Fiberglass corespun fabrics for use in flame resistant drywall installations

Inactive Publication Date: 2010-10-14
BASOFIL FIBERS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0018]To overcome or conspicuously ameliorate the disadvantages of the related art, it is an object of the present invention to provide a flame resistant drywall installation capable of passing open flame tests such as ASTM E119. In the preferred usages of the present invention, a FR corespun woven and a FR stitchbonded fabric are adhered between layers of conventional gypsum drywall panels, with the use of standard latex wall paint, and test

Problems solved by technology

The usual drywall board comprising gypsum between two layers of paper is not sufficiently fire resis

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 i

Fiberglass Corespun Fr Fabrics for use in Flame Resistant Drywall Installations

[0035]A 6.0 ounce per square yard (osy) batting of 100% cotton is stitchbonded with 14 / 1 Alessandra corespun yarn such that the final fabric weight is 8.0 osy. The stitchbonded FR fabric has the equivalent of 20% Alessandra corespun yarn and 80% cotton batting.

The Alessandra Corespun Stitching Yarn Consisted of:

[0036]melamine fiber (Basofil Fiber)—(in sheath)[0037]modacrylic fiber—(in sheath)[0038]polyester fiber—(in sheath)[0039]multifilament fiberglass—(in core)[0040]multifilament nylon fiber—(in core)

[0041]A 5.0 osy woven 44×34 twill fabric of 10 / 1 Alessandra corespun yarn, consisting of the fiber blend described above, is painted with standard latex paint and applied to one side of a ⅝″ drywall panel. The stitchbonded nonwoven fabric described above is also painted with latex paint and applied to a second ⅝″ drywall panel.

[0042]After the two fabric painted surfaces are allowed to thoroughly dry they a...

example ii

Example II

Fiberglass Corespun Fr Fabrics for use in Flame Resistant Drywall Installations

[0043]A 6.0 ounce per square yard (osy) batting of 100% cotton is stitchbonded with 14 / 1 Alessandra corespun yarn such that the final fabric weight is 8.0 osy. The stitchbonded FR fabric has the equivalent of 20% Alessandra corespun yarn and 80% cotton batting.

The Alessandra Corespun Stitching Yarn Consisted of:

[0044]melamine fiber (Basofil Fiber)—(in sheath)[0045]modacrylic fiber—(in sheath)[0046]polyester fiber—(in sheath)[0047]multifilament fiberglass—(in core)[0048]multifilament nylon fiber—(in core)

[0049]A 5.0 osy woven 44×34 twill fabric of 10 / 1 Alessandra corespun yarn, consisting of the fiber blend described above, is painted with standard latex paint and applied to one side of a ⅝″ drywall panel and the other side has the stitchbonded nonwoven fabric described above painted with latex paint and applied to it. A second ⅝″ drywall panel has the twill fabric painted and applied to one sid...

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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Abstract

Provided is a flame resistant drywall installation, especially those designed to meet ASTM E119. The installations comprise the use of fiberglass corespun flame resistant (FR) woven and fiberglass corespun stitchbonded nonwoven fabrics. The preferred forms of the woven and stitchbonded fabric used in this invention include:
WOVEN FABRIC: A 3-8 opsy woven fabric consisting of fiberglass corespun yarns as described below.
STITCHBONDED FABRIC: A 4-10 nonwoven batting of 100% cotton, 100% rayon, 100% lyocell, cotton/non-FR fiber blends, rayon/non-FR fiber blends or lyocell/non-FR fiber blends stitched with fiberglass corespun yarns as described below.
Fiberglass corespun weaving and stitching yarns, for use in the invention, include those known in the textile industry as Alessandra® yarn (U.S. Pat. Nos. 6,146,759; 6,287,690; 6,410,140; 6,606,846; 6,553,749 by McKinnon Land LLC) and Firegard® yarn (by Springs Industries).
The two fabric types mentioned above are used in tandom, between layers of conventional gypsum style drywall paneling to obtain a higher flame rating than would otherwise be able to be obtain in a layered drywall construction which does not include these fabrics. Conventional latex paint or flame resistant coating materials can be used to adhere the fabrics between the drywall paneling.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The invention relates to the use of fiberglass corespun flame resistant (FR) woven and fiberglass corespun stitchbonded nonwoven fabrics for use in flame resistant drywall installations, especially those designed to meet ASTM E119. The preferred forms of the woven and stitchbonded fabric used in this invention include:[0003]WOVEN FABRIC: A 3-8 opsy woven fabric consisting of fiberglass corespun yarns as described below.[0004]STITCHBONDED FABRIC: A 4-10 nonwoven batting of 100% cotton, 100% rayon, 100% lyocell, cotton / non-FR fiber blends, rayon / non-FR fiber blends or lyocell / non-FR fiber blends stitched with fiberglass corespun yarns as described below.[0005]Fiberglass corespun weaving and stitching yarns, for use in the invention, include those known in the textile industry as Alessandra® yarn (U.S. Pat. Nos. 6,146,759; 6,287,690; 6,410,140; 6,606,846; 6,553,749 by McKinnon Land LLC) and Firegard® yarn (by Springs Indus...

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): D03D15/00D03D13/00
CPCB32B5/26D02G3/185E04B2/7411D03D15/12D02G3/443B32B5/022B32B5/024B32B5/06B32B5/08B32B5/22B32B7/12B32B13/14B32B2255/02B32B2255/26B32B2262/02B32B2262/0223B32B2262/0238B32B2262/0246B32B2262/0253B32B2262/0261B32B2262/0269B32B2262/0276B32B2262/04B32B2262/062B32B2262/065B32B2262/08B32B2262/101B32B2262/14B32B2307/304B32B2307/3065B32B2307/718B32B2419/00B32B2419/06B32B2471/00B32B2607/00Y10T442/3179Y10T442/3724Y10T442/3073D03D15/513D04B21/165D10B2503/04
Inventor DRY, NATHANHANDERMANN, ALAN C.GIBSON, RODNEY
Owner BASOFIL FIBERS
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