U.S. patent application number 16/528749 was filed with the patent office on 2021-02-04 for fabrics for flame retardation.
The applicant listed for this patent is Precision Textiles, LLC. Invention is credited to Aneta Konior, Peter Longo, Christopher Keith Martin.
Application Number | 20210032802 16/528749 |
Document ID | / |
Family ID | 1000004247579 |
Filed Date | 2021-02-04 |
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United States Patent
Application |
20210032802 |
Kind Code |
A1 |
Martin; Christopher Keith ;
et al. |
February 4, 2021 |
Fabrics for Flame Retardation
Abstract
A flame-retardant fabric comprises a textile substrate having a
layer of an aluminum material extending along a surface of the
textile substrate and integrated with the textile substrate.
Inventors: |
Martin; Christopher Keith;
(Wayne, NJ) ; Konior; Aneta; (Oak Ridge, NJ)
; Longo; Peter; (Saddle River, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Precision Textiles, LLC |
Totowa |
NJ |
US |
|
|
Family ID: |
1000004247579 |
Appl. No.: |
16/528749 |
Filed: |
August 1, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06M 11/83 20130101;
D04H 1/425 20130101; D06M 2200/30 20130101 |
International
Class: |
D06M 11/83 20060101
D06M011/83; D04H 1/425 20060101 D04H001/425 |
Claims
1. A flame-retardant fabric, comprising a non-woven textile
substrate consisting of cellulosic fibers and thermoplastic
polymeric fibers, the substrate having first and second filamentous
surfaces opposite each other, each of the first and second
filamentous surfaces having a plurality of the cellulosic fibers
and thermoplastic polymeric fibers projecting therefrom, and
further having interstices among the projecting fibers of the first
and second filamentous surfaces, wherein the first filamentous
surface of the substrate has a first non-intumescent coating
consisting of a solvent, a latex binder and aluminum particles and
optionally a wetting agent, a surfactant and a pigment stabilizer,
the first non-intumescent coating being distinct from the substrate
and extends along the first filamentous surface and into the
interstices thereof, whereby the first non-intumescent coating is
integrated with the substrate, and the flame-retardant fabric does
not have added flame-retardant chemistry.
2. The flame-retardant fabric of claim 1, wherein the second
filamentous surface of the textile substrate has a second
non-intumescent coating consisting of a solvent, a latex binder and
aluminum particles and optionally a wetting agent, a surfactant and
a pigment stabilizer, the second non-intumescent coating being
distinct from the substrate and extends along the second
filamentous surface and into the interstices thereof, whereby the
second intumescent coating is integrated with the substrate.
3. The flame retardant fabric of claim 2, wherein the solvent of
the first non-intumescent coating and the solvent of the second
non-intumescent coating are each water.
4. The flame-retardant fabric of claim 1, wherein the aluminum
particles are present in the flame-retardant fabric in an amount in
the range of about 0.005% to about 20% by weight of the
flame-retardant fabric.
5. The flame-retardant fabric of claim 1, wherein the aluminum
particles are present in the flame-retardant fabric in an amount in
the range of about 0.005% to about 10% by weight of the
flame-retardant fabric.
6. The flame-retardant fabric of claim 1, wherein the aluminum
particles are present in the flame-retardant fabric in an amount in
the range of about 1% to about 5% by weight of the flame-retardant
fabric.
7. The flame-retardant fabric of claim 1, wherein the aluminum
particles are present in the flame-retardant fabric in an amount in
the range of about 1% to about 3% by weight of the flame-retardant
fabric.
8. The flame retardant fabric of claim 1, wherein the fabric has a
weight in the range of 2 through 8 ounces per square yard.
9. The flame retardant fabric of claim 1, wherein the fabric has a
weight in the range of about 3.4 to about 3.6 ounces per square
yard.
10. The flame retardant fabric of claim 1, wherein the solvent is
water.
11. A method of making a flame-retardant fabric of claim 1, the
method comprising the steps of: providing the textile substrate;
providing the first intumescent coating as a flowable coating
material including the aluminum particles in an amount in the range
of about 1% to about 30% by weight of the flowable coating
material; and applying the flowable coating material to the first
surface of the textile substrate such that the flowable coating
material forms the first intumescent coating.
