Patent Application
20210032802
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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:
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
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.
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.
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.
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.
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.
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.
Continuing to refer to
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.
Referring now to
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
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
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.
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.
