U.S. patent application number 14/663014 was filed with the patent office on 2015-09-24 for decorative mattress border fabric with inherent flame barrier.
This patent application is currently assigned to SPRINGS CREATIVE PRODUCTS GROUP, LLC. The applicant listed for this patent is Springs Creative Products Group, LLC. Invention is credited to George BOOTH, James FLEMING, Scott FRISCH.
Application Number | 20150267323 14/663014 |
Document ID | / |
Family ID | 54141549 |
Filed Date | 2015-09-24 |
United States Patent
Application |
20150267323 |
Kind Code |
A1 |
FRISCH; Scott ; et
al. |
September 24, 2015 |
DECORATIVE MATTRESS BORDER FABRIC WITH INHERENT FLAME BARRIER
Abstract
A flame barrier substrate consisting principally of
non-fire-retardant (non-FR) fiber with fire-resistant properties
and affinity for sublistatic dyes. The flame barrier substrate
includes a balanced fine core-spun yarn whose face may include
fibers with an affinity for dyes, e.g., sublistatic dyes. The
balanced fine core-spun yarn may also include a heat-stable core
enveloped in a sheath of low-temperature-resistant fibers such as,
for example, non-fire-retardant (non-FR) fibers. The balanced fine
core-spun yarns may be further combined with other balanced fine
core-spun yarns made with a sheath of fire-retardant fibers for
added flame barrier performance. This flame barrier substrate may
be constructed to concentrate the dye-receptive yarns on the
technical face of the fabric for optimal aesthetics.
Inventors: |
FRISCH; Scott; (Fort Mill,
SC) ; BOOTH; George; (Rock Hill, SC) ;
FLEMING; James; (Cowpens, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Springs Creative Products Group, LLC |
Rock Hill |
SC |
US |
|
|
Assignee: |
SPRINGS CREATIVE PRODUCTS GROUP,
LLC
Rock Hill
SC
|
Family ID: |
54141549 |
Appl. No.: |
14/663014 |
Filed: |
March 19, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61955441 |
Mar 19, 2014 |
|
|
|
Current U.S.
Class: |
428/221 ;
139/420C; 28/163; 28/165; 428/373 |
Current CPC
Class: |
D10B 2331/021 20130101;
D10B 2503/00 20130101; D02G 3/443 20130101; D10B 2331/04 20130101;
D10B 2331/02 20130101; D03D 15/0011 20130101; D03D 15/0027
20130101; D10B 2101/20 20130101; D03D 1/0035 20130101; Y10T
428/249921 20150401; D10B 2101/06 20130101; D02G 3/36 20130101;
Y10T 428/2929 20150115; D03D 1/0017 20130101; D03D 15/12 20130101;
D10B 2401/14 20130101 |
International
Class: |
D02G 3/36 20060101
D02G003/36; D03D 15/12 20060101 D03D015/12; D03D 1/00 20060101
D03D001/00; D03D 15/00 20060101 D03D015/00 |
Claims
1. A flame barrier substrate, comprising: a balanced fine core-spun
yarn, and a sheath of low-temperature-resistant fibers comprising
non-fire retardant fibers with an affinity for sublistatic dyes,
wherein the balanced fine core-spun yarn comprises a heat-stable
core enveloped in the sheath of low-temperature-resistant
fibers.
2. The flame barrier substrate of claim 1, wherein the non-fire
retardant fibers comprise at least one of: polyester, nylon, and
any other fiber that has an affinity for sublistatic dyes.
3. The flame barrier substrate of claim 1, wherein the non-fire
retardant fibers are configured to melt in presence of a flame
reducing air permeability and simultaneously depriving the
potential fuel of oxygen while creating a physical impediment to
progress of the flame to potential fuel within a mattress or other
upholstered article thereby creating a flame barrier.
4. The flame barrier substrate of claim 1, wherein the heat-stable
core comprises at least one of: multi-filament fiberglass, aramid,
and steel.
5. The flame barrier substrate of claim 1, wherein the flame
barrier substrate is configured to be used as a decorative outer
fabric that comprises the side and end walls of a mattress.
6. A method for manufacturing a flame barrier substrate with
decorative or functional patterns comprising: providing a balanced
fine core-spun yarn, wherein the balanced fine core-spun yarn
further comprises a heat stable core enveloped in a sheath of
fibers; and printing a decorative or functional patterns onto the
sheath of fibers.
7. The method of claim 6, wherein the printing comprises at least
one of: digital printing, and heat-transfer printing.
8. The method of claim 6, wherein the heat-stable core comprises at
least one of: multi-filament fiberglass, aramid, and steel.
9. The method of claim 6, wherein the sheath of fibers comprises
fibers with an affinity for sublistatic dyes.
10. The method of claim 6, wherein the sheath of fibers comprise
non-fire retardant fibers that are configured to melt in presence
of a flame thereby limiting air permeability for the flame and
creating a physical impediment to the progress of the flame to
potential fuel within a mattress or other upholstered article
thereby creating a flame barrier.
11. The method of claim 10, wherein the non-fire retardant fibers
comprise at least one of: polyester, nylon, and any other fiber
that has an affinity for sublistatic dyes.
12. A method for manufacturing a flame barrier substrate with
decorative or functional patterns comprising: providing a first
balanced fine core-spun yarn; providing a sheath of non-fire
retardant fibers with an affinity for sublistatic dyestuffs and a
second balanced fine core-spun yarn; providing a sheath of fibers
with fire-retardant properties; and combining the first balanced
fine core-spun yarn and the second balanced core-spun yarn in a
woven substrate, wherein the first core-spun yarn comprises a heat
stable core, and wherein the second balanced fine core spun yarn
comprises a heat stable core.
13. The method of claim 12, wherein the fabric is configured to be
engineered in a way to concentrate the sheath of non-fire retardant
fibers with an affinity for sublistatic dyestuffs on one side of
the substrate, thereby creating a decorative, technical face of the
fabric.
14. The method of claim 12, wherein the non-fire retardant fibers
comprise at least 60% of the flame barrier substrate.