12. The method of claim 11, wherein the applying step is performed
using a foam coating process.
13. The method of claim 11, wherein the applying step is performed
using a spray-coating process.
14. The method of claim 11, wherein the applying step is performed
using a dip coating process.
15. The method of claim 11, wherein the applying step is performed
using a slot coating process.
16. The method of claim 11, wherein the applying step includes the
step of driving off the liquid carrier from the first coating.
17. A flame-retardant fabric, comprising a non-woven textile
substrate having cellulosic fibers and thermoplastic polymeric
fibers, the substrate having first and second filamentous surfaces
opposite each other, each of the first and second filamentous
surfaces having a plurality of the cellulosic fibers and
thermoplastic polymeric fibers projecting therefrom, and further
having interstices among the projecting fibers of the first and
second filamentous surfaces, wherein the first filamentous surface
of the substrate has a first non-intumescent coating comprising a
solvent, a latex binder and aluminum particles, the first
non-intumescent coating being distinct from the substrate and
extends along the first filamentous surface and into the
interstices thereof, whereby the first non-intumescent coating is
integrated with the substrate, and the flame-retardant fabric does
not have added flame-retardant chemistry.
18. A method of making a flame-retardant fabric of claim 1, the
method comprising the steps of: providing the textile substrate;
providing the first intumescent coating as a flowable coating
material including the aluminum particles in an amount in the range
of about 1% to about 30% by weight of the flowable coating
material; and applying the flowable coating material to the first
surface of the textile substrate such that the flowable coating
material forms the first intumescent coating.
19. A flame-retardant fabric, comprising a non-woven textile
substrate having cellulosic fibers, the substrate having first and
second filamentous surfaces opposite each other, each of the first
and second filamentous surfaces having a plurality of the
cellulosic fibers projecting therefrom, and further having
interstices among the projecting fibers of the first and second
filamentous surfaces, wherein the first filamentous surface of the
substrate has a first non-intumescent coating comprising a solvent,
a latex binder and aluminum particles, the first non-intumescent
coating being distinct from the substrate and extends along the
first filamentous surface and into the interstices thereof, whereby
the first non-intumescent coating is integrated with the substrate,
and the flame-retardant fabric does not have added flame-retardant
chemistry.
20. A flame-retardant fabric, comprising a non-woven textile
substrate having thermoplastic polymeric fibers, the substrate
having first and second filamentous surfaces opposite each other,
each of the first and second filamentous surfaces having a
plurality of the thermoplastic polymeric fibers projecting
therefrom, and further having interstices among the projecting
fibers of the first and second filamentous surfaces, wherein the
first filamentous surface of the substrate has a first
non-intumescent coating comprising a solvent, a latex binder and
aluminum particles, the first non-intumescent coating being
distinct from the substrate and extends along the first filamentous
surface and into the interstices thereof, whereby the first
non-intumescent coating is integrated with the substrate, and the
flame-retardant fabric does not have added flame-retardant
chemistry.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to the field of
flame-resistant fabrics, and, more specifically, to enhancements
for improving the flame resistance of such fabrics and the flame
resistance of items incorporating such fabrics.
BACKGROUND OF THE INVENTION
[0002] Each year, thousands of residential fires are caused in the
United States by the ignition of mattresses and bedding, resulting
in hundreds of deaths and hundreds of millions of dollars in
property losses. Heightened awareness of fire prevention has led to
the development of standards and regulations directed to the
reducing the likelihood that such fires will occur. One approach to
reducing the likelihood of residential fires is to use
flame-resistant fabrics as flame barriers in mattresses and
bedding.
SUMMARY OF THE INVENTION
[0003] A first embodiment of the present invention includes textile
fibers modified by incorporation of aluminum particles into the
matrix of the fibers. In such an embodiment, the fibers may
incorporate inherently flame-resistant polymers and/or cellulosic
materials.
[0004] A second embodiment of the present invention includes
methods of incorporating aluminum particles into textile fibers. In
such an embodiment, the aluminum particles may be mixed into a
flowable polymer or solution of polymeric precursors, which is then
extruded to form the aluminum-modified fibers.
