Light weight nonwoven fire retardant barrier

• US 20060093870A1
• Filed: 11/02/2004
• Published: 05/04/2006
• Est. Priority Date: 11/02/2004
• Status: Active Grant

• Current Assignee: Wm. T. Burnett Ip, LLC
• Original Assignee: WM T Burnett Operating LLP
• Inventors: Davis, Greg
• Granted Patent: US 7,410,920 B2
• Time in Patent Office: Days
• US Class Current: 442/334
• CPC Class Codes: A47C 31/001 Fireproof means
• CPC Class Codes: D04H 1/4209 Inorganic fibres
• CPC Class Codes: D04H 1/425 Cellulose series
• CPC Class Codes: D04H 1/4258 Regenerated cellulose series
• CPC Class Codes: D04H 1/4266 Natural fibres not provided for in group D04H1/425
• CPC Class Codes: D04H 1/43828 sheath-core
• CPC Class Codes: D04H 1/43835 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/48 in combination with at least one other method of consolidation
• CPC Class Codes: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 1/74 the fibres being orientated, e.g. in parallel (anisotropic fleeces)
• CPC Class Codes: Y10S 428/92 Fire or heat protection feature
• CPC Class Codes: Y10S 428/921 Fire or flameproofing
• CPC Class Codes: Y10T 442/608 Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/614 Strand or fiber material specified as having microdimensions [i.e., microfiber]
• CPC Class Codes: Y10T 442/619 Including other strand or fiber material in the same layer not specified as having microdimensions
• CPC Class Codes: Y10T 442/621 Including other strand or fiber material in a different layer not specified as having microdimensions
• CPC Class Codes: Y10T 442/696 Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/697 Containing at least two chemically different strand or fiber materials

Abstract

A non-woven flame retardant barrier can be prepared from low denier, charring fibers and substantially free of polymers made from halogenated monomers. The charring fibers can be modified viscose fibers, for example Visil®. The blend of low denier fibers can be, for example, a blend of 1.5 denier fibers and 3.0 denier fibers.

Claims

1. A non-woven flame retardant barrier comprising low denier, charring fibers and substantially free of polymers made from halogenated monomers.

2. The non-woven of claim 1, wherein the charring fibers comprise modified viscose fibers.

3. The nonwoven of claim 2, wherein the modified viscose fibers comprise Visil®

.

4. The nonwoven of claim 1, wherein the charring fibers comprise more than about 50% of the formulation.

5. The nonwoven of claim 1, wherein less than about 10% of the polymers are made from halogenated monomers, not including any binder in the formulation.

6. The nonwoven of claim 2, wherein modified viscose accounts for more than about 85% of the charring fibers, not including any binder in the formulation.

7. The nonwoven of claim 1, having a basis weight of about 0.2 to about 1.0 osf.

8. The nonwoven of claim 1, having a basis weight of about 0.5 osf or less.

9. The nonwoven of claim 1, comprising a blend of low and higher denier fibers.

10. The nonwoven of claim 1, comprising a fiber of a denier of about 7 or more, and a fiber having a denier of about 3 or less.

11. The nonwoven of claim 1, comprising a blend of fibers of varying deniers.

12. The nonwoven of claim 1, comprising fibers of about 1.5 denier and about 3 denier.

13. The nonwoven of claim 1, comprising fibers of about 1.5 denier exclusively.

14. The nonwoven of claim 1, comprising fibers of about 3 denier exclusively.

15. The nonwoven of claim 12, comprising about 40-50% of fibers of 1.5 denier, about 20-40% fibers of 3 denier, and about 5-30% binder.

16. The nonwoven of claim 12, comprising about 25-75% fibers of 1.5 denier and about 75-25% of fibers of 3 denier, not including any binder in the formulation.

17. The nonwoven of claim 12, comprising a ratio of 1.5 denier fibers to 3 denier fibers of about 1:

1 to about 2.5;

1.

18. The nonwoven of claim 12, wherein the charring fibers comprise modified viscose fibers.

19. The nonwoven of claim 12, wherein the modified viscose fibers comprise Visil®

.

20. An article comprising the nonwoven of claim 12, wherein the article meets the requirement of Cal. AB603.

21. The nonwoven of claim 1, wherein the flame retardant barrier is a highloft nonwoven.

22. The nonwoven of claim 21, wherein the loft is about ¼

inch to about 1.5 inches as manufactured.

23. An article comprising the nonwoven of claim 1.

24. The article of claim 23, wherein the article meets the requirement of Cal. AB603.

25. The article of claim 23, wherein the article is a mattress.

26. The article of claim 23, wherein the article is an insulator.

27. The article of claim 24, wherein the article is a highloft batt.

43. A method of manufacturing an article comprising providing a flame retardant barrier according to claim 1, placing the barrier as a layer extending along a surface, and covering the surface with a fabric.

44. The method of claim 43 where the article comprises a mattress, mattress foundation, sofa, or chair.

45. The method of claim 43 wherein the article comprises an insulator.

46. The method of claim 44, wherein the article is a mattress, and further comprising providing a mattress material, wherein placing the barrier layer comprises placing the barrier on the top and sides of the mattress material.

47. The method of claim 44 wherein the article is a box spring and further comprising providing a box spring, wherein placing the barrier layer comprises placing the barrier material on the top and sides of the box spring.

28. A method of manufacturing a nonwoven flame retardant barrier comprising:

carding low denier, charring fibers; and

cross-lapping the carded fibers to form a batt.

29. The method of claim 28 further comprising adding a binder to the charring fibers to create a fiber blend, and thermally bonding the fibers.

30. The method of claim 28 wherein the charring fibers comprise modified viscose fibers.

31. The method of claim 28 wherein the fiber blend is about 5 to about 30% binder.

32. The method of claim 28 further comprising blending charring fibers of 1.5 and 3 denier.

33. The method of claim 28 comprising blending charring fibers of about 1.5 denier exclusively.

34. The method of claim 28 comprising blending modified viscose fibers of about 3 denier exclusively.

35. The method of claim 29 comprising about 25-75% of charring fibers of 1.5 denier and about 75-25% of fibers of 3 denier.

36. The method of claim 28 comprising a blend of high and low denier fibers.

37. The nonwoven of claim 28, comprising a fiber of a denier of about 7 or more, and a fiber having a denier of about 3 or less.

38. The nonwoven of claim 28, comprising a blend of fibers of varying deniers.

39. The method of claim 28 further comprising needle punching the carded and lapped fibers.

40. The method of claim 28, wherein the nonwoven has a basis weight of about 0.2 to about 1.0 osf.

41. The method of claim 28, wherein the nonwoven has a loft of about ¼

inch to 1.5 inches.

42. A highloft batt produced by the method of claim 28.