U.S. patent application number 13/179227 was filed with the patent office on 2012-06-07 for coated fire barriers made from corespun yarns - coated fibers comprising the sheath of the corespun yarns.
This patent application is currently assigned to Springs Creative Products Group, LLC. Invention is credited to George E. BOOTH.
Application Number | 20120142241 13/179227 |
Document ID | / |
Family ID | 45441841 |
Filed Date | 2012-06-07 |
United States Patent
Application |
20120142241 |
Kind Code |
A1 |
BOOTH; George E. |
June 7, 2012 |
COATED FIRE BARRIERS MADE FROM CORESPUN YARNS - COATED FIBERS
COMPRISING THE SHEATH OF THE CORESPUN YARNS
Abstract
The invention relates to a fire resistant flame barrier
lightweight fabric substrate consisting of a high temperature
resistant continuous filament fiberglass core and a low temperature
resistant staple fiber sheath treated with a durable or non-durable
fire retardant agent prior to yarn formation. The invention also
discloses a process for making a fire resistant corespun yarn by
treating fibers with fire retardant agent to make the sheath of the
corespun yarn.
Inventors: |
BOOTH; George E.; (Rock
Hill, SC) |
Assignee: |
Springs Creative Products Group,
LLC
Rock Hill
SC
|
Family ID: |
45441841 |
Appl. No.: |
13/179227 |
Filed: |
July 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61362421 |
Jul 8, 2010 |
|
|
|
Current U.S.
Class: |
442/190 ;
428/373; 442/308; 57/362 |
Current CPC
Class: |
Y10T 442/425 20150401;
D06M 11/72 20130101; Y10T 442/3073 20150401; D02G 3/185 20130101;
D02G 3/443 20130101; D06M 23/06 20130101; D06M 11/82 20130101; D06M
23/08 20130101; Y10T 428/2929 20150115; D06M 11/74 20130101 |
Class at
Publication: |
442/190 ;
428/373; 442/308; 57/362 |
International
Class: |
D03D 15/00 20060101
D03D015/00; D04B 21/14 20060101 D04B021/14; D02G 3/02 20060101
D02G003/02; D02G 3/00 20060101 D02G003/00 |
Claims
1. A fire resistant fabric comprising: a fine textured fire
resistant flame barrier lightweight fabric substrate formed of a
nonlively nonplied fine balanced corespun yarn comprising: the yarn
being air jet spun without any appreciable twist and including a
core of high temperature resistant continuous filament fiberglass
constituting about 20% to 40% of total weight of the corespun yarn;
a sheath of low temperature resistant staple fibers treated with at
least one of a durable or non-durable fire retardant agent prior to
the yarn formation process; and the sheath surrounding and covering
said core constituting about 80% to 60% of the total weight of the
corespun yarn.
2. The sheath of claim 1, wherein at least some of the sheath
fibers are micro-coated with durable or non-durable fire retardant
agents.
3. The sheath of claim 1, wherein the fire retardant agent
comprises at least one of: Ammonium polyphosphate; Graphite; Boric
acid; or other environmentally friendly chemicals.
4. The fire resistant fabric of claim 3 wherein the retardant agent
comprises one of a: gas; liquid; and powder.
5. The fire resistant fabric of claim 1, wherein said fabric
substrate is one of knit or woven construction.
6. The corespun yarn of claim 1, wherein said sheath comprises
blends of natural and or man-made fibers comprising at least one
of: animal; vegetable; mineral; wool; cotton; polyester;
modacrylic; nylon; rayon; Lyocell; Kenaf; Hemp; Jute; acetate; and
blends thereof.
7. The corespun yarn of claim 1, wherein the sheath is comprised of
substantially 100% fire retardant micro-coated fibers.
8. The corespun yarn of claim 1, wherein the sheath is comprised of
fire retardant micro-coated fibers blended with other non-treated
fibers.
9. The corespun yarn of claim 1, wherein the sheath is comprised of
fire retardant micro-coated fibers blended with other inherently
fire retardant fibers.
10. A process for making a fire retardant corespun yarn by treating
the fibers with fire retardant agent to make the sheath of the
corespun yarn comprising: preparing a fire retardant composition;
applying the fire retardant composition to the fiber; drying and or
curing the treated fiber; and forming a yarn from the treated
fiber.
11. The process of claim 10, wherein the treated fibers cover the
core high temperature resistant fibers to create a sheath of
treated fibers.
12. The process of claim 10, wherein the treated fibers are blended
with other fibers to create a sheath of treated and untreated
fibers.
13. The process of claim 10, wherein the fire retardant composition
is applied to the sheath of the corespun yarn and comprises at
least one of: Ammonium polyphosphate; Graphite; Boric Acid; and
other environmentally friendly chemicals.