[0005] A third embodiment of the present invention includes a woven
or non-woven textile fabric modified by application to the fabric
of a flowable coating material that includes aluminum. In such an
embodiment, the flowable coating material may include a latex
binder and the aluminum as a suspension.
[0006] A fourth embodiment of the present invention is a coating
material for textiles that includes aluminum particles. In such an
embodiment, the coating material includes the aluminum particles
and a latex binder in a suspension.
[0007] A fifth embodiment of the present invention includes a woven
or non-woven textile fabric that includes textile threads
incorporating aluminum, the fabric also having a coating that
includes aluminum particles. In such an embodiment, the fabric may
be a filler cloth for a mattress.
[0008] A sixth embodiment of the present invention includes an
article of manufacture incorporating a textile fabric of the
present invention. In such an embodiment, the article may be a
mattress.
[0009] In an embodiment, a flame-retardant fabric, comprises a
non-woven textile substrate consisting of cellulosic fibers and
thermoplastic polymeric fibers, the substrate having first and
second filamentous surfaces opposite each other, each of the first
and second filamentous surfaces having a plurality of the
cellulosic fibers and thermoplastic polymeric fibers projecting
therefrom, and further having interstices among the projecting
fibers of the first and second filamentous surfaces, wherein the
first filamentous surface of the substrate has a first
non-intumescent coating consisting of a solvent, a latex binder and
aluminum particles and optionally a wetting agent, a surfactant and
a pigment stabilizer, the first non-intumescent coating being
distinct from the substrate and extends along the first filamentous
surface and into the interstices thereof, whereby the first
non-intumescent coating is integrated with the substrate, and the
flame-retardant fabric does not have added flame-retardant
chemistry.
[0010] In an embodiment, the second filamentous surface of the
textile substrate has a second non-intumescent coating consisting
of a solvent, a latex binder and aluminum particles and optionally
a wetting agent, a surfactant and a pigment stabilizer, the second
non-intumescent coating being distinct from the substrate and
extends along the second filamentous surface and into the
interstices thereof, whereby the second intumescent coating is
integrated with the substrate. In an embodiment, the solvent of the
first non-intumescent coating and the solvent of the second
non-intumescent coating are each water. In an embodiment, the
aluminum particles are present in the flame-retardant fabric in an
amount in the range of about 0.005% to about 20% by weight of the
flame-retardant fabric. In an embodiment, the aluminum particles
are present in the flame-retardant fabric in an amount in the range
of about 0.005% to about 10% by weight of the flame-retardant
fabric. In an embodiment, the aluminum particles are present in the
flame-retardant fabric in an amount in the range of about 1% to
about 5% by weight of the flame-retardant fabric. In an embodiment,
the aluminum particles are present in the flame-retardant fabric in
an amount in the range of about 1% to about 3% by weight of the
flame-retardant fabric.
[0011] In an embodiment, the fabric has a weight in the range of 2
through 8 ounces per square yard. In an embodiment, the fabric has
a weight in the range of about 3.4 to about 3.6 ounces per square
yard. In an embodiment, the solvent is water.
[0012] In an embodiment, a method of making a flame-retardant
fabric above, the method comprising the steps of: providing the
textile substrate; providing the first intumescent coating as a
flowable coating material including the aluminum particles in an
amount in the range of about 1% to about 30% by weight of the
flowable coating material; and applying the flowable coating
material to the first surface of the textile substrate such that
the flowable coating material forms the first intumescent coating.
In an embodiment, the applying step is performed using a foam
coating process. In an embodiment, the applying step is performed
using a spray-coating process. In an embodiment, the applying step
is performed using a dip coating process. In an embodiment, the
applying step is performed using a slot coating process. In an
embodiment, the applying step includes the step of driving off the
liquid carrier from the first coating.
