MXPA06010733A - Reinforced nonwoven fire blocking fabric, method for making such fabric, and articles fire blocked therewith - Google Patents

Abstract

This invention relates to a thin reinforced nonwoven fabric for fire blocking an article, articles containing such fabrics, and methods for making the fabrics and fire blocking the articles. When exposed to heat or flame, the fabric is capable of increasing its thickness by at least three times. The fabric comprises an open mesh scrim having a having crimped, heat-resistant organic fibers compressed thereon and held in a compressed state by a thermoplastic binder. When subjected to high heat or flame, the binder in the structure softens and flows, releasing the restrained crimped fibers and allowing the thickness of the fabric to increase dramatically.

Description

REINFORCED NON-WOVEN FABRIC THAT BLOCKS FIRE, METHOD TO MANUFACTURE FABRIC, AND ITEMS THAT BLOCK FIRE WITH THE FABRIC. FIELD OF THE INVENTION This invention relates to a thin reinforced non-woven fabric, made of a compressed veil of curled fiber and a reinforced grid, which sponges when exposed to heat or flame and which is useful as a component for blocking mattresses. fire, upholstery, and the like. This invention is additionally related to a fire blocking article that incorporates this fabric. This invention also relates to processes for manufacturing this reinforced nonwoven fabric and incorporating the fabric into an article. BACKGROUND OF THE INVENTION The State of California has led the action of regulating and reducing the inflammability of mattresses and mattress sets in an attempt to reduce the number of lives lost in homes, hotels, and institutional fires.

In particular, The Office of Home Furnishings and Thermal Insulation of the Consumer Affairs Department of the State of California published the Bulletin Technical 603"Requirements and Test Procedure for Resistance of a game Mattress / Box Spring Residential a Flame-Open Long "to quantify the performance of inflatable mattress sets In many cases, mattress manufacturers want to include a blocking layer Ref: 175300 fire, however, they do not want the additional layer to detract from the aesthetics Existing mattresses, strong thin fabrics, such as a combination of discontinuous fibers and a thin reinforced grid cloth, are therefore desired in many instances because these are durable and are also probably not objectionable in the intended use. methods in the art for combining discontinuous fibers and grid fabrics that secure discontinuous fibers in place One such process is hydroentangled, also known in various publications as hydro-sewage, non-woven process, and water jet treatments, in the jets of water with high pressure impact the discontinuous fibers and drive them inside the grid, consolidating the fiber and the grid Non-woven sheets manufactured by this process mechanically entangle discontinuous fibers with these or with the grid or both, limiting the ability of the fabric to sponge when heated or exposed to the flame. The following patents are representative of non-woven fabrics manufactured primarily by the hydroentanglement process. PCT Publication WO 98/42905 discloses a multi-layered textile material consisting of a complex textile network inserted within a textile structure consisting of non-woven turns arranged on either side of the net, the tangles entangled with each other and the network by the force of hydro-entangled. U.S. Patent No. 4,840,838 to Wyss discloses a high temperature filter felt of a grid and mattress of fibers of matted fibers within that grid. US Pat. No. 6,596 to Putnam et al discloses a laminated fabric having a three-dimensional image, the fabric formed of a light layer of heat-resistant fibers and a heavy layer joined by the hydroentangling route. Another process known in the art for combining discontinuous fibers and grid fabrics is by punching. In this process, needles of entangle imprison discontinuous fibers and conduct them inside the grid, or inside the mattress of internal fibers, securing them to the structure. Once again, the non-woven sheets manufactured by this process have their discontinuous fibers