15. The method of claim 12, wherein the heat stable core comprises
at least one of: multi-filament fiberglass, aramid, and steel.
16. The method of claim 12, wherein the sheath of fibers with
fire-retardant properties comprise at least one of: modacrylics,
treated cotton or rayon, fire-retardant lyocell, meta-aramids,
para-aramids, fluoropolymers and copolymers thereof,
chloropolymers, polybenzimidazole, polyimides, polyamideimides,
partially oxidized polyacrylonitriles, novoloids, poly (p-phenylene
benzobisoxazoles), poly (p-phenylene benzothiazoles), polyphenylene
sulfides, flame-retardant viscose rayons, polyvinyl chloride
homopolymers and copolymers thereof, polyetheretherketones,
polyketones, polyetherimides, polylactides, and any combinations
thereof.
17. The method of claim 12, wherein the non-fire retardant fibers
comprise at least one of: polyester, nylon, and any other fiber
that has an affinity for sublistatic dyes.
18. The method of claim 12, wherein the woven substrate comprises a
twill weave or other warp face fabric.
19. The method of claim 12, wherein the woven substrate is formed
to impart a three-dimensional surface texture.
20. A flame barrier substrate, comprising: a balanced fine
core-spun yarn, and a sheath of low-temperature-resistant fibers
comprising non-fire retardant fibers with an affinity for
sublistatic dyes wherein the non-fire retardant fibers are
configured to melt in presence of a flame reducing air permeability
and simultaneously depriving the potential fuel of oxygen while
creating a physical impediment to progress of the flame to
potential fuel within a mattress or other upholstered article
thereby creating a flame barrier, wherein the balanced fine
core-spun yarn comprises a heat-stable core enveloped in the sheath
of low-temperature-resistant fibers.
Description
CROSS REFERENCE TO PRIOR APPLICATION
[0001] This application claims priority to and the benefit thereof
from U.S. provisional patent application No. 61/955,441, filed Mar.
19, 2014 titled "DECORATIVE MATTRESS BORDER FABRIC WITH INHERENT
FLAME BARRIER," the entirety of which is hereby incorporated herein
by reference.
BACKGROUND OF THE DISCLOSURE
[0002] 1.0 Field of the Disclosure
[0003] The present disclosure relates generally to a flame barrier
substrate, and more specifically, it relates, among other things,
to a flame barrier substrate made using balanced fine core-spun
yarns whose sheath fibers are principally non-fire-retardant
(non-FR) and have an affinity for sublistatic dyes.
[0004] 2.0 Related Art
[0005] United States mattress manufacturers are required to meet
federal flammability regulations for mattresses sold in the United
States. Mattress manufacturers have employed various methods to
provide mattress constructions with fire-retardant properties, with
solutions ranging from knitted flame barrier interliners, to
barriers knitted into decorative tickings, to highloft nonwoven
battings, to stitchbonded nonwovens, or to laminates involving any
of these combinations. In the case of innerspring mattresses,
manufacturers have gravitated toward quilted composites consisting
of a decorative ticking backed with a high-loft fire-retardant
batting, with or without a nonwoven scrim behind the high-loft.
This quilted approach is used for the sleep surface(s), but is also
a technique specifically employed in the border (i.e., the side and
end "walls" of the mattress structure) to help ensure compliance
with full-scale mattress burn tests. Although this technique can be
effective, mattress makers often complain that quilting is an
expensive, time consuming and wasteful process. Other suppliers to
the industry have sought to use lamination of the high-loft to the
border ticking. While lamination is more efficient than quilting,
laminated composites are generally less durable than quilted
composites, and they depend on longer production runs for their
cost-efficiency.
[0006] Specialty sleep mattress constructions, i.e., those
mattresses consisting principally of foam, or those mattresses
whose sleep surfaces are principally unquilted foam, are made using
stretchable fire-retardant flame barrier interliners. These
articles are most frequently tubular knit fabrics made using
inherently fire-retardant (FR) core-spun yarns, or from
combinations of core-spun and other yarns. Mattress manufacturers
often prefer these solutions for specialty mattresses, because of
their simplicity and ease of application, and also because the
stretch and recovery of the barrier structures enables consumers to
feel the responsiveness of the foams they use. The disadvantage of
these types of barriers lies in their expense compared to high-loft
solutions. Mattress manufacturers would prefer to deploy these
barriers only where they would provide a marketing advantage or
consumer benefit.
[0007] Ticking manufacturers have produced low-cost, printed,
stitchbonded tickings, to some effect, but these are generally not
seen as suitable for top-quality mattress brands. These tickings
are also printed on rotary screen print or flexographic print
ranges, making larger lot sizes more economical, but creating a
risk of fashion obsolescence if the entire printing run is not sold
in a timely manner.
[0008] The producers of integrated barrier knit tickings have
sought to address this issue by knitting heavier-duty tickings,
specifically for use as mattress borders. These products are
effective as flame barriers, but they are still subject to minimum
run sizes and subject to the same fashion obsolescence risk, as the
design is imparted at the time the fabric is formed.
[0009] Meanwhile, mattress manufacturers have continued to seek
lower-cost methods to provide mattresses with fire-retardant (FR)
properties and aesthetic appearances while preserving or enhancing
the comfort and perceived value of their respective mattress
constructions.
[0010] It is known in the textile industry to produce
fire-retardant and or flame-resistant fabrics for use as mattress
tickings, bedspreads, furniture, and the like, by using yarn formed
of natural or synthetic fibers and then treating the fabric with
fire retarding chemicals, such as halogen-based and/or
phosphorus-based chemicals. This type of fabric is heavier than
similar types of non-fire retardant fabrics, and has a limited wear
life. Also, this type of fabric typically melts or forms brittle
chars which break away when the fabric is burned.