[0013] In an embodiment, a flame-retardant fabric comprises a
non-woven textile substrate having cellulosic fibers and
thermoplastic polymeric fibers, the substrate having first and
second filamentous surfaces opposite each other, each of the first
and second filamentous surfaces having a plurality of the
cellulosic fibers and thermoplastic polymeric fibers projecting
therefrom, and further having interstices among the projecting
fibers of the first and second filamentous surfaces, wherein the
first filamentous surface of the substrate has a first
non-intumescent coating comprising a solvent, a latex binder and
aluminum particles, the first non-intumescent coating being
distinct from the substrate and extends along the first filamentous
surface and into the interstices thereof, whereby the first
non-intumescent coating is integrated with the substrate, and the
flame-retardant fabric does not have added flame-retardant
chemistry.
[0014] In an embodiment, a flame-retardant fabric, comprises a
non-woven textile substrate having cellulosic fibers, the substrate
having first and second filamentous surfaces opposite each other,
each of the first and second filamentous surfaces having a
plurality of the cellulosic fibers projecting therefrom, and
further having interstices among the projecting fibers of the first
and second filamentous surfaces, wherein the first filamentous
surface of the substrate has a first non-intumescent coating
comprising a solvent, a latex binder and aluminum particles, the
first non-intumescent coating being distinct from the substrate and
extends along the first filamentous surface and into the
interstices thereof, whereby the first non-intumescent coating is
integrated with the substrate, and the flame-retardant fabric does
not have added flame-retardant chemistry.
[0015] In an embodiment, a flame-retardant fabric, comprises a
non-woven textile substrate having thermoplastic polymeric fibers,
the substrate having first and second filamentous surfaces opposite
each other, each of the first and second filamentous surfaces
having a plurality of the thermoplastic polymeric fibers projecting
therefrom, and further having interstices among the projecting
fibers of the first and second filamentous surfaces, wherein the
first filamentous surface of the substrate has a first
non-intumescent coating comprising a solvent, a latex binder and
aluminum particles, the first non-intumescent coating being
distinct from the substrate and extends along the first filamentous
surface and into the interstices thereof, whereby the first
non-intumescent coating is integrated with the substrate, and the
flame-retardant fabric does not have added flame-retardant
chemistry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For a more complete understanding of the present invention,
reference is made to the following detailed description of
exemplary embodiments considered in conjunction with the
accompanying drawings, in which:
[0017] FIG. 1 illustrates cross-sections of aluminum-modified
textile fibers according to an embodiment of the present
invention;
[0018] FIG. 2 illustrates another cross-section of an
aluminum-modified textile fiber according to the embodiment of FIG.
1;
[0019] FIG. 3 is a schematic process diagram of the burning
behavior of an aluminum-modified fiber of the same general type as
the fiber of FIG. 1;
[0020] FIG. 4 is a schematic cross-sectional diagram of a mattress
constructed in accordance with an embodiment of the present
invention;
[0021] FIG. 5 is a schematic fragmentary view of a portion 5 of the
mattress of FIG. 4;
[0022] FIG. 6 is a diagrammatic depiction of an apparatus
conducting a method of manufacture of a high-loft fabric fire
barrier constructed in accordance with the present invention;
[0023] FIG. 7 is an enlarged, fragmentary cross-sectional view
taken along line 7-7 of FIG. 6;
[0024] FIG. 8 is a further enlarged fragmentary cross-sectional
view of a portion of FIG. 7, designated by arrow 8 in FIG. 7;
[0025] FIG. 9 is a diagrammatic, fragmentary view taken in the
direction of arrow 9 in FIG. 6; and
[0026] FIG. 10 is an enlarged, fragmentary cross-sectional view
taken along line 10-10 of FIG. 6.
DETAILED DESCRIPTION OF THE DRAWINGS
[0027] An embodiment of the present invention includes textiles and
textile fibers modified by incorporation of aluminum particles into
the matrix of the fibers. One embodiment of the present invention
includes an aluminum-modified textile fiber. In such an embodiment,
the textile fiber is an extruded fiber, such as viscose rayon.
Referring to FIGS. 1 and 2, aluminum-modified textile fibers 10
according to an embodiment of the present invention have aluminum
particles 12 distributed throughout the fiber matrix 14.