mechanically entangled with them or with the grid, limiting the ability of the fabric to sponge when heated or exposed to the flame. Some products manufactured by punching can be manufactured by hydroentanglement, or vice versa, since both products require the entanglement of the fibers with and towards the grid and other fibers in the fabrics. The following patents are representative of non-woven fabrics manufactured primarily by the punching process. U.S. Patent No. 4, 743,495 by Lilani et al. discloses a non-woven fabric for fire-blocking seat comprising at least two felted covers comprising aramid fibers and phenolic fibers which are joined together with a stabilized woven grid. U.S. Patent No. 5,691,036 to Lin et al. discloses a quilting material having at least two layers of non-woven temperature resistant staple fibers with reinforcement grid layers between the layers, wherein the entire structure is punctured for integrity and a face is embossed with a pattern. U.S. Patent No. 3,819,465 to Parsons et al. Discloses a textile construction having an elastic textured surface formed of punctured nonwoven fibers within a layer of plastic netting material. Then the net is caused to fold back and causes the non-woven fibers to be arched out of the plane of the fiber mattress, forming the textured surface. U.S. Patent No. 5,578,368 to Forsten et al. discloses a fire resistant material useful in upholstered furniture and mattress tops, comprising a mattress of synthetic down fibers and a fire resistant aramid fiber layer in contact with at least one side of the synthetic down mattress. Another fire-blocking material that is manufactured by entangled, flame-resistant fibers toward and with a grid via the hydro-entanglement, punching, and / or chemical means is disclosed in Latham US Patent Application No. 2002/0098753. et al. Such materials are useful for airplane-resistant airplane seats. Yet another process known in the art for combining discontinuous fibers and grid cloth is by adhesive lamination or the addition of binders. In this process, a binder or adhesive is used to adhere or join individual layers or fibers together. The following patents are representative of non-woven fabrics manufactured by this process. U.S. Patent Nos. 6,579,396 and 6,383,623 to Erb disclose a very low density insulating material having non-thermoplastic fibers that are bonded by a flammable thermoplastic binder. European Patent No. EP 622 332 of Yamaguchi et al. describes a heat-resistant and flame-retardant padded structure that - comprises a matrix fiber of a non-woven foamed non-elastic discontinuous fleece fiber, a curled flame retardant fiber exhibiting a residual weight of at least 35% as tested by an ignition test method, and a thermoplastic elastic fiber , with at least some of the points of intersection between the matrix fiber and the flame retardant fiber with thermoplastic fiber being joined by fusion. The matrix fiber is preferably polyester or aramid fiber, but preferably the polyester contains a flame retardant compound and the preferred aramid fiber is a meta-aramid fiber. The flame retardant fiber is preferably oxidized acrylonitrile polymer fiber, but may be carbon fiber, cross-linked felonic resin fiber, or polybenzimidazole fiber. The preferred thermoplastic elastomer fiber is a sheath / core composite fiber made of thermoplastic elastomer and a non-elastic polyester. The Erb and Yamaguchi patents both use the binder to keep the non-woven fabric in an elevated or fluffed form such that it will have elasticity. The American Patent No. 5,470,648 to Pearlman et al. discloses a three layer composite fabric for use in a carpet backing, the composite fabric made of two layers of entangled nylon filaments attached adhesively to a fiberglass screen. This fabric has the same problem as hydro-entangled or punctured fabrics, that is, because the fibers are mechanically entangled together they lose their ability to sponge when heated or exposed to the flame. Therefore, what is needed is a reinforced non-woven fabric that provides flame protection but that is light and thin during normal use but then sponges when subjected to high heat or flame.

