexpectedly discovered that staining can be
dramatically reduced or eliminated in composite articles wherein
expandable graphite particles are incorporated as an intumescent
material if the graphite particles are increased in size from
conventional sizes. Applicant has discovered that staining does not
occur if the particle size of the graphite is maintained above
about 150 microns. Although not fully understood and not wishing to
be bound by any particular theory, Applicant believes that graphite
particles greater than about 150 microns (50 mesh) in size are not
capable of adhering to needles and thread used in sewing and
quilting operations and/or are unable to pass through fibrous
layers of material. As such, graphite particles greater than about
150 microns are not transported to the surface of composite
articles.
[0038] FIG. 2 is an enlarged cross sectional view of the composite
upholstery panel 10 of FIGS. 1A-1B with a quilting needle 25
passing therethrough to quilt the layers of the panel 10 together
via thread 20. The graphite particles 19 in the coating layer 18
have a size less than about 150 microns which allows them to adhere
to the needle 25 and thread 20 and to be drawn upwardly through the
cushioning layer 14 and ticking layer 12 and deposited on and
adjacent to the surface 12a of the ticking layer 12.
[0039] Referring to FIGS. 3A-3B, a composite upholstery panel 110,
according to embodiments of the present invention, is illustrated.
The composite upholstery panel 110 includes a layer of ticking
fabric 112, a layer of resilient cushioning material 114, and a
layer of backing fabric 116 having a coating 118 of intumescent
material disposed on a surface thereof. The coating 118 includes
expandable graphite particles having sizes that resist adherence to
needles and thread and passage thereof through the layer of
cushioning material 114 and ticking layer 112. The ticking layer
112, cushioning layer 114, and backing layer 116 are quilted
together with thread 20 that forms spaced-apart patterns of
stitches extending along the composite upholstery panel 110, as
illustrated.
[0040] According to some embodiments of the present invention, the
graphite particles in the coating 118 have sizes greater than or
equal to 150 microns. A preferable size range for the graphite
particles is between 150 microns and 1000 microns with an average
particle size generally between about 250 microns and 350 microns.
Preferably, no more than about one percent (1%) of the total
graphite particles in the coating 118 have a size less than 150
microns. When exposed to flame, the graphite particles in the
coating 118 are configured to expand at least about fifty times an
original volume and form a barrier to flame, hot gases, and heat
for a predetermined period of time.
[0041] Exemplary graphite particles that may be used in coatings in
accordance with some embodiments of the present invention include
Nyacol Nyagraph 251, from Nyacol Corp. Ashland Mass., Signature
Graphite 7800B from Superior Graphite Co. of Chicago Ill., and
Graphguard 220-50, from Graphtech International, Lakewood Ohio.
When preparing a coating containing graphite particles, it is
important not to create small graphite particles (i.e., graphite
particles smaller than 150 microns) when mixing, foaming, stirring,
or coating the graphite containing mixtures. Graphite content
within the coating may range from about 5% to about 50%, with 10%
to 30% being a preferred range. At higher levels of graphite
content, graphite particle size becomes even more important with
regard to the potential for causing staining.
[0042] FIG. 4 is an enlarged cross sectional view of the composite
upholstery panel of FIGS. 3A-3B with a quilting needle 25 passing
therethrough to quilt the layers of the panel 110 together via
thread 20. Because average graphite particle size is greater than
150 microns, no graphite particles 19 are being pulled from the
coating 118 via the quilting needle 25 and thread 20 and through
the cushioning and ticking layers 114, 116.
[0043] According to embodiments of the present invention, the
backing fabric 116 may be a fibrous layer of material, may be woven
or nonwoven and may contain one or more types of fibers. For
example, the backing layer 116 may be a nonwoven needlepunched
fabric prepared from a blend of non-thermoplastic and thermoplastic
fibers.
[0044] The coating 118 of intumescent material containing graphite
particles may be applied to the backing layer 116 as a foam
coating. Alternatively, the coating 118 may be applied as a paste
coating. An exemplary foam coating process includes aerating the
coating material using mechanical stirring while injecting air. The
use of air as a diluent creates a mixture that has a higher
viscosity than the precursor material and helps the coating
maintain a foam structure during application to a substrate
surface. The foam coating compound may then be applied using a
knife or roller coater, reverse roll, slot coater, gravure coater,
spraying, extrusion, dipping, or printing, each of which is well
understood by those skilled in the art.
[0045] The composition of coating 118 may be compounded with
binders and thickeners and the like to aid in the specific
application of the coating. Additionally, flame retardant fillers
such as alumina trihydrate, silicates, kaolin, gypsum and hydrated
clay may be added.
[0046] If a foam coating process is utilized, the foam coating
process can be designed to retain the foam structure when dried, or
to have the foam structure rupture and disperse, leaving no foam
structure in the dried coating. However, a coating with a retained
foam structure may be preferred.
[0047] A technique for applying a foam coating containing
expandable graphite, in accordance with embodiments of the present
invention, is via a parabolic foam coating unit available from
Gaston Systems, Inc., Stanley, N.C., and which is described in U.S.
Pat. Nos. 6,395,088 and 6,508,882, both of which are incorporated
herein by reference in their entireties.
[0048] The coating 118 may be dried using conventional means such
as tentering, convection oven, infrared drying, flotation dryer or
other common sheet or web drying equipment.
[0049] The layer of cushioning material 114 may be a foam material,
a fibrous material or a combination of foam material and fibrous
material.
Example 1
[0050] An exemplary formulation for a coating containing expandable
graphite is as follows:
TABLE-US-00001 INGREDIENT % (ACTIVE) Water 39.8 Noveon MW
3141(blend of 40.0 Acrylic binder and clay) Titanium dioxide
dispersion 3.0 Ammonium lauryl sulfate 0.1 Nyacol Nyagraph 251 17.0
Acrysol TT-615 thickener 0.1
This mixture is prepared at a viscosity of 3000-7000 cps, and then
foamed to a blow ratio of about 2 parts air to 1 part mixture. The
resulting viscosity is 10,000-15,000 cps. This foam was coated on a
3.5 ounce/sq. yd needlepunched nonwoven that was composed of 90%
viscose, and 10% para-aramid fiber. The chemical add on is 6.64
ounces/sq yard wet, or 4.0 ounces/sq yard dry. This coated fabric
is soft, has excellent flame blocking properties, and does not
cause marking when quilted or stitched.
Example 2
[0051] If the same compound and coated fabric of Example 1 is
prepared using Superior 7800 graphite, then the same soft, highly
flame resistant compound is produced but since this graphite has
3.15% small particle graphite with sizes down to 45 microns or
less, then the coated fabric will stain the stitching thread, the
needles, and small particles will be extracted from the coating and
deposited on the surface, which is unacceptable.
[0052] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although a few
exemplary embodiments of is this invention have been described,
those skilled in the art will readily appreciate that many
modifications are possible in the exemplary embodiments without
materially departing from the novel teachings and advantages of
this invention. Accordingly, all such modifications are intended to
be included within the scope of this invention as defined in the
claims. The invention is defined by the following claims, with
equivalents of the claims to be included therein.
* * * * *