[0011] It is also known to form fire-resistant fabrics of
fire-resistant relatively heavy weight yarns in which a low
temperature-resistant fiber is ring spun around a core of
continuous filament fiberglass. However, this type of ring spun
yarn has torque imparted thereto during the spinning process and is
very lively. Because of the lively nature of the yarn, it is
necessary to ply "S" and "Z" ring spun yarns together so that the
torque and liveliness in the yarn is balanced in order to
satisfactorily weave or knit the yarn into the fabric, without
experiencing problems of tangles occurring in the yarn during the
knitting or weaving process. This plying of the "S" and "Z" yarns
together results in a composite yarn which is so large that it
cannot be used in the formation of fine textured, lightweight
fabrics. In some instances the fiberglass filaments in the core
protrude through the natural fiber sheath. It is believed that the
problem of protruding core fibers is associated with the twist,
torque and liveliness being imparted to the fiberglass core during
the ring spinning process.
[0012] It is also known to produce coated upholstery fabrics by
weaving or knitting a substrate or scrim of a cotton or cotton and
polyester blend yarn. This scrim is then coated with a layered
structure of thermoplastic polyvinyl halide composition, such as
polyvinyl chloride (PVC). This coated upholstery fabric has very
little, if any, fire-resistance and no flame barrier properties. In
addition to the coating chemical having a limited shelf life, the
chemical coatings pose a safety hazard in case of contact with
skin.
[0013] Yet another solution involves the creation of core spun
yarns using sheath fiber that includes fire-resistant fibers such
as, for example, rayon, modacrylic, aramids, melamine, phenolic,
and so on. However, this solution can often be costly due to, for
example, higher raw material costs.
[0014] Furthermore, currently available fire-retardant and or
flame-resistant fibers are unable to be printed using sublistatic
heat transfer or digital printing because these fibers are not
chemically or physically receptive to the dyes used under normal
processing conditions. These printing methods make use of
sublistatic dyes to impart decorative and/or functional
patterns.
[0015] Heat-transfer-printing may use dyestuffs, which may, at a
specified process temperature, sublimate and allow for creation of
a pattern on a flame barrier substrate. In such a printing process,
a substrate may be fed into a transfer printing range that presses
the dye-infused transfer paper, which includes a specific pattern
and/or design to the substrate and exposes the joined
substrate-paper combination to a specified sublimation temperature
for a predetermined dwell time. The sublimation of the dyestuff
causes the pattern/design to impregnate the receptive fibers in the
substrate, thereby creating a precise likeness of the design on the
transfer paper on the substrate. This process may be carried out on
a batch or on a continuous basis.
[0016] These aesthetic patterns are often desired in, e.g.,
mattress tickings, bedspreads, furniture, and the like. Unlike
rotary screen printing or other well-known printing technologies,
sublistatic printing enables shorter lead times and shorter print
runs for increased styling flexibility with less waste.
[0017] In order to address the root cause of, for example,
inability to easily heat-transfer print decorative elements onto
fabrics with fire-retardant properties, an unfulfilled need exists
for a fire-retardant core-spun yarn that can receive the dyestuffs
used to print a decorative and/or functional pattern onto the
fabric made from the yarn.
SUMMARY OF THE INVENTION
[0018] In one aspect, the present disclosure provides an open flame
barrier fabric with affinity for sublistatic dyes. The flame
barrier substrate includes a balanced fine core-spun yarn, a sheath
of low-temperature-resistant fibers. For purpose of this invention,
low-temperature-resistant fibers may include fibers that would melt
or char at or near typical combustion temperatures. Polyester melts
at 482-550.degree. F., and modacrylic fibers melt at
371-410.degree. F. By contrast fiberglass softens at 1,224.degree.
F. This designation may be used to distinguish the sheath material
from the core which has a higher melting point, wherein the
balanced fine core-spun yarn may include a heat-stable core
enveloped in the sheath of low-temperature-resistant fibers.
[0019] The sheath of low-temperature-resistant fibers may include
fibers with an affinity for sublistatic dyes. The
low-temperature-resistant fibers comprise non-fire retardant
(non-FR) fibers. The non-FR fibers may include at least one of:
polyester, nylon, and any other fiber that has an affinity for
sublistatic dyes. The heat-stable core may include at least one of:
multi-filament fiberglass, aramid, and steel. The flame barrier
substrate may be configured to be used as a decorative outer fabric
that comprises the side and end walls of a mattress. The non-fire
retardant fibers may be configured to melt in presence of a flame
thereby reducing air permeability and simultaneously depriving
potential fuel of oxygen while creating a physical impediment to
the progress of the flame to potential fuel within a mattress or
other upholstered article thereby creating a flame barrier. The
yarn's heat stable core may provide a supporting structure or
lattice for melted and congealed non-fire retardant fibers and
provide structural stability (for e.g., charred material) to
maintain a barrier to the flame.
[0020] In one aspect, the present disclosure provides a method for
manufacturing a flame barrier substrate with decorative and or
functional patterns. The method for manufacturing the flame barrier
substrate with decorative and/or functional patterns includes
providing a balanced fine core-spun yarn wherein the core-spun yarn
includes a heat stable core enveloped in a sheath of fibers, and
printing a decorative and or functional pattern onto the fabric
made from balanced fine core-spun yarn. The fibers may include
non-fire retardant fibers with an affinity for sublistatic dyes.
The fabric may be configured to be engineered in a way to
concentrate the sheath of non-fire retardant fibers with an
affinity for sublistatic dyestuffs on one side of the substrate,
thereby creating a decorative, technical face of the fabric. The
printing may include digital printing, rotary screen printing,
heat-transfer printing, and the like. The heat-stable core may
include at least one of: multi-filament fiberglass, aramid, and
steel.
[0021] In one aspect, the present disclosure provides a method for
manufacturing a flame barrier substrate with decorative and or
functional patterns. The method for manufacturing a flame barrier
substrate with decorative and/or functional patterns includes
providing a balanced fine core-spun yarn wherein the core-spun yarn
includes a heat stable core, providing a sheath of non-FR fibers
with an affinity for sublistatic dyestuffs and a second balanced
fine core spun yarn wherein the core-spun yarn includes a heat
stable core, providing a sheath of fibers with fire-retardant (FR)
properties, and combining the two core spun yarn types in a woven
substrate. The structure of the fabric may be engineered in such a
way as to concentrate the dye receptive warp yarns on the technical
face of the fabric, while concentrating the filling yarns
containing FR sheath fibers on the technical back of the fabric.