BRIEF DESCRIPTION OF THE INVENTION This invention relates to a reinforced nonwoven fabric that blocks fire to an article, and an article that blocks fire with the nonwoven fabric, wherein the fabric comprises an open mesh grid having a first side and a second side, the first side has heat-resistant organic fibers, crimped, compressed thereon, the fibers maintained in a state compressed by a thermoplastic binder, wherein when the fabric is exposed to heat or flame, the fabric is able to increase its thickness by at least three times. This invention also relates to a process for manufacturing a reinforced non-woven fabric that is heat-swelled or flame-retardant to block fire to an article comprising the steps of: a) forming a mat comprising heat-resistant organic fiber and binder fiber , b) contacting the mat with the first side of an open mesh grid, the grid with a first and a second side, to form a fabric assembly. c) applying binder powder to the fabric assembly, d) heating the fabric assembly to activate the binder fiber and binder powder, e) compressing the fabric assembly to a compressed state, and f) cooling the fabric assembly in a compressed state to form a reinforced nonwoven fabric. This invention also relates to a fire-blocking padding comprising an outer fabric ply or a cover fabric layer; one or more layers of the reinforced nonwoven fabric fire blocker, a foam cushion layer or fiber mattress, and optionally a stitched backing layer, wherein the reinforced nonwoven fabric fire blocker comprises an open mesh grid having heat-resistant organic fibers, crimps compressed thereon, fibers held in a state compressed by a thermoplastic binder. This invention also relates to a method of blocking fire of an article with a reinforced nonwoven fabric layer that is heat or flame sponge, comprising the steps of: a) combining a layer of reinforced nonwoven fabric, a cuti fabric or layer of upholstery, and optionally a layer of quilting, b) make the layers together to form a fabric padding that blocks fire, ec) incorporate the fabric padding that blocks fire inside the article, the layer of Reinforced nonwoven fabric comprising one. open mesh grid having a first side and a second side, the first side with heat-resistant organic fibers, curled compressed thereon, the fibers maintained in a state compressed by a thermoplastic binder, wherein when the fabric cushion is exposed To heat or flame, the nonwoven fabric layer is able to increase its thickness by at least three times. DETAILED DESCRIPTION OF THE INVENTION This invention relates to a reinforced non-woven fabric that blocks an article from fire. When exposed to heat or flame, the fabric is able to increase its thickness by at least three times. The fabric comprises an open mesh grid having a first side and a second side, the first side having heat-resistant organic fibers, crimped compressed thereon and held in a state compressed by a thermoplastic binder. Preferably the organic fibers are compressed on the first and second sides of the open mesh grid. When subjected to high heat or flame, the binder in the structure softens and flows, releasing the curled fibers contained and allowing the thickness of the fabric to increase dramatically. This increase creates air cavities in the fabric, which are believed to increase the thermal performance of the fabric. The fabric is able to increase its thickness in response to heat or high flame because the heat-resistant organic fibers curled are compressed but not tangled appreciably in the fabric, while the previously developed fiber-grid sheets have been concentrated ensuring good matting of the fibers with the grid and with the other fibers in the sheet. Typically, this good matting is done by imparting energy within the veils of fluffed fibers and / or the grid that forms the sheet to entangle the fibers and densify the sheet. When this is done, the fibers of the leaf are so entangled that they are not free to move when subjected to heat and flame. The fabrics of this invention have only enough matting of the fibers to make the sheet; that is, the fibers are only entangled with each other in the necessary extent to form a light veil that can be coated or combined with the open mesh grid. No additional energy is imparted to the sheet to entangle the fibers with each other or with the grid. The light hair is then laminated to the grid by heating and compressing the combination and then cooling the combination to seat the structure while the crimped fibers are compressed and contained. By compressing a foamed sheet in this manner, when the binder material is softened or melted, the fibers in the sheet are free to return to a foamed state formally similar to that which they had prior to compression. The thickness of the reinforced fabric of this invention increases by at least three times when exposed to