Thermally Protective Flame Retardant Fabric

• US 20120052217A1
• Filed: 11/07/2011
• Published: 03/01/2012
• Est. Priority Date: 05/14/2002
• Status: Active Grant

• Current Assignee: Charles Detwiler Roberson, Ladson L. Fraser Jr, Vincent Andrews Iii Monfalcone
• Original Assignee: Charles Detwiler Roberson, Ladson L. Fraser Jr, Vincent Andrews Iii Monfalcone
• Inventors: Monfalcone, Vincent Andrews III, Roberson, Charles Detwiler, Fraser, Ladson L. Jr.
• Granted Patent: US 8,501,639 B2
• Time in Patent Office: Days
• US Class Current: 428/7
• CPC Class Codes: A62B 17/003 Fire-resistant or fire-fighters' clothes
• CPC Class Codes: D04H 1/46 by needling or like operations to cause entanglement of fibres D04H1/45 takes precedence; needling machines D04H18/00
• CPC Class Codes: D06M 11/36 with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
• CPC Class Codes: D06M 11/47 Oxides or hydroxides of elements of Groups 5 or 15 of the Periodic Table; Vanadates; Niobates; Tantalates; Arsenates; Antimonates; Bismuthates
• CPC Class Codes: D06M 11/68 with phosphorus or compounds thereof, e.g. with chlorophosphonic acid or salts thereof with phosphines or diphosphines D06M11/01; with selenium or tellurium compounds D06M11/52; with polyphosphazene or derivatives thereof D06M15/673
• CPC Class Codes: D06M 11/69 with phosphorus; with halides or oxyhalides of phosphorus; with chlorophosphonic acid or its salts
• CPC Class Codes: D06M 11/70 with oxides of phosphorus; with hypophosphorous, phosphorous or phosphoric acids or their salts
• CPC Class Codes: D06M 11/71 Salts of phosphoric acids
• CPC Class Codes: D06M 13/282 with compounds containing phosphorus
• CPC Class Codes: D06M 13/292 Mono-, di- or triesters of phosphoric or phosphorous acids; Salts thereof
• CPC Class Codes: D06M 13/44 containing nitrogen and phosphorus
• CPC Class Codes: D06M 13/453 Phosphates or phosphites containing nitrogen atoms
• CPC Class Codes: D06M 2200/30 Flame or heat resistance, fire retardancy properties
• CPC Class Codes: D06M 23/00 Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
• CPC Class Codes: D21H 21/34 Ignifugeants
• CPC Class Codes: Y10S 428/92 Fire or heat protection feature
• CPC Class Codes: Y10S 428/921 Fire or flameproofing
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/1345 Single layer [continuous layer]
• CPC Class Codes: Y10T 428/1348 Cellular material derived from plant or animal source [e.g., wood, cotton, wool, leather, etc.]
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1362 : Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 442/2648 : Coating or impregnation is specified as an intumescent material
• CPC Class Codes: Y10T 442/643 : Including parallel strand or fiber material within the nonwoven fabric
• CPC Class Codes: Y10T 442/697 : Containing at least two chemically different strand or fiber materials

Abstract

A thermally protective, flame retardant fabric includes a substrate treated with a combination of a flame retardant agent and an intumescent agent. The substrate includes non-thermoplastic fibers or a blend of non-thermoplastic fibers and thermoplastic fibers having a basis weight ranging from 2.0 to 15.0 ounces per square yard. The fabric has a contact thermal protective performance value of at least 4.5 and a contact thermal protective performance efficiency greater than 1.1. Applications of the fabric include protective garments, articles of furniture, vehicle components, building components, electrical components, decorative components, appliances, and containers.

Claims

1. A fabric consisting of a single layer of a non-woven substrate treated with a finish consisting essentially of an intumescent, flame retardant coating,

wherein the non-woven substrate is chosen from needlepunched, spunbonded, thermalbonded, spunlaced, resin bonded, and stitch bonded fabrics comprising cellulosic fibers, said non-woven substrate having a basis weight ranging from 3.0 to 8.0 ounces per square yard, and

wherein the single-layer, finished fabric has a thickness ranging from 0.01 to 0.15 inches and a contact thermal protective performance value of at least 4.5.

2. The fabric of claim 1, wherein the single-layer, finished fabric has a contact thermal protective performance value of at least 6.5.

3. The fabric of claim 2, wherein the single-layer, finished fabric has a contact thermal protective performance value of at least 9.0.

4. The fabric of claim 1, wherein the single-layer, finished fabric has a contact thermal protective performance efficiency greater than 1.1.

6. The fabric of claim 1, wherein the single-layer, finished fabric has a thickness ranging from 0.04 to 0.09 inches.

7. The fabric of claim 1, wherein the non-woven substrate comprises a blend of cellulosic fibers combined with at least one temperature resistant fiber.