This technique may enable sublistatic printing of the technical
face with optimal color yield and image fidelity, as inherently FR
fibers resist sublistatic dyestuffs under normal processing
conditions. The aforementioned technique minimizes the
dye-resistive fibers' presence on the technical face of the
substrate.
[0022] In one aspect, a flame barrier substrate is provided that
includes a balanced fine core-spun yarn and a sheath of
low-temperature-resistant fibers comprising non-fire retardant
fibers with an affinity for sublistatic dyes wherein the non-fire
retardant fibers are configured to melt in presence of a flame
reducing air permeability and simultaneously depriving the
potential fuel of oxygen while creating a physical impediment to
progress of the flame to potential fuel within a mattress or other
upholstered article thereby creating a flame barrier, wherein the
balanced fine core-spun yarn comprises a heat-stable core enveloped
in the sheath of low-temperature-resistant fibers.
[0023] 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
[0024] The accompanying drawings, which are included to provide a
further understanding of the disclosure, are incorporated in and
constitute a part of this specification, illustrate embodiments of
the disclosure and together with the detailed description serve to
explain the principles of the disclosure. No attempt is made to
show structural details of the invention in more detail than may be
necessary for a fundamental understanding of the disclosure and the
various ways in which it may be practiced.
[0025] FIG. 1A shows an example of a SEM photomicrograph of the
cross-section of a core spun flame barrier yarn substrate with
affinity for sublistatic dyes in accordance with the principles of
this disclosure.
[0026] FIG. 1B shows a schematic example of a flame barrier yarn
substrate with affinity for sublistatic dyes in accordance with the
principles of this disclosure.
[0027] FIG. 2 discloses an example of a flame barrier substrate
constructed according to principles of the disclosure.
[0028] FIG. 3 shows an example photograph of a flame barrier
substrate constructed according to principles of the
disclosure.
[0029] FIG. 4A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0030] FIG. 4B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0031] FIG. 5A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0032] FIG. 5B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0033] FIG. 6A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0034] FIG. 6B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0035] FIG. 7A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0036] FIG. 7B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0037] FIG. 8A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0038] FIG. 8B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0039] FIG. 9A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0040] FIG. 9B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0041] FIG. 10A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0042] FIG. 10B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0043] FIG. 11A shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
[0044] FIG. 11B shows an example of flammability test result for a
flame barrier substrate constructed according to principles of the
disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0045] 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 detailed in the following attached description. It
should be noted that the 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.
[0046] The terms "including", "comprising" and variations thereof,
as used in this disclosure, mean "including, but not limited to,"
unless expressly specified otherwise.
[0047] The terms "a", "an", and "the," as used in this disclosure,
means "one of more", unless expressly specified otherwise.
[0048] Although process steps, method steps, algorithms, or the
like, may be described in a sequential order, such processes,
methods and algorithms may be configured to work in alternate
orders. In other words, any sequence or order of steps that may be
described does not necessarily indicate a requirement that the
steps be performed in that order. The steps of the processes,
methods or algorithms described herein may be performed in any
order practical. Further, some steps may be performed
simultaneously.
[0049] When a single device or article is described herein, it will
be readily apparent that more than one device or article may be
used in place of a single device or article. Similarly, where more
than one device or article is described herein, it will be readily
apparent that a single device or article may be used in place of
the more than one device or article. The functionality or the
features of a device may be alternatively embodied by one of more
other devices which are not explicitly described as having such
functionality or features.
[0050] The disclosure provides examples of a flame barrier
substrate composed principally of non-fire-retardant (non-FR)
fiber. The non-FR fiber may make up at least 60% of the product
substrate. Further, core spun yarns may be made with non-FR fiber
sheaths having an affinity for sublistatic dyes. If it is deemed
desirable or necessary to mix dye-receptive non-FR sheath warp
yarns with filling yarns whose sheaths contain FR fibers that
resist sublistatic dyes (in whole or in part), the structure of the
fabric may be engineered to concentrate the dye receptive yarns on
the technical face of the fabric.
[0051] An aspect of the present disclosure provides a flame barrier
substrate with flame-retardant properties and affinity for
sublistatic dyes. The flame barrier substrate may include a
balanced fine core-spun yarn whose sheath may include non-FR fibers
with an affinity for dyes, e.g., sublistatic dyes (as shown in, for
example, FIGS. 1A and 1B).
[0052] The balanced fine core-spun yarn may also include a
heat-stable core enveloped in a sheath of low-temperature-resistant
fibers such as, for example, non-fire retardant (non-FR) fibers in
a sheath-to-core ratio ranging from 75:25-to-25:75. The balanced
fine core-spun yarn may comprise, for example, at least 60% non-FR
fibers with an affinity for sublistatic dyes. This will result in
higher concentration of dye-receptive non-FR fibers on the surface
of the balanced fine core-spun yarn which will better facilitate
printing of sublistatic dyes onto the substrate made from these
yarns.
[0053] The non-FR fibers may include polyester, nylon, and any
other fiber that has an affinity for sublistatic dyes. The
heat-stable core may include multi-filament fiberglass (silica),
aramid, steel, and the like.
[0054] The flame barrier substrate may function as a flame barrier
by virtue of the cores' maintenance of a lattice or scrim that does
not melt, crack, breach or deform in the presence of an ignition
source. For purposes of quantifying the level of performance, the
NIST Burner cited in 16 CFR 1633 is typical of the ignition
exposures that the flame barrier substrate is intended to
withstand.