14. The process of claim 10, wherein the fire retardant composition
is applied to at least a surface of the fiber by at least one of:
mixing; spraying; rolling; and brushing.
15. The process of claim 10, wherein the fiber used to make the
sheath of the corespun yarn is immersed in the fire retardant
composition.
16. The process of claim 10, wherein the fire retardant composition
is reapplied as necessary.
Description
CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This application claims priority and the benefit thereof
from a U.S. Provisional Application No. 61/362,421, filed on Jul.
8, 2010 and entitled COATED FIRE BARRIERS MADE FROM CORE SPUN
YARNS--COATED FIBERS COMPRISING THE SHEATH OF THE CORE SPUN YARNS,
the entire contents of which are herein incorporated by reference
in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a fire resistant flame barrier
lightweight fabric substrate consisting of a high temperature
resistant continuous filament fiberglass core and a low temperature
resistant staple fiber sheath treated with a durable or non-durable
fire retardant agent prior to yarn formation. The invention also
discloses a process for making a fire resistant corespun yarn by
treating fibers with fire retardant agent to make the sheath of the
corespun yarn.
BACKGROUND OF THE INVENTION
[0003] The United States mattress industry is constantly striving
to improve mattress comfort, while complying with 16 Code of
Federal Regulations Part 1633, the United States standards for the
flammability of mattress sets and improving profitability by
reducing manufacturing costs or increasing value added features
such as use of more environmentally friendly components, lighter,
or more aesthetically pleasing fabrics.
[0004] Fire resistant fabrics used in the manufacture of mattresses
today typically require the application of chemical fire retardant
agents after fabric formation. Application of fire retardant agents
after fabric formation often results in changes to the physical and
or aesthetic properties of the fabric, such as changes in strength,
elongation, and feel of the fabrics, thereby making the fabrics
less desirable in the construction of mattresses, pillow tickings,
bedspreads, draperies, upholstery, and other bedding products.
(Note: As an alternative, inherently fire-retardant materials can
be used; however, these can be more expensive.)
[0005] There is a need to meet United States federal flammability
regulations for mattresses and other demands for fire resistant
fabrics, by making such fire resistant fabrics more ecologically
friendly while maintaining the fabrics' original physical and
aesthetic properties.
SUMMARY OF THE INVENTION
[0006] The invention, as described below, discloses micro-coating
some or all the sheath fiber components of balanced fine corespun
yarn, with a durable or non-durable fire retardant agent in the
fiber state, which includes a high temperature resistant continuous
multifilament fiberglass core and a low temperature resistant
staple fiber sheath surrounding the fiberglass core. The invention
further includes the process of making the same.
[0007] This invention may include aspects of U.S. Pat. No.
5,540,980 for fire resistant fabric made of balanced, fine corespun
yarn incorporated herein by reference in its entirety. The
invention may also include aspects of U.S. Pat. No. 4,958,485 for
corespun yarn for fire resistant safety apparel incorporated herein
by reference in its entirety. U.S. Pat. No. 5,540,980 teaches the
formation of fire resistant fabric from corespun yarn comprising of
a high temperature resistant continuous filament fiberglass core
and a low temperature resistant staple fiber sheath surrounding the
core, which may then be woven or knit in a fine, non-plied form.
This invention improves upon the previous teaching in that it
incorporates into the corespun yarn itself, micro-coated or treated
fibers, which are fibers that have been subject to the application
of a durable or non-durable fire retardant agent in the fiber state
prior to yarn formation, for use as one hundred percent of the
sheath fibers in corespun yarn, or blended with other fibers in the
sheath.
[0008] According to one aspect of the invention, a fire resistant
fabric may include a fine textured fire resistant flame barrier
lightweight fabric substrate formed of a nonlively nonplied fine
balanced corespun yarn including the yarn being air jet spun
without any appreciable twist and including a core of high
temperature resistant fibers constituting about 20% to 40% of total
weight of the corespun yarn, a sheath of low temperature resistant
staple fibers treated with at least one durable or non-durable fire
retardant agent prior to the yarn formation process, and the sheath
surrounding and covering the core constituting about 80% to 60% of
the total weight of the corespun yarn.
[0009] Some of or all the sheath of the corespun yarn may be
micro-coated with durable or non-durable fire retardant agents. The
fire retardant agent may include at least one of ammonium
polyphosphate, graphite, boric acid, or others as the fire
retardant agent, in gaseous, liquid and/or powder form. The fabric
substrate may be knit or woven. The sheath may include blends of
natural and or man-made fibers including at least one of animal,
vegetable, mineral, wool, cotton, polyester, modacrylic, nylon,
rayon, Lyocell, Kenaf, Hemp, Jute, acetate, and blends thereof.