heat or high flame. Generally, when the temperature increases, the rate of swelling increases and the amount of swelling also increases, and it has been observed that the thickness increases more than 25 times the compressed thickness. It is believed that temperatures as low as 150 centigrade are required to initiate the swelling effect, and it is believed that starting at temperatures of about 225 centigrade the swelling action proceeds immediately. The maximum amount of fabric sponge is achieved when the fabric is directly subjected to the flame, where it has been observed that the fabric sponges approximately 29 times its original thickness. When exposed directly to the flame, the cloth thickness preferably increases at least 5 times, and preferably 10 times its original thickness. The compressed reinforced non-woven fabrics of this invention preferably have an overall thickness of 0.025 to 0.12 centimeters (0.010 to 0.050 inches). Such fabrics also preferably have a basis weight in the range of 20 to 136 g / m2 (0.6 to 4 oz / yd2), with the grid component preferably doing 3.4 to 34 g / m2 (0.1 to 1.0 oz / yd2) and the fibrous web component preferably in the range from 1.7 to 102 g / m2 (0.5 to 3.0 oz / yd2). The reinforced nonwoven fabric of this invention comprises heat-resistant organic fibers crimped. Such crimped fibers are preferably discontinuous fibers having cut lengths in the range of 1 to 6.3 cm (0.4 to 2.5 inches) preferably 1.9 to 5.1 cm (0.75 to 2 inches) and preferably have 2 to 5 crimps per centimeter (5 to 12) curls per inch). By "heat resistant fiber" it is meant that the fiber preferably retains 90 percent of its fiber weight when heated in air at 500 ° C at a rate of 20 degrees C per minute. Such a fiber is normally flame resistant, which means that the fiber or fabric made from the fiber has a Limited Oxygen Index (LOI) such that the fiber or fabric will not support a flame in air, the preferred range of LOI being approximately 26 and higher. Preferred fibers do not shrink excessively when exposed to a flame, that is, the length of the fiber will not shorten significantly when exposed to the flame. Fabrics that contain an organic fiber that retains 90 percent of its fiber weight when heated in air to 500 ° C at a rate of 20 degrees C per minute tend to have a limited amount of cracks and openings when burned by a flame impacting, which is important for the performance of the fabric as a fire blocker. Stable, heat resistant fibers useful in the fire retardant reinforced non-woven fabric of this invention include fiber made from para-aramid polymer, polybenzazole, polybenzimidazole, and polyimide. The heat resistant fiber is made of aramid polymer, especially para-aramid polymer. As used herein, "aramid" means a polyamide wherein at least 85% of the amide bonds (-CONH-) are directly attached to two aromatic rings. "Para-aramid" means that the two rings or radicals are for oriented with respect to each other along the molecular chain. The additives can be used with aramid. In fact, it has been found that up to as much as 10 percent by weight of other polymeric material can be mixed with aramid or that copolymers having as much as 10 percent of another diamine substituted by diamine of aramid can be used or both. as 10 percent of another diacid chloride substituted by the diacid chloride of aramid. In the practice of this invention, the preferred para-aramid is poly (para-phenyleneterephthalamide). Methods for making aramid fibers useful in this invention are generally described in, for example, U.S. Patent Nos. 3,869,430, 3,869,429, and 3,767,756. Such aromatic polyamide organic fibers and various forms of these fibers are available from DuPont Company, Wilmington, Delaware under the trademark of Kevlar® fibers. Commercially available polybenzazole fibers useful in this invention include Zylon PBO-AS fiber (Poly (p-phenylene-2,6-benzobisoxazole), Zylon® PBO-HM fiber (poly (p-phenylene-2,6-benzobisoxazole), available from Toyobo, Japan Commercially available polybenzimidazole fibers useful in this invention include PBI® fiber available from Celanese Acétate LLC Commercially available polyimide fibers useful in this invention include P-84® fiber available from LaPlace Chemical Alternatively, "heat resistant fiber" It can include a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air at 700 ° C at a rate of 20 degrees C per minute.These fibers are said to be carbon-forming. Regenerated cellulose having 10 percent inorganic compounds incorporated within the fibers are the preferred cellulose fibers Such fibers, and methods for making such fibers, are described US Patent No. 3,565,749 and British Patent No. 1,064,271. A preferred carbon-forming regenerated cellulose fiber for this invention is a viscous fiber containing silicon dioxide in the form of a polycyclic acid with