[0055] The flame barrier substrate may be used, e.g., as a mattress
border, a decorative outer fabric that comprises the side and end
"walls" of a mattress. The flame barrier substrate can provide
aesthetic benefits as part of the mattress's exterior, as well as
function as a flame barrier. The flame barrier substrate may also
be used as the outer ticking of an entire mattress, or as an
upholstery fabric for furniture such as chair cushions, sofas,
wheelchair cushions, and so on. The flame barrier substrate may be
further configured to be used as a decorative outer fabric of
furniture. The flame barrier substrate may also be configured to be
used in e.g., office interiors.
[0056] An example of the present disclosure provides a functional
flame barrier fabric made principally using core-spun yarns, the
sheaths of which may include primarily synthetic fibers with an
affinity for sublistatic dyes even if these dye accepting fibers
may not be inherently fire-retardant or flame-resistant. The
resulting flame barrier fabric may be made decorative in
small-batch heat-transfer printing runs in order to create a
decorative flame barrier fabric with improved aesthetics, e.g.,
sharper color, increased color yield, sharper printed design,
improved colorfastness, and the like.
[0057] The synthetic fibers with affinity for dyes currently used
in sublistatic printing may include polyester, nylon, and the like.
The synthetic fibers may be wrapped around a heat stable core to
hold these fibers in place on exposure to flame. The fibers'
tendency to melt in the presence of the flame is utilized
advantageously as the flow of melting sheath fiber is used to fill
in the air spaces--the interstices--between yarns, restricting the
amount of air that can be drawn through the barrier layer into the
combustible material within the barrier envelope. The fabric made
from these yarns should have sufficient textile cover--that is, the
percentage of the area of one square inch of fabric that is covered
by yarn--to limit air permeability. The limited air permeability
will help deprive incipient fire of oxygen thereby slowing down or
stopping the fire from growing. The resulting fabric may exhibit
cover greater than, e.g., about 80% cover, resulting in air
permeability less than, e.g., about 90 cubic feet per minute
(CFM).
[0058] In another embodiment of the present disclosure, a flame
barrier substrate with flame-retardant properties and affinity for
sublistatic dyes is provided. The flame barrier substrate may
include a combination of dye-friendly core spun yarns and core spun
yarns made using inherently fire-retardant (FR) fibers. The
combination may be carried out by creating a warp using non-FR
sheath fibers in all core spun warp yarns. Filling yarns may
include these same yarns, but may also be alternated with core spun
yarns made using inherently FR fibers or blends of FR fibers in the
sheath. The FR fibers may include modacrylics, treated cotton or
rayon, fire-retardant lyocell, meta-aramids, para-aramids,
fluoropolymers and copolymers thereof, chloropolymers,
polybenzimidazole, polyimides, polyamideimides, partially oxidized
polyacrylonitriles, novoloids, poly (p-phenylene benzobisoxazoles),
poly (p-phenylene benzothiazoles), polyphenylene sulfides,
flame-retardant viscose rayons, polyvinyl chloride homopolymers and
copolymers thereof, polyetheretherketones, polyketones,
polyetherimides, polylactides, and combinations thereof, and the
like.
[0059] Part of this embodiment may include making the dye receptive
yarns more numerous than the inherently FR core-spun yarns. This
can be accomplished by making warp yarns more numerous than filling
yarns, but the percentage of warp and filling yarns made with
dye-receptive non-FR fiber sheaths will vastly outnumber the yarns
containing FR fiber. For example, non-FR-clad yarns may include 80%
of the total fabric mass.
[0060] In addition, through careful fabric design, these more
numerous non-FR dye receptive core yarns may be woven or knitted so
that they predominate on the face of the fabric, directing yarns
that contain inherently fire-retardant fibers to the reverse. In
this way, the substrate would have a decorative technical face
(e.g., the printed or printable side) and a reverse side, the
technical back of the fabric.
[0061] In yet another embodiment of the present disclosure, a woven
substrate with fire-retardant (FR) properties is disclosed. The
woven substrate includes a warp wherein the warp includes
dye-receptive flame barrier yarns. The dye-receptive flame barrier
yarns may constitute the totality or the majority of the fabric's
warp. These more numerous dye receptive yarns would be concentrated
on the face of the fabric through the creation of warp-face
fabrics, such as twills (as shown in, e.g., FIG. 2-3) or sateens.
The perpendicular fill yarns could include, for example, a mix of
dye-receptive non-FR core-spun yarns, core-spun yarns made with
inherently fire-retardant fibers and or non-core-spun yarns in a
variety of blend compositions and sizes to achieve desired
physical, mechanical and flame resistant properties. The population
of yarns may include at least 60% non-FR core-spun yarns. There may
be interlacings between warp and filling yarns wherein each
contains a heat-stable core so that the substrate may function as
an effective flame barrier.
[0062] In yet another embodiment of the present disclosure, a
knitted substrate is disclosed. The knitted substrate may include
dye receptive flame barrier core spun yarns knitted with other
core-spun yarns made with inherently fire-retardant (FR) fibers to
create a double face fabric. This manufacturing method may result
in a concentration of dye-receptive flame barrier yarns on one face
of the fabric to enable both better color saturation and sufficient
char formation to restrict airflow. The total population of yarns
in this embodiment may include at least 50% yarns made using non-FR
dye receptive core spun yarns.
[0063] Further to the above embodiment, the dye receptive core spun
yarns may be knitted alone in a tightly knitted construction as a
single layer fabric, to fashion a knitted all-in-one ticking that
would serve as an exterior decorative mattress cover fabric while
serving simultaneously as a flame barrier. Similarly, this
construction could also function as a flame barrier interliner.
[0064] Another aspect of the present disclosure provides a method
for manufacturing a flame barrier substrate with decorative and or
functional patterns. The method for manufacturing the flame barrier
substrate with decorative and/or functional patterns includes
providing a balanced fine core-spun yarn wherein the core-spun yarn
includes a heat stable core enveloped in a sheath of non-FR fibers,
and printing a decorative and or functional pattern onto the fabric
made from these balanced fine core-spun yarns. The fibers may
include non-fire-retardant fibers with an affinity for sublistatic
dyes. The printing may include digital printing, rotary screen
printing, heat-transfer printing, wet printing, flexographic
printing techniques, and the like. By use of these printing
technologies, the flame barrier substrate may be enhanced through
the use of metallic, pearlescent or iridescent pigment
formulations, and may also be printed with "puff printing"
techniques to create designs with three-dimensional relief. Unlike
rotary screen printing or other well-known printing technologies,
sublistatic printing enables shorter print runs for increased
styling flexibility with less waste.