[0028] In a method of making such fibers, according to an
embodiment of the present invention, the aluminum particles may be
mixed or dispersed into a flowable polymer or solution of polymeric
precursors, which is then extruded to form the aluminum-modified
fibers. Conventional extrusion methods or modifications of
conventional extrusion methods may be used to form the fibers. In
an embodiment of the present invention, the flowable polymer is
cellulose of a type used to make viscose rayon. In an exemplary
embodiment, the aluminum content of the fiber is no more than 80%
w/w. In an exemplary embodiment, the aluminum content of the fiber
is in the range of about 60% w/w to about 70% w/w. In an exemplary
embodiment, the fiber is a viscose rayon fiber. In an embodiment,
the aluminum particles each have a particle size in a range of
about 10 microns to about 200 microns. In an embodiment, the
aluminum particles each have a particle size in a range of about 20
microns to about 200 microns. In an embodiment, the aluminum
particles each have a particle size in a range of about 30 microns
to about 200 microns. In an embodiment, the aluminum particles each
have a particle size in a range of about 40 microns to about 200
microns. In an embodiment, the aluminum particles each have a
particle size in a range of about 50 microns to about 200 microns.
In an embodiment, the aluminum particles each have a particle size
in a range of about 100 microns to about 200 microns. In an
embodiment, the aluminum particles each have a particle size in a
range of about 150 microns to about 200 microns. In an embodiment,
the aluminum particles each have a particle size in a range of
about 100 microns to about 200 microns. In an embodiment, the
aluminum particles each have a particle size in a range of about 50
microns to about 100 microns.
[0029] FIG. 3 is a schematic process diagram of the burning
behavior of an aluminum-modified fiber 16 according to an
embodiment of the present invention. The fiber 16 comprises
aluminum particles 18 in a cellulosic matrix 20. As a conventional
cellulosic fiber (not shown) burns, it generally forms a char and
releases gaseous decomposition products. When the aluminum-modified
fiber 16 is ignited, the aluminum particles 18 migrate from the
degraded matrix 20 to the fiber surfaces 22, 24, forming barriers
26, 28 to mass and heat transport. The aluminum-filled barrier 26,
28 itself is non-combustible, and provides structural reinforcement
to the charred fiber 16.
[0030] Another embodiment of the present invention includes a woven
or non-woven textile fabric modified by application of an
aluminum-filled coating material to the fabric. FIG. 4 illustrates
an arrangement of fabrics used in a non-flip mattress 30 in a
schematic cross-sectional view. The non-flip mattress 30 includes a
non-fabric core 32, which may be of any known type used in non-flip
mattresses in general or of types yet to be developed. The core 32
is surrounded by mattress ticking 34, which may be of any known
type, and a filler cloth 36 including a textile fabric according to
an embodiment of the present invention. A fabric fire barrier 38 is
provided between the ticking 34 and core 32. In mattresses
according to embodiments of the present invention, one or both of
the filler cloth 36 and the fabric fire barrier 38 are
fire-resistant fabrics according to embodiments of the present
invention. Further, the arrangement of fabrics in the mattress of
FIG. 4 and similarly-arranged mattresses according to embodiments
of the present invention may be readily adapted to reversible
mattresses (not shown) in arrangements understood in the prior art
or yet to be developed. Yet further, filler cloths or fabric fire
barriers such as those shown in FIGS. 4 and 5, or discussed
elsewhere herein, may be used in other household furnishings (e.g.,
without limitation, mattress foundations or upholstered furniture)
in arrangements known in the art.
[0031] FIG. 5 is a detail of the filler cloth 36, which is an
embodiment of the fire-resistant fabric of the present invention.
The filler cloth 36 includes a textile substrate 40, and upper and
lower coatings 42, 44, each of which extends along a respective
surface of the textile substrate 40 and is integrated with the
textile substrate 40. In embodiments of the present invention, the
upper coating 42 and/or the lower coating 44 each extends along a
respective surface of the textile substrate 40 and is integrated
with the textile substrate 40. Filler cloth 36 is an exemplary
embodiment of the flame-retardant fabrics of the present invention,
which also include fire barriers, such as fire barrier 38, and
other coated flame-retardant fabrics.
[0032] In embodiments of the present invention, the textile
substrate 40 includes a woven or non-woven textile containing at
least cellulosic fibers (not shown). The cellulosic fibers may be
fire-resistant cellulosic fibers, such as fire-resistant rayon
(e.g., viscose) fibers, or non-fire-resistant cellulosic fibers.