aluminum silicate sites. Such fibers, and methods for making such fibers are generally described in U.S. Patent Nos. 5,417,752 and PCT Patent Application WO 9217629. The viscose fiber containing silicic acid and has about 31 (+/- 3) percent inorganic material is sells under the trademark Visil® by Sateri Oy Company of Finland. The heat resistant fibers can be mixed with other fibers, however, it is preferred that the other fibers do not compromise the ability of the fabric to function as a flame blocker. For example, up to 50 percent modacrylic fibers can be mixed with heat-resistant fiber. Modacrylic fiber is useful because this fiber releases halogen-containing gases that suppress flames when burned. By modacrylic fiber is meant acrylic synthetic fiber made of a polymer comprising acrylonitrile. Preferably the polymer is a copolymer comprising 30 to 70 weight percent of an acrylonitrile and 70 to 30 weight percent of a vinyl monomer containing halogen. The halogen-containing vinyl monomer is at least one monomer selected, for example, from vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, etc. Examples of copolymerizable vinyl monomers are acrylic acid, methacrylic acid, salts or esters of such acids, acrylamide, methylacrylamide, vinyl acetate, etc. The preferred modacrylic fibers used in this invention are copolymers of acrylonitrile combined with vinylidene chloride, the copolymer further having an antimony oxide or antimony oxides to improve fire retardancy. Such useful modacrylic fibers include, but are not limited to, the fibers described in U.S. Patent No. 3,193,602 having 2 weight percent antimony trioxide, the fibers described in US Pat. No. 3, 748, 302 manufactured with various antimony oxides which are present in an amount of at least 2 weight percent and preferably no more than 8 weight percent, and the fibers described in US Patent Nos. 5,208,105 &; 5,506,042 which has 8 to 40 weight percent of an antimony compound. The preferred modacrylic fiber is Protex C commercially available from aneka Corporation, Japan, which is said to contain 10 to 15 antimony oxides by weight, although fibers having less antimony oxide, in the range of 6 percent in weight or less, can also be used. The crimped organic fibers are held in place with up to 30 parts by weight of binder material. The preferred binder material is a combination of binder fiber and binder powder which is activated by the application of heat. The binder fibers are typically made of a thermoplastic material that flows at a temperature that is lower (i.e., have a lower softening temperature) than the softening temperature of any other discontinuous fibers in the fiber blend. Coating / core bicomponent fibers are preferred as binder fibers, especially bicomponent binder fibers having a polyester homopolymer core and a copolyester coating which is a binder material, such as those commonly available from Unitika Co., Japan (for example, sold under the registered trademark MELTY®). Useful types of binder fibers can include those made of polypropylene, polyethylene, or polyester polymers or copolymers, fibers containing only that polymer or copolymer, or as a bicomponent fiber in side-by-side or coating / core configuration. Preferably the binder fibers are present in an amount of up to 20 percent of the reinforced nonwoven fabric. The binder powder is preferably present in an amount of up to 30 percent of the reinforced nonwoven fabric. The preferred binder powder is a thermoplastic binder powder such as Griltex EMS 6E copolyester adhesive powder. The reinforced nonwoven fabric of this invention also contains an open mesh grid. Such grids preferably have a basis weight in the range of 3.4 to 34 g / m2 (0.1 to 1.0 oz / yd2) and are referred to as a grid of "open mesh" because these grids have only 0.8 to 6 ends per centimeter (2 to 15 ends per inch). The most preferred open mesh grids have a basis weight in the range of 6.8 to 17 g / m2 (0.2 to 0.5 oz / yd2) and preferably have 1 to 4 ends per centimeter (3 to 10 ends per inch), in the of warp and weft. Preferably, the mesh is made by joining together two sets of cross twisted polyester continuous filaments or continuous filament yarns having a binder coating. Representative open mesh grids are available from Saint-Gobain Technical Fabrics of Niagara Falls, New York under the name Bayes® Grid Fabrics. Two styles of the open mesh grids are useful especially in the reinforced non-woven fabrics of this invention. Bayex® Product Number KPM4410 / P3 is manufactured from 78 dtex (70 denier) continuous polyester filaments in both warp and weft directions and has 1.6 ends per cm (4 ends per inch) in both directions. It has a basis weight of 6.8 g / m2 (0.2 oz / yd2) and the continuous filament has a thermoplastic coating that keeps the twisted strands crossed in place. Also, Bayex® Product