[0065] FIGS. 1A and 1B disclose an example of a flame barrier yarn
constructed according to principles of the disclosure. The flame
barrier yarn may be typical Firegard.RTM. core-spun yarn. The
cylindrical fibers may be silica (a/k/a glass fiber or fiberglass)
and they may be surrounded by low-temperature resistant fibers. For
purposes of this invention, low-temperature-resistant fibers are
those fibers that would melt or char at or near typical combustion
temperatures. This designation is intended to distinguish the
sheath material from the core which would have a much higher
melting point,
[0066] The flame barrier substrate may include a balanced fine
core-spun yarn 100 wherein the core-spun yarn 100 includes a heat
stable core 110 and a sheath of fibers with an affinity for
sublistatic dyestuffs 120. The heat stable core 110 may include
e.g., multi-filament fiberglass (silica), aramid, steel, and the
like. The sheath of fibers 120 may include non-fire retardant
(non-FR) fibers which may include e.g., polyester, nylon, and any
other fabric that has an affinity for sublistatic dyes. The sheath
of fibers 120 may also include fibers with fire-retardant (FR)
properties e.g., modacrylics, treated cotton or rayon,
fire-retardant lyocell, meta-aramids, para-aramids, fluoropolymers
and copolymers thereof, chloropolymers, polybenzimidazole,
polyimides, polyamideimides, partially oxidized polyacrylonitriles,
novoloids, poly (p-phenylene benzobisoxazoles), poly (p-phenylene
benzothiazoles), polyphenylene sulfides, flame-retardant viscose
rayons, polyvinyl chloride homopolymers and copolymers thereof,
polyetheretherketones, polyketones, polyetherimides, polylactides,
and combinations thereof, and the like. These FR fibers may also be
blended with non-FR fibers, for example, to enhance the formation
of char on exposure to flame. These fibers can include those fibers
with an affinity for sublistatic dyes, but they constitute a much
smaller percentage of the fiber blend than contemplated in this
invention.
[0067] The core-spun yarn 100 may include a combination of the
sheath of non-fire retardant fibers 120 with an affinity for
sublistatic dyestuffs and the heat resistant core 110. The sheath
of fibers 120 may include, e.g., at least about 50% non-fire
retardant fibers, such as, e.g., 60%, 70%, or 80%.
[0068] The structure of the fabric may be engineered in such a way
as to concentrate the dye receptive warp yarns on the technical
face of the fabric, while concentrating the filling yarns
containing FR sheath fibers on the technical back of the fabric.
This technique may enable sublistatic printing of the technical
face with optimal color yield and image fidelity, as inherently FR
fibers resist sublilstatic dyestuffs under normal processing
conditions.
[0069] The structure of the fabric may be further engineered to
modify the surface texture of the fabric to mimic that of e.g.,
woven linen.
[0070] As shown in FIG. 1B, the heat stable core 110 may be
surrounded by the sheath of fibers 120. The perimeter formed by
fibers 120 may be partially open or may be fully enclosed.
[0071] FIG. 2 discloses an example of a flame barrier substrate
constructed according to principles of the disclosure. The flame
barrier substrate may include a woven substrate 200 such as, for
example, a twill weave. The woven substrate 200 may include a warp
yarn 210 and a filling yarn 220. The warp yarn 210 may include
non-fire retardant (non-FR) sheath fibers with an affinity for
sublistatic dyes. The filling yarn 220 may also include non-FR
fibers in its sheath; however, a weaving technique is disclosed
wherein filling yarns made with non-FR sheaths can be alternated
with core spun yarns made with FR fiber (or FR fiber blend)
sheaths. The warp yarn 210 may be more numerous than the filling
yarn 220 in order to make the dye receptive yarns more numerous
than non-dye receptive yarns. In one embodiment, the non-FR fibers
may include, e.g., up to 80% of the total fiber mass.
Alternatively, the warp yarn 210 may be equal to or less than the
amount of filling yarn 220, provided that the filling yarn 220 is
composed of non-FR dye-receptive fiber in its sheath and the
resultant fabric forces the filling yarns to the technical face. To
function as an aesthetic flame barrier, the dye receptive yarns
must predominate on one side of the substrate.
[0072] FIG. 3 shows an example photograph of a flame barrier
substrate constructed according to principles of the disclosure.
The flame barrier substrate includes a woven substrate 300 such as,
for example, a twill weave. While FIG. 3 shows the woven substrate
300 in 2/1 Left Hand Twill configuration, the woven substrate 300
may also include e.g., 1/1 plain weaves, 2/1 Right-Hand Twill
(RHT), oxford weaves, sateens, and so on. The woven substrate 300
may further include a warp yarn 310 and a filling yarn 320. In 2/1
LHT, the numerator indicates that the warp yarn 310 crosses over
two filling yarns 320 and then under one filling yarn 320. It is
noted that the texture imparted by the diagonal wales rising to the
left (typical of a 2/1 Left-Hand Twill (LHT) is a result of each
warp yarn's crossing two filling yarns in a stepwise sequence. As
shown in FIG. 3, the interlacing of the warp yarn 310 and the
filling yarn 320 may progress to the left, forming a set of
distinct ascending diagonal lines (i.e., wales).
Example 1
[0073] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 1.
TABLE-US-00001 TABLE 1 Test Results: Item Readings Limit Result
Maximum Rate of Heat 24 200 Met Release (kW) Total Heat Release in
10 3.19 15 Met minutes (MJ)
[0074] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed, or the development
of a fire of such size as to require suppression for the safety of
the facility. The test specimen was placed under the open
calorimeter and tested. At the time of testing, the ambient
temperature was 72.degree. F. with a relative humidity of 67%. The
data recorded includes Heath Release Rate (HRR) and Total Heat
Release (THR) as shown in FIGS. 4A and 4B.
