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Lofted lightly needlepunched flame-retardant nonwovens

a non-woven fabric and loft technology, applied in the field of flame-retardant (fr) lofted lightly needlepunched non-woven fabrics, can solve the problems of no binder employed or desired

Inactive Publication Date: 2006-07-13
SYLVAN CHEM CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

No binder is employed or desired as it makes the resulting article stiff, compared to a highloft product, but flexible compared to traditional needlepunch nonwovens.

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0046] Various combinations of FR fibers with other synthetic or natural fibers such as rayon, PET, flax and kenaf were produced. The various fibers were dry laid onto a moving conveyor belt as is known in the art. For Samples 1-5 and 11, where an FR resin was employed via saturation method, it was applied to individual fibers before they were laid onto the moving conveyor. The nonwoven fiber batt was transported via the conveyor belt to a card, then to a needlepunch loom where the individual fibers were mechanically entangled through the needling process to create the interlocked web.

[0047] These various nonwoven batts, at various weights, were then subjected to Western Nonwovens bench scale test. In the test the nonwoven fabric was wrapped once around the foam. A flame was applied directly to the nonwoven fabric for at least 600 seconds and the structural integrity was noted. All of the test samples maintained their structural integrity for at least the time indicated, and the fl...

example 2

[0055] This example shows the results from a bench scale burn test conducted for 90 seconds. A comparison between FR lofted lightly needlepunch nonwoven batts and traditional FR needlepunch nonwoven batts was made with batt weights of 7.2 oz. / sq.yd. for all samples and the only difference being that of lofted lightly (LNP) versus traditional flat construction (NP). The batts were ¼inch for the traditional needlepunch article and ½ inch loft for the lofted lightly needlepunch articles. A flame was applied to one side of the nonwoven and the temperature, in degrees Fahrenheit, was measured every 10 seconds on the opposite side. Three samples of each type were tested and the temperatures were averaged, and the delta or difference was determined at each time. The results are set forth in Table 2.

TABLE 2Sample type102030405060708090NP356710733743749744746741747NP366726748762771774769769778NP488753765779782787795796801LNP256652689696694688678682680LNP286689698697699698697702703LNP257658...

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Abstract

The present invention concerns a flame retardant (FR) lofted lightly needlepunch nonwoven fabric useful in household goods and particularly for mattresses. The nonwoven fabric comprises at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber and nonbonding, nonFR synthetic and / or natural fiber mechanically bound together by a needlepunch process. The present invention also contemplates a mattress constructed from the FR lofted lightly needlepunch nonwoven fabric comprising FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber. The mattress from this construction passes the California Test Bulletin 603 stringent conditions for mattresses used in residential places. Preferably the nonwoven fabric has a batt weight of at least 2.25 oz. / sq.yd. and preferably between 2.25 oz. / sq.yd. and 20 oz. / sq.yd.

Description

[0001] This application is a Continuation-In-Part of our co-pending U.S. patent application Ser. No. 10 / 714,132 filed Nov. 14, 2003, which is a Continuation-In-Part of our co-pending U.S. patent application Ser. No. 10 / 298,990 filed Nov. 18, 2002.BACKGROUND OF THE INVENTION [0002] 1) Field of the Invention [0003] The present invention concerns a flame-retardant (FR) lofted lightly needlepunched nonwoven fabric that can be employed in many applications, particularly in household goods such as a fabric FR layer for comforters, pillows, or furniture; backing for curtains and rugs; and especially for mattress fabrics. The nonwoven fabric comprises at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, FR polyolefin fiber, or FR resin coated fiber; and non-bonding, non-FR synthetic fiber and / or natural fiber, all of which are mechanically bonded together through a needlepunch process. Nonwoven fabric prepared from these components, possessing a batt weig...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Application Information

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IPC IPC(8): A47C17/00A47C27/00D04H1/42D04H1/64
CPCA47C27/122A47C31/001D04H1/42D04H1/641D04H1/4258D04H1/4266D04H1/4291D04H1/435D04H1/425D04H1/43835
Inventor MCGUIRE, SHERI L.TAYLOR, THOMAS E.
Owner SYLVAN CHEM CO
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