[0010] The fire retardant micro-coated fibers may comprise 100% of
the sheath fibers in the corespun yarn. The treated fibers may be
blended with other fibers to create a sheath of treated and
untreated fibers. The sheath may also include fire retardant
micro-coated fibers blended with other inherently fire retardant
fibers.
[0011] A process for making a fire retardant corespun yarn by
treating the fibers with fire retardant agent to make the sheath of
the corespun yarn is also disclosed. The process may include at
least one of: mixing the fire retardant chemical or chemicals
together, applying the fire retardant chemicals to the fiber,
drying and or curing the treated fiber, and forming a yarn from the
treated fiber. The treated fibers may partially or fully cover the
core high temperature resistant fibers to create a sheath of
treated fibers. The treated fibers may also be blended with other
non-treated fibers to create a sheath of treated and untreated
fibers.
[0012] The application of the fire retardant agent to the fiber may
include topically treating the surface of the fiber and or
immersing the fiber in at least one fire retardant agent solution,
followed by drying and or curing the treated fiber. The process may
also include where a fire retardant agent is applied, and reapplied
as necessary, to a surface of the fiber by at least one of: mixing,
spraying, rolling, and or brushing.
[0013] Potential benefits from applying fire retardant agents to
the creation of fine balanced corespun yarn prior to fabric
formation may include the production of fire resistant and or flame
barrier fabrics that can be deployed in the greige state to
preserve the physical and aesthetic properties of the fabrics as
well as the upholstered articles made from them. The formation of
these yarns may potentially enable businesses to simplify the
process routing for these fabrics and maintain lower yarn inventory
levels as the same yarn can be used for several end products.
[0014] The invention contemplates the use of environmentally
favorable fire retardant chemicals, avoiding those suspect
chemicals on Europe's REACH list or California's Green Chemistry
Initiative, thereby possibly making the fabric more consumer and
retailer desirable and potentially lowering the risk of claims of
harm from use of other fire retardant chemicals. In addition, this
yarn structure may enable the micro-coated fibers to form a char,
while the heat stable core creates a lattice to hold the char in
place. The coating of the fibers may emit vapor-phase flame
retardants that would encourage the extinguishment of flames
immediately adjacent to the fire resistant fabric. The possible
increase in char strength may enable the use of lighter, more
responsive fire barrier fabrics than that using treated cotton
alone.
[0015] Additional features, advantages, and embodiments of the
invention may be set forth or apparent from consideration of the
detailed description and drawings. Moreover, it is to be understood
that both the foregoing summary of the invention and the following
detailed description are exemplary and intended to provide further
explanation without limiting the scope of the invention as
claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are included to provide a
further understanding of the invention, are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention and together with the detailed description serve to
explain the principles of the invention. No attempt is made to show
structural details of the invention in more detail than may be
necessary for a fundamental understanding of the invention and the
various ways in which it may be practiced. In the drawings:
[0017] FIG. 1 shows a greatly enlarged fragment of the balanced
corespun yarn of the invention with a portion of the sheath
revealed at one end thereof.
[0018] FIG. 2 shows a process for making a fire retardant corespun
yarn by treating the fibers used to make the sheath of the corespun
yarn with a fire retardant agent.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The embodiments of the invention and the various features
and advantageous details thereof are explained more fully with
reference to the non-limiting embodiments and examples that are
described and/or illustrated in the accompanying drawings and
detailed in the following attached description. It should be noted
that the features illustrated in the drawings are not necessarily
drawn to scale, and features of one embodiment may be employed with
other embodiments as the skilled artisan would recognize, even if
not explicitly stated herein. Descriptions of well-known components
and processing techniques may be omitted so as to not unnecessarily
obscure the embodiments of the invention. The examples used herein
are intended merely to facilitate an understanding of ways in which
the invention may be practiced and to further enable those of skill
in the art to practice the embodiments of the invention.
Accordingly, the examples and embodiments herein should not be
construed as limiting the scope of the invention, which is defined
solely by the appended claims and applicable law. Moreover, it is
noted that like reference numerals represent similar parts
throughout the several views of the drawings.
[0020] The invention sets forth an application of at least one fire
retardant agent to some or all of the low temperature resistant
sheath fibers, which surround and cover a high temperature
resistant continuous multifilament fiberglass core, while in a
fiber state.
[0021] FIG. 1 shows a greatly enlarged fragment of the balanced
corespun yarn of the invention with a portion of the sheath
revealed at one end thereof.