[0075] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 20% of the cover was consumed. Internal Components:
0% consumed. Foundation: 0% consumed.
Mattress Barrier: Intact.
[0076] As a conclusion, the sample specimen met the requirements
set forth in the 16 CFR 1633, Standard for the Flammability (Open
Flame) of Mattresses Sets.
Example 2
[0077] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 4.
TABLE-US-00002 TABLE 4 Test Results: Item Readings Limit Result
Maximum Rate of Heat 29 200 Met Release (kW) Total Heat Release in
10 4.09 15 Met minutes (MJ)
[0078] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed, or the development
of a fire of such size as to require suppression for the safety of
the facility. The test specimen was placed under the open
calorimeter and tested. At the time of testing, the ambient
temperature was 72.degree. F. with a relative humidity of 58%. The
data recorded includes Heath Release Rate (HRR) and Total Heat
Release (THR) as shown in FIGS. 5A and 5B.
[0079] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 60% of the cover was consumed. Internal Components:
10% consumed. Foundation: 10% consumed.
Mattress Barrier: Intact.
[0080] As a conclusion, the sample specimen met the requirements
set forth in the 16 CFR 1633, Standard for the Flammability (Open
Flame) of Mattresses Sets.
Example 3
[0081] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 7.
TABLE-US-00003 TABLE 7 Test Results: Item Readings Limit Result
Maximum Rate of Heat 29 200 Met Release (kW) Total Heat Release in
10 5.43 15 Met minutes (MJ)
[0082] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed. The test specimen
was placed under the open calorimeter and tested. At the time of
testing, the ambient temperature was 71.degree. F. with a relative
humidity of 45%. The data recorded includes Heath Release Rate
(HRR) and Total Heat Release (THR) as shown in FIGS. 6A and 6B.
[0083] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 40% of the cover was consumed. Internal Components:
5% consumed. Foundation: 10% consumed.
Mattress Barrier: Intact.
[0084] The test specimen met the requirements set forth in the 16
CFR 1633, Standard for the Flammability (Open Flame) of Mattresses
Sets.
Example 4
[0085] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 10.
TABLE-US-00004 TABLE 10 Test Results: Item Readings Limit Result
Maximum Rate of Heat 28 200 Met Release (kW) Total Heat Release in
10 2.59 15 Met minutes (MJ)
[0086] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed, or the development
of a fire of such size as to require suppression for the safety of
the facility. The test specimen was placed under the open
calorimeter and tested. At the time of testing, the ambient
temperature was 68.degree. F. with a relative humidity of 51%. The
data recorded includes Heath Release Rate (HRR) and Total Heat
Release (THR) as shown in FIGS. 7A and 7B.
[0087] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 30% of the cover was consumed. Internal Components:
0% consumed. Foundation: 0% consumed.
Mattress Barrier: Intact.
[0088] The test specimen met the requirements set forth in the 16
CFR 1633, Standard for the Flammability (Open Flame) of Mattresses
Sets.
Example 5
[0089] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 13.
TABLE-US-00005 TABLE 13 Test Results: Item Readings Limit Result
Maximum Rate of Heat 22 200 Met Release (kW) Total Heat Release in
10 4.42 15 Met minutes (MJ)
[0090] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed, or the development
of a fire of such size as to require suppression for the safety of
the facility. The test specimen was placed under the open
calorimeter and tested. At the time of testing, the ambient
temperature was 68.degree. F. with a relative humidity of 58%. The
data recorded includes Heath Release Rate (HRR) and Total Heat
Release (THR) as shown in FIGS. 8A and 8B.
[0091] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 30% of the cover was consumed. Internal Components:
0% consumed. Foundation: 0% consumed.
Mattress Barrier: Intact.
[0092] The test specimen met the requirements set forth in the 16
CFR 1633, Standard for the Flammability (Open Flame) of Mattresses
Sets.
Example 6
[0093] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 16.
TABLE-US-00006 TABLE 16 Test Results: Item Readings Limit Result
Maximum Rate of Heat 25 200 Met Release (kW) Total Heat Release in
10 4.76 15 Met minutes (MJ)
[0094] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed, or the development
of a fire of such size as to require suppression for the safety of
the facility. The test specimen was placed under the open
calorimeter and tested. At the time of testing, the ambient
temperature was 70.degree. F. with a relative humidity of 55%. The
data recorded includes Heath Release Rate (HRR) and Total Heat
Release (THR) as shown in FIGS. 9A and 9B.
[0095] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 20% of the cover was consumed. Internal Components:
0% consumed. Foundation: 0% consumed.
Mattress Barrier: Intact.
[0096] The test specimen met the requirements set forth in the 16
CFR 1633, Standard for the Flammability (Open Flame) of Mattresses
Sets.
Example 7
[0097] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 19.
TABLE-US-00007 TABLE 19 Test Results: Item Readings Limit Result
Maximum Rate of Heat 25 200 Met Release (kW) Total Heat Release in
10 3.23 15 Met minutes (MJ)
[0098] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed, or the development
of a fire of such size as to require suppression for the safety of
the facility. The test specimen was placed under the open
calorimeter and tested. At the time of testing, the ambient
temperature was 72.degree. F. with a relative humidity of 56%. The
data recorded includes Heath Release Rate (HRR) and Total Heat
Release (THR) as shown in FIGS. 10A and 10B.
[0099] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 20% of the cover was consumed. Internal Components:
0% consumed. Foundation: 10% consumed.
Mattress Barrier: Intact.
[0100] The test specimen met the requirements set forth in the 16
CFR 1633, Standard for the Flammability (Open Flame) of Mattresses
Sets.
Example 8
[0101] A flammability test for requirements set forth in the 16 CFR
1633 on a non-limiting example of a flame barrier substrate with
flame-retardant properties and affinity for sublistatic dyes (the
"test specimen") is shown in Table 22.