Fire-resistant aluminum-modified fibers according to embodiments of
the present invention are one of the types of fire-resistant fibers
that may be used in the fire-resistant fabric of the present
invention. Other types of fire-resistant fibers known in the art
may also be used in the fire-resistant fabric of the present
invention, including, without limitation, silica-modified fibers,
chemically-treated fibers, polyester fibers, and thermoplastic
polymeric fibers. In an embodiment, the textile substrate 40 is a
blend of cellulosic fibers and thermoplastic polymeric fibers. In
an embodiment, the cellulosic fibers constitute from about 60% to
about 90% of the textile substrate 40, with the balance of the
textile substrate being thermoplastic polymer fibers. In an
embodiment, the textile substrate 40 is one of a 60/40 blend, a
65/35 blend, a 70/30 blend, a 75/25 blend, an 80/20 blend, an 85/25
blend, and a 90/10 blend of cellulosic fibers/thermoplastic fibers.
The selection and manufacture of appropriate textile substrates for
use in the present invention will be understood by those having
ordinary skill in the art and possession of the present
disclosure.
[0033] In embodiments of the present invention, the coatings 42, 44
are latex coatings filled with aluminum particles 46. In other
embodiments of the present invention (not shown), one of the upper
and lower coatings 42, 44 contains aluminum particles 46 and the
other does not. In yet other embodiments of the present invention,
the filler cloth 36 has only an upper coating 42 or a lower coating
44.
[0034] In embodiments of the present invention, the coatings 42, 44
are applied to the textile substrate 40 as flowable coating
materials. In embodiments of the present invention, such flowable
coating materials include a solvent (e.g., water), a binder (e.g.,
a latex binder), and aluminum particles. In some embodiments, the
flowable coating materials further include a pigment. In some
embodiments, the flowable coating materials further include
auxiliary chemistries, such as wetting agents, surfactants, or
pigment stabilizers. The selection and use of appropriate solvents,
binders, pigments, and auxiliary chemistries will be understood by
those having ordinary skill in the art and possession of the
present disclosure.
[0035] In embodiments of the present invention, the flowable
coating material has a composition in which the aluminum is present
in the coating material in the range of about 1% to about 30% by
weight. In some embodiments, the aluminum is present in the
flowable coating material in range of about 10% to about 20% by
weight. Workable flowable coating materials include from about 10%
to about 20% aluminum by weight in an aqueous suspension with about
5% acrylic latex as a binder. The total solids content of such
workable coating materials is roughly 50% w/w. The foregoing
amounts of aluminum, binder, and other solids may be varied without
departing from the scope and spirit of the invention, as will be
understood by those having ordinary skill in the art and possession
of the present disclosure.
[0036] Continuing to refer to FIG. 5, in embodiments of the present
invention, the flowable coating material is applied to the textile
substrate 40 to form the coatings 42, 44. The flowable coating
material may be applied to the textile substrate 40 by one or more
of processes known in the art or yet to be developed for applying
flowable materials to sheets. Such methods include, without
limitation, dip coating processes, spray coating processes, slot
coating processes, and foam coating processes. Foam coating
processes have been found to be particularly effective in applying
the coating materials of the present invention to textiles. In an
embodiment, the flowable coating material includes a liquid
carrier, and the liquid carrier is driven off from the coatings 42,
44 after the flowable coating material is applied to the textile
substrate.
[0037] In exemplary embodiments of the present invention, the
aluminum is present in the filler cloth 36 in an amount of about
20% by weight of the filler cloth 36. In exemplary embodiments of
the present invention, the aluminum is present in the filler cloth
36 in an amount in the range of about 0.005% about 20% by weight of
the filler cloth 36. In exemplary embodiments of the present
invention, the aluminum is present in the filler cloth 36 in an
amount in the range of about 0.005% to about 10% by weight of the
filler cloth 36. In exemplary embodiments of the present invention,
the aluminum is present in the filler cloth 36 in an amount in the
range of about 1% to about 3% by weight of the filler cloth 36,
although, in some embodiments, the aluminum is present in the
filler cloth 36 in an amount of up to about 5% of the filler cloth
36. The amounts of coating material and/or aluminum added to the
textile may be varied without departing from the scope and spirit
of the invention, as will be understood by those having ordinary
skill in the art and possession of the present disclosure. In an
embodiment of the present invention, the coated fabric has a weight
in the range of 2 ounces per square yard to 8 ounces per square
yard.