Number KPM10510 / P3 is manufactured from continuous 78 dtex (70 denier) polyester filaments in the warp and continuous polyester filaments 167 dtex (150 denier) in the direction of the weft and has 4 ends per cm ( 10 ends per inch) in the direction of the warp and 2 ends per cm (5 ends per inch) in the direction of the weft. It has a basis weight of 12.1 g / m2 (0.36 oz / yd2) and the continuous filament has a thermoplastic coating that keeps the twisted strands crossed in place. This type of grid provides adequate strength while not contributing excessively to flammability. It is also believed that the open mesh also contributes to the formation of open air cavities in the fabric when the fabric is exposed to high heat because a mesh grid should contain less of the heat resistant fibers due to the small number of agglutination points. with fibrous veils. The grid may be comprised of thermoplastic or non-thermoplastic filaments, and may be aramid, nylon, glass, or polyester. If the grid is a thermoplastic such as polyester, when the non-woven fabric is burned, this mesh essentially disappears into the burned area when the crimped heat resistant fibers sponge. This invention also relates to a process for manufacturing a reinforced non-woven fabric that is heat-sponge or fire-blocking flame an article comprising the steps of: a) forming a mat comprising curled heat-resistant organic fiber and binder fiber, b) contacting the mat with the first side of an open mesh grid, the grid having a first and second side, to form a fabric assembly, c) applying binder powder to the fabric assembly, d) heating the assembly of fabric for activating the binder fiber and binder powder, e) compressing the fabric assembly to a compressed state, and f) cooling the fabric assembly in a compressed state to form a reinforced nonwoven fabric. The mat can be formed by any method that can create low density veils. For example, packages of crimped staple fibers and binder fibers obtained from fiber bales can be opened by a device such as a fuller. Preferably these fibers are staple fibers having a linear density of from about 0.55 to about 110 dtex per filament (0.5 to 100 denier per filament), preferably 0.88 to 56 dtex / filament (0.8 to 50 denier / filament) with the linear density range from about 1 to 33 dtex / filament (0.9 to 30 denier / filament) being more preferred. The open fiber mixture can then be mixed by any appropriate method, such as pneumatic transport, to form a more uniform mixture. Alternatively, the fibers can be mixed to form a uniform mixture prior to the fiber opening in the fulling mill. The fiber mixture can then be converted into a fibrous web by the use of a device such as a card, although other methods, such as air settling of the fibers can be used. It is preferable that the fibrous web be used directly from the card without any transverse overlap. However, if desired, the fibrous web can then be sent via a conveyor to a device such as a transverse web tensioner to create the transverse overlay structure by placing individual webs on top of another in a zig-zig structure. . The fibrous webs from one or more cards and an open mesh grid can then be collected on a transport belt. Preferably the grid is inserted between two webs to make a two-leaf structure, although an individual web structure can be made by superimposing a grid over an individual web or single web over the grid. Additional veils can be placed over the structures of one or two veils if desired. Preferably the final structure has two carded veils on one side of the open mesh grid and a veil carded on the other side of the grid. Binder powder is then applied to the combined webs and the grid in a preferred amount of about 3.4 to 24 g / m2 (0.1 to 0.7 oz / yd2). The combined webs, the binder powder, and the grid are then transported over an oven at a temperature sufficient to soften and partially melt the fiber and binder powder and allow them to adhere to the fibers together. At the exit of the furnace the sheet is preferably compressed between two steel rollers to consolidate the layers in a cohesive fabric. The fabric is then cooled in this compressed state. The invention additionally relates to a fire-blocking method of an article, comprising the steps of (1) combining a layer of reinforced non-woven fire blocking fabric, a cuti fabric or upholstery layer, and optionally a quilting layer; (2) bake the layers together to form a quilt that blocks fire or upholstery fabric, and (3) incorporate the quilting that blocks fire or upholstery fabric in the article. The reinforced non-woven fire blocking fabric comprises an open mesh grid having a first side and a second side the first side with heat-resistant organic fibers, crimped, compressed thereon, the fibers maintained in a state compressed by a thermoplastic binder , where when the