TABLE-US-00008 TABLE 22 Test Results: Item Readings Limit Result
Maximum Rate of Heat 20 200 Met Release (kW) Total Heat Release in
10 1.84 15 Met minutes (MJ)
[0102] The test specimen consisted of a single sided tight top
mattress with bed base. The test specimen, after conditioning for
not less than 48 hours, to 70.degree. F. and 50% R.H., was placed
underneath the collection hood. The test was started no more than
20 minutes after removal from the conditioning chamber. The
specified pair of propane test burners was placed on the top panel
and border as specified in the test protocol. The computer data
acquisition system was started. After one minute of ambient data
acquisition, the burners were ignited and left to burn for 70
seconds (top) and 50 seconds (border). After both burners were out
the top burner was lifted and pinned and the apparatus was backed
away from the specimen. The test was allowed to proceed until
either all combustion ceased, 30 minutes passed, or the development
of a fire of such size as to require suppression for the safety of
the facility. The test specimen was placed under the open
calorimeter and tested. At the time of testing, the ambient
temperature was 68.degree. F. with a relative humidity of 55%. The
data recorded includes Heath Release Rate (HRR) and Total Heat
Release (THR) as shown in FIGS. 11A and 11B.
[0103] After cooling, the mattress was observed to be damaged as
follows:
Mattress Cover: 30% of the cover was consumed. Internal Components:
0% consumed. Foundation: 0% consumed.
Mattress Barrier: Intact.
[0104] The test specimen met the requirements set forth in the 16
CFR 1633, Standard for the Flammability (Open Flame) of Mattresses
Sets.
[0105] A flame barrier substrate with flame-retardant properties
and affinity for sublistatic dyes as described herein, may disrupt
the progress of fire by accomplishing one of the following:
[0106] (1) Physically block the advance of the flame front by
establishing and maintaining a char barrier that isolates the
combustible material within the barrier envelope.
[0107] (2) Restrict or otherwise limit the flow of air into the
barrier envelope to help deprive the incipient fire of oxygen.
[0108] (3) Reduce the temperature at the flame front through the
emission of vapor-phase flame retardants that capture free radicals
at the flame front.
[0109] The "fire triangle" is used to describe the three components
necessary for self-propagating combustion which are heat, fuel and
oxygen. The disruption stated above may be accomplished through
breaking one or more sides of the fire triangle. It is noted that
an effective barrier does not have to provide all three functions
to serve as a flame barrier.
[0110] A flame barrier substrate with flame-retardant properties
and affinity for sublistatic dyes as described herein, may be used
in a variety of ways including, but not limited to, mattress
tickings, mattress border fabric, bedspreads, furniture, upholstery
fabric, and so on. The flame barrier substrate seeks to address
limitations inherent in prior arts in the following ways:
[0111] A flame barrier substrate that can be heat transfer printed
[0112] Heat transfer printing is the most agile printing
technology. In this technology, run size has a negligible effect on
cost, but heat transfer printing is significantly more
cost-effective than screen printing for short runs.
[0113] A flame barrier substrate that can be printed to order
[0114] The proposed invention can be produced in large lots at the
point of fabric formation and differentiated closer to the point of
sale by print pattern, color or design according to the customer's
preferences and yardage requirements [0115] This reduces fashion
obsolescence risk and waste while decreasing lead time
[0116] Greater design flexibility [0117] Near-infinite color and
design possibilities [0118] Optical effects (e.g., trompe l'oeil)
to create the appearance of texture [0119] Rapid style changes with
minimal waste
[0120] A higher perceived value versus quilted laminates and or
stitchbonds [0121] Woven fabrics are regarded as more permanent
than nonwovens. [0122] Heavier base weight and denser appearance
conveys premium quality
[0123] A flame barrier that has increased char strength--compared
to previous solutions --after exposure to flame [0124] Burst
strength after 60 second exposure to NIST burner was 50 lbs. PSI
[0125] Equal to burst strength of lighter weight knits prior to
exposure. [0126] Much lower propensity for cracking or breaching
during or after flame exposure
[0127] A flame barrier composed primarily of non-FR fibers--a
minimum 60% of content to be non-FR fiber
[0128] A tightly constructed flame barrier made substantially from
core-spun yarns whose sheath fibers melt, flow, and congeal on
exposure to flame thereby filling interstices (i.e., the spaces
between yarns) resulting in a char with decreased air
permeability
[0129] A result of air permeability testing on the non-limiting
examples of a flame barrier substrate (e.g., core-spun yarns) is as
follows:
TABLE-US-00009 Sample# and Identification: 1-C-11/1 R11 42 ppi
2-C-11/1 R11 44 ppi 3-C-11/1 R11 46 ppi 4-C-11/1 R11 48 ppi
5-C-11/1 R11 50 ppi Item Description Units 1 2 3 4 5 Weight (osy)
oz/yd.sup.2 7.28 7.36 7.52 7.68 7.84 Air Permeability (cfm) 92.0
82.0 69.0 60.3 52.7 Air Permeability After (cfm) -- 56 -- 56 --
Burn Flammability 603 (Small Pass/Fail Pass Pass Pass Pass Pass
Scale)
[0130] As shown in Samples 2 and 4 above, the air permeablities
were assessed prior to and following exposure to flame.
[0131] It is also noted that some core-spun filling yarns may be
eliminated if the barrier structure of a flame barrier substrate
can be maintained without them. Additionally, some of the core-spun
yarns may be replaced with non-core yarns as a method of reducing
cost. The technical face yarns may include fibers with an affinity
for sublistatic dyes. Filling yarns may include the same yarns or
blends of dye receptive and functional fire-retardant (FR) fibers.
Anyone familiar with weaving techniques would recognize that there
are other warp-face constructions aside from twill weaves (as shown
in, e.g., FIG. 2) that may be used to realize the goal of
concentrating the dye-receptive yarns on the technical face of the
fabric.
[0132] 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.
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