8. The fabric of claim 7, wherein the cellulosic fibers are chosen from rayon, cotton, and woodpulp.

9. The fabric of claim 7, wherein the at least one temperature resistant fiber is chosen from poly-paraphenylene terephthalamide, asbestos, carbon, polyphenylene benzobisoxazole, polybenzimidazole, para-aramids, meta-aramids, fluorocarbons, polyphenylene sulfides, melamines, and polyimides.

10. The fabric of claim 1, wherein the non-woven substrate comprises at least one thermoplastic fiber.

11. The fabric of claim 10, wherein the least one thermoplastic fiber is a polyester fiber.

12. The fabric of claim 1, wherein the non-woven substrate comprises cellulosic fibers, aramid fibers and polyester fibers.

13. The fabric of claim 12, wherein the cellulosic fibers comprise rayon.

14. The fabric of claim 1, wherein the finish comprises at least one phosphorous compound.

15. The fabric of claim 1, wherein the finish comprises a colorant.

16. The fabric of claim 1, wherein the single-layer, finished fabric has a heat attenuation factor according to ASTM F-1959-99 of at least 70%.

17. The fabric of claim 16, wherein the single-layer, finished fabric has a heat attenuation factor according to ASTM F-1959-99 of at least 85%.

18. The fabric of claim 1, wherein the single-layer, finished fabric has an energy breakthrough threshold of at least 8.0 cal/cm².

19. The fabric of claim 18, wherein the single-layer, finished fabric has an energy breakthrough threshold of at least 14.0 cal/cm².

20. A protective garment constructed from the fabric claimed in claim 1.

21. The protective garment of claim 20, wherein the protective garment is chosen from fire retardant suits, fire retardant gloves, fire blankets, blast blankets, welding suits, welding drapes, welding pads, and welding filters.

22. An article of furniture constructed from the fabric claimed in claim 1.

23. The article of furniture of claim 22, wherein the article of furniture is chosen from mattresses, chairs, sofas, and seats.

24. A vehicle component constructed from the fabric claimed in claim 1.

25. The vehicle component of claim 24, wherein the vehicle component is chosen from vehicle seats, vehicle beds, vehicle doors, vehicle bodies, mobile homes, trailers, insulation, and fuel tank exterior liners.

26. A building component constructed from the fabric claimed in claim 1.

27. The building component of claim 26, wherein the building component is chosen from insulation, air filters, chimney casing liners, roofing underlayments, building partitions, ceiling tiles, modular homes, and bomb shelters.

28. An electrical component constructed from the fabric claimed in claim 1.

29. The electrical component of claim 28, wherein the electrical component is chosen from electrical panels, wire conduit liner, and lightning protection devices.

30. A decorative component constructed from the fabric claimed in claim 1.

31. The decorative component of claim 30, wherein the decorative component is chosen from fireplace rugs, Christmas stockings, and Christmas tree skirts.

32. An appliance constructed from the fabric claimed in claim 1.

33. The appliance of claim 32, wherein the appliance is chosen from attic fans, liners for water heaters, liners for clothes dryers, and exhaust duct liners for heaters, and exhaust duct liners for clothes dryers.

34. A container constructed from the fabric claimed in claim 1.

35. The container of claim 34, wherein the container is chosen from fire retardant document pouches, fire retardant safes, packaging containers for explosives, shipping containers for explosives, and fire retardant ammunition cases.

5. The fabric of claim 5, wherein the non-woven substrate has a basis weight ranging from 5.0 to 6.5 ounces per square yard.

36. A thermally protective, flame retardant fabric formed using a method comprising:

applying a finish to a single layer of a non-woven substrate having a basis weight ranging from 3.0 to 8.0 ounces per square yard,

wherein the finish consists essentially of an intumescent, flame retardant coating, and

wherein the non-woven substrate is chosen from needlepunched, spunbonded, thermalbonded, spunlaced, resin bonded, and stitch bonded fabrics comprising cellulosic fibers; and

drying the substrate;

wherein the single-layer, finished fabric has a thickness ranging from 0.01 to 0.15 inches and a contact thermal protective performance value of at least 4.5.

37. The fabric of claim 36, wherein the single-layer, finished fabric has a contact thermal protective performance value of at least 6.5.

38. The fabric of claim 36, wherein the single-layer, finished fabric has a contact thermal protective performance value of at least 9.0.

39. A thermally protective, flame retardant fabric formed using a method comprising:

applying a finish to a single layer of a non-woven substrate having a basis weight ranging from 3.0 to 8.0 ounces per square yard,

wherein the finish consists essentially of an intumescent, flame retardant coating, and

wherein the non-woven substrate is chosen from needlepunched, spunbonded, thermalbonded, spunlaced, resin bonded, and stitch bonded fabrics comprising cellulosic fibers and

drying the substrate;

wherein the single-layer, finished fabric has a thickness ranging from 0.01 to 0.15 inches and a contact thermal protective performance efficiency greater than 1.1.