Coated fire barriers made from corespun yarns - coated fibers comprising the sheath of the corespun yarns

Abstract

The invention relates to a fire resistant flame barrier lightweight fabric substrate consisting of a high temperature resistant continuous filament fiberglass core and a low temperature resistant staple fiber sheath treated with a durable or non-durable fire retardant agent prior to yarn formation. The invention also discloses a process for making a fire resistant corespun yarn by treating fibers with fire retardant agent to make the sheath of the corespun yarn.

Description

CROSS REFERENCE TO PRIOR APPLICATIONS[0001]This application claims priority and the benefit thereof from a U.S. Provisional Application No. 61 / 362,421, filed on Jul. 8, 2010 and entitled COATED FIRE BARRIERS MADE FROM CORE SPUN YARNS—COATED FIBERS COMPRISING THE SHEATH OF THE CORE SPUN YARNS, the entire contents of which are herein incorporated by reference in their entirety.FIELD OF THE INVENTION[0002]The invention relates to a fire resistant flame barrier lightweight fabric substrate consisting of a high temperature resistant continuous filament fiberglass core and a low temperature resistant staple fiber sheath treated with a durable or non-durable fire retardant agent prior to yarn formation. The invention also discloses a process for making a fire resistant corespun yarn by treating fibers with fire retardant agent to make the sheath of the corespun yarn.BACKGROUND OF THE INVENTION[0003]The United States mattress industry is constantly striving to improve mattress comfort, whil...

AI Technical Summary

Benefits of technology

[0013]Potential benefits from applying fire retardant agents to the creation of fine balanced corespun yarn prior to fabric formation may include the production of fire resistant and or flame barrier fabrics that can be deployed in the greige state to preserve the physical and aesthetic properties of the fabrics as well as the upholstered articles made from them. The formation of these yarns may potentially enable businesses to simplify the process routing for these fabrics and maintain lower yarn inventory levels as the same yarn can be used for several end products.

[0014]The invention contemplates the use of environmentally favorable fire retardant chemicals, avoiding those suspect chemicals on Europe's REACH list or California's Green Chemistry Initiative, thereby possibly making the fabric more consumer and retailer desirable and potentially lowering the risk of claims of harm from use of other fire retardant chemicals. In addition, this yarn structure may enable the micro-coated fibers to form a char, while the heat stable core creates a lattice to hold the char in place. The coating of the fibers may emit vapor-phase flame retardants that would encourage the extinguishment of flames immediately adjacent to the fire resistant fabric. The possible increase in char strength may enable the use of lighter, more responsive fire barrier fabrics than that using treated cotton alone.

Problems solved by technology

Application of fire retardant agents after fabric formation often results in changes to the physical and or aesthetic properties of the fabric, such as changes in strength, elongation, and feel of the fabrics, thereby making the fabrics less desirable in the construction of mattresses, pillow tickings, bedspreads, draperies, upholstery, and other bedding products.

(Note: As an alternative, inherently fire-retardant materials can be used; however, these can be more expensive.)

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