[0022] Referring to FIG. 1, the fire resistant balanced corespun
yarn 100, which may be knit or woven, may include a core of high
temperature resistant continuous filament fiberglass 110 and a
sheath of low temperature resistant staple fibers 120 which
surround and cover the core 110. Although the core is described as
fiberglass, it should be noted that other heat-stable materials
could be used as the core. The fiberglass core 110 extends
generally in an axial direction and longitudinally of the corespun
yarn 100, while the majority of the fibers of the sheath 120 extend
in a slightly spiraled direction around the core 110. A few of
fibers of the sheath may form a binding wrapper around a majority
of the staple fibers 130. The core 110 may consist of a high
temperature resistant continuous multifilament fiberglass, which
constitutes about 20% to 40% of the total weight of the corespun
yarn 100.
[0023] The sheath 120 may completely cover the core 110 and the
yarn 100 will take on the characteristics of the fiber which forms
the sheath 120, such as the low temperature resistant staple fibers
in this case. The sheath 120 may include low temperature resistant
staple fibers, which constitutes about 80% to 60% of the total
weight of the corespun yarn 100 and may consist of all or some
fibers that are micro-coated with durable or non-durable fire
retardant agents. The sheath 120 may also consist of fire retardant
micro-coated fibers blended with other non-treated fibers or
inherently fire retardant fibers to form the sheath 120.
[0024] The sheath 120 may include blends of natural occurring
fibers, such as animal, vegetable, or mineral fibers, and or
unnaturally occurring fibers, such as cotton, wool, polyester,
modacrylic, nylon, rayon, Lycocell, Kenaf, Hemp, Jute, acetate, and
blends thereof. The preferred low temperature resistant staple
fibers 120 are cotton and polyester micro-coated with durable or
non-durable fire retardant agents. The total practical size of the
fine corespun yarn 100 is around 43/1 to 3.5/1 conventional cotton
count.
[0025] The invention describes a corespun yarn 100 that may be
produced on a Murata air jet spinning apparatus, as disclosed in
one or more of U.S. Pat. Nos. 4,718,225; 4,551,887; and 4,497,167.
An air jet spinning apparatus may include an entrance trumpet for
feeding the fire retardant chemically treated low temperature
resistant sheath fibers 120, one or more drafting rolls, feeding of
the high temperature core fibers 110 between two or more drafting
rolls, at least one fluid swirling air jet nozzle that may produce
air jet spun yarn 100 without any appreciable twist, torque or
liveliness, and a delivery roll assembly.
[0026] The fire retardant agents applied to some or all of the
fibers in the sheath 120 may include ammonium polyphosphate,
graphite, boric acid, and or other mixtures, which may be applied
in gaseous, liquid and or powder form.
[0027] This invention may also involve a process for treating the
sheath fibers with at least one fire retardant chemical or
mixtures. FIG. 2 shows a process for making fire retardant corespun
yarn by treating the fibers used to make the sheath of the corespun
yarn with a fire retardant agent.
[0028] Referring to FIG. 2, one or more fire retardant chemicals
may be mixed together 210 and applied to the low temperature
resistant staple fiber sheath 220 which may surround the high
temperature resistant fiberglass core. The fire retardant chemicals
may be applied 220 to the surface of the sheath fiber by mixing,
spraying, rolling, and or brushing, or may be immersed in a fire
retardant chemical solution before being dried 230 or allowed to
dry. The fire retardant chemical agent or solution may include at
least one of ammonium polyphosphate, graphite, boric acid, or other
mixtures, and may be applied at least once and reapplied to the
fiber as necessary. Drying the chemically treated sheath fibers 230
may involve natural air drying as well as other drying methods as
known in the industry.
[0029] The process may further include blending other fibers with
the treated fibers to create a sheath of treated and untreated
fibers, and then covering the high temperature resistant core with
the sheath of treated fibers to form a fire resistant corespun yarn
240. The process may conclude with the making of a fire resistant
fabric 250 which is then used in the manufacture of an end product
260, such as a mattress, mattress topper, or other upholstery
components.
[0030] It should be noted that although the figures show a single
core and a single sheath, these aspects are merely exemplary. It is
within the scope and spirit of the invention to have multiple cores
and/or multiple sheaths. The cores may be the same material or they
may include different materials. Similarly, the sheaths may be the
same material or they may include different materials.
[0031] While the invention has been described in terms of exemplary
embodiments, those skilled in the art will recognize that the
invention can be practiced with modifications in the spirit and
scope of the appended claims. These examples given above are merely
illustrative and are not meant to be an exhaustive list of all
possible designs, embodiments, applications or modifications of the
invention.
* * * * *