[0038] Referring now to FIGS. 6 through 10, manufacture of fire
barrier 120 in accordance with the present invention is depicted
diagrammatically in FIG. 6 wherein it is seen that a blend of
non-woven inherently flame retardant cellulosic fibers and
thermoplastic polymeric fibers in the form of a continuous batt 140
is advanced through an apparatus 142, from a supply roll 143, into
an oven 144 where the blend of fibers within batt 140 is bound into
a high-loft fabric that emerges from the oven 144 in the form of a
sheet 16 that includes opposite filamentous surfaces 148. As best
seen in FIGS. 7 and 8, the filamentous nature of surfaces 148 is a
result of fibers of the batt 140 projecting from the batt 140 in
the form of a multitude of filaments 150, with interstices 152
between the filaments 150.
[0039] Apparatus 142 includes a supply 160 of a dispersion 162 of
finely divided aluminum material dispersed within a liquid carrier,
the preferred liquid being water. The sheet 146 is passed to a
station 170 where dispersion 162 is applied to each surface 148 of
sheet 146, preferably through respective banks 172 of spray heads
174 which direct a fine mist spray 176 to each corresponding
surface 148, as seen in FIG. 9. The fine mist spray 176 assures
that the dispersion 162 enters the interstices 152 between the
filaments 150 or sheet 146.
[0040] Upon leaving station 170, sheet 146 is directed back into
oven 144 where the liquid carrier of the dispersion 162 within the
interstices 152 is driven off, leaving aluminum material deposited
within the interstices 152 to be integrated with the sheet 146, in
a layer 180 of aluminum material extending along each surface 148
of the sheet 146, as seen in FIG. 10. The sheet 146 is then ready
for dividing into appropriately dimensioned fire barriers 38 in
which layers 42, 44 of aluminum material extend along the
corresponding upper and lower surfaces of the substrate 40, and are
integrated with the substrate 40. The layers 42, 44 of aluminum
material provide the fire barrier 38 with lowered thermal
transmission properties as compared to previous fabric fire
barriers. In addition, by filling the interstices with aluminum
material, the filamentous nature of the surfaces of the substrate
40 is substantially reduced, and preferably eliminated, producing a
concomitant reduction in flame propagation across the completed
fire barrier 38.
[0041] It will be seen that the present invention attains all of
the objects and advantages summarized above, namely: establishes
enhanced flame retardant characteristics in high-ion fabric fire
barriers constructed of non-woven inherently flame retardant
fibers; provides high-loft fabric fire barriers of exceptional
strength, durability and superior flame retardant characteristics;
enables the economical manufacture of high-loft fabric fire
barriers that exhibit exemplary performance, especially in the
construction of mattresses, as well as in domestic bedding and
upholstered items; utilizes inherently flame retardant fibers
together with aluminum material for attaining enhanced flame
retardant characteristics for exemplary flame retardant performance
in the nature of lower thermal transfer and reduced flame
propagation, coupled with durability and strength, together with
desirable physical characteristics, without the necessity for
additional coating operations, or otherwise adding flame retardant
chemistry, in order to attain requisite flame retardant properties;
simplifies the manufacture of fabric fire barriers exhibiting a
high degree of flame retardant performance, utilizing relatively
simple, conventional manufacturing techniques; provides highly
reliable flame retardant performance in high-loft fabric fire
barriers and the like, intended for rugged, long-term service;
provides a mattress construction that exhibits enhanced flame
retardant characteristics; makes available a wide variety of
economical fabric fire barriers for exemplary performance over an
extended service life.
[0042] Further embodiments of coated filler cloths and other coated
textile fabrics according to the present invention, as well as
articles of manufacture incorporating such coated textile fabrics,
are disclosed in U.S. Pat. No. 9,469,935, which is incorporated by
reference herein in its entirety.
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