fabric is exposed to heat or flame, the fabric is able to increase its thickness by at least three times. Preferably the organic fibers are compressed on both the first and second sides of the open mesh grid. The combination of non-woven fire-blocking fabric, cuti fabric or upholstery layer, and optionally a quilting layer, are basted or sewn together to form a pre-sewn quilting and these quilts can take many forms. A basic example of a padding comprises, in order, an outer cuticle fabric or cover fabric layer, one or more layers of reinforced fire retardant nonwoven fabric of this invention, a foam padding layer or fiber mattress, and a stitched back layer. The layers are combined and then sewn together using any sewing pattern, typically a quilting pattern, to form a cushion that is used on the edges of mattresses and panels as needed. Useful fabrics such as the outer cuti fabric or the cover fabric layer are usually woven fabrics or very durable knitted fabrics using any number of fabrics, and tend to have base weights in the range of 68 to 271 grams per square meter (2 to 8 ounces per square yard). The cuti fabrics may contain but are not limited to cotton, polyester fibers, polypropylene fibers, or rayon fibers. The optional foam cushion or fiber mattress layer may include one or more light density fibrous fiber mattresses or foams, or a combination thereof that provides the desired surface effect or cushion. The fiber mattress and / or foams act similar to a cushion under the skin, providing very tactile padding, the kind that can be easily discerned by simply touching or sliding a hand through the mattress. The preferred fibrous fiber mattress material is polyester fiber (PET) mattress and is typically present in an amount of about 153 to 610 grams / square meter (0.5 to 2.0 ounces per square foot). While not intended to be limiting, if the cushioning material is a fibrous fiber mattress, such a fiber mattress may include a vertically folded structure such as that described for example, in PCT Publication WO2003049581 or a fiber mattress such as described for example in U.S. Patent No. 3,118,750. If foam is used, it is commonly polyurethane or latex foam and is typically 1.2 to 7.6 cm (0.5 to 3 inches) thick. The stitched backing layer is typically used to hold the seams on the side of the quilt opposite the cuti when the quilted material is not substantially sufficient to maintain a seam. Typically, stitched backing layers are light weight fabrics that have a basis weight in the range of 17 grams per square meter (0.5 ounces per square yard) and are made from materials such as polypropylene. An alternative padding layer configuration can be, in order, an outer skin or layer of upholstery, a layer of padding material, and one or more layers of reinforced non-woven fabric fire-retardant, where the padding material is placed between the fire-blocker and the cutí. In this padding, stitched backing is not needed because the fire blocker serves the purpose of maintaining the seams. Another version of the padding can be made with multiple layers of quilting material. For example, a padding can be formed by combining, in order of exterior cutie or upholstery fabric, a layer of quilting material, one or more layers of reinforced non-woven fabric fire-retardant, another layer of quilting material, and then a layer of stitched backing. Another possible configuration of padding is one in which a layer of the reinforced non-woven fire-blocking fabric of this invention is placed directly under the outer cover fabric, followed by a padding layer, with a second layer of the non-woven fabric. reinforced fire retardant under the padding layer. In this configuration the last layer of reinforced non-woven fabric fire-blocking also functions as a stitched backing. In an alternative version of this particular padding configuration, another padding layer may be disposed between the cover fabric and the reinforced non-woven fire blocking fabric. Yet another padding configuration could be comprised of an outer skin or upholstery layer and one or more layers of the reinforced non-woven fire-blocking fabric of this invention, without substantial padding layer. As one can see, many different padding is possible and other layers of materials can be combined in the padding while the padding performance of the padding is not adversely affected. The pre-basted padding can then be incorporated into an article such as a piece of furniture, or preferably, a set of mattress and base. One method for the mattress to block fire is to completely cover the panels and edges of the mattress core with the pre-sewn quilts, and baste the quilts together at the seams to encase the mattress. This ensures that the mattress will block fire regardless of which panel or edge is exposed to the flame. Pre-sewn quilts of various types can be incorporated into an article, such as a quilting having little padding can be used on the edge of a mattress while a quilting having a considerable quilting amount can be used on the top and bottom panels thereof mattresses Bases, such as box springs, usually do not have to be completely fire-blocking but are usually only required to block fire at the edges with fire blocking being optional for the top face or base panel. This base panel is normally in contact with the mattress and is thus generally protected from the flame such that the material used in the base panel typically does not have the same degree of fire blocking as the mattress panel. Additionally, the base of the mattress may not have a high degree of cushioning material on the edge and / or the panel. However, the reinforced nonwoven fabric of this invention can be used on the edge of the base or on the panel as desired. The reinforced nonwoven fabric provides adequate fire blocking to an article that is not capable of passing the California Technical Bulletin 603 published in July 2003 without adding a flame retardant chemical material. The reinforced non-woven fabric can be incorporated into the article, such as a mattress, in any way that allows the mattresses to pass the test when it would otherwise not pass it. METHODS OF TEST ThermoGravimetric Analysis. The fibers used in this invention retain a portion of their fiber weight when heated at a high temperature to a specific heating rate. This fiber weight was measured using a Model 2950 Thermogravimetric Analyzer (TGA) available from TA Instruments (a division of Waters Corporation) of Newark, Delaware. The TGA provides an exploration of the weight loss of the sample against the increase in temperature. Using the TA Universal Analysis program, the percentage of weight loss can be measured at any recorded temperature. The profile of the program consists of balancing the sample at 50 degrees C; raising the temperature from 10 or 20 degrees C per minute from 50 to 1000 degrees C; using air as the gas, provided at 10 ml / minute; and using a 500 microliter ceramic cup sample container (PN 952018910). The test procedure is as follows. The TGA was programmed using the TGA screen on the TA Systems 2900 Controller. The sample ID was entered and the planned temperature rise program of 20 degrees per minute was selected. The empty sample cup was tapped using the tare function of the instrument. The fiber sample was cut into lengths of approx. 0.16 cm (1/16") and the sample container was filled comfortably with the sample.The weight of the sample should be in the range of 10 to 50 mg.The TGA has a balance therefore the exact weight does not have To be determined in advance, none of the samples should be outside the container.The full sample container was loaded onto the balance wire making sure that the thermocouple is close to the upper edge of the container but not touching it. Once the program is complete, the TGA will automatically lower the incinerator, remove the sample container, and go to a cooling mode.The 2900TA Universal Systems Analysis program is then used to Analyze and produce the TGA exploration for percentage losses in weight over the temperature range Performance of Burning the Mattress.

Home Furnishings and Thermal Insulation of the California Department of Consumer Affairs (3485 Orange Grove Avenue, North Highlands, California 95660-5595, USA) published Technical Bulletin 603"Requirements and Test Procedure for Resistance of a Game Mattress / Box Spring Residential to a Flame-Open Long "dated February 2003 to quantify the flammability performance of mattress sets. The bulletin was subsequently revised in July 2003, requiring that the Limit of Peak Heat Release Ratio (PHRR) be less than 200 kilowatts and the limit of total heat release in 10 minutes be less than 25 Megajoules. This protocol provides a means to determine the burning behavior of the sucker / base games by measuring the responses to the specific fire test when the mattress plus the base is exposed to a specified ignition source under well-ventilated conditions. This is based on the Publication of the National Institute of Standards and Technology entitled "Mattress / Base Games Test Protocol Using a Pair of Gas Burners" dated February 2003. Test data describing the burn during and subsequent to the application of a specific pair of gas burners from the point of ignition until (1) the burn of the entire sleeping set has ended, (2) a period of 30 minutes has elapsed, or (3) the flare of the fourth Test seems inevitable. The reason for the release of heat from the burning specimen (the energy generated by the fire) is measured by oxygen consumption calorimetry. A discussion of the principles, limitations, and requirement instrumentation is found in ASTM E 1590"Standard Mattress Fire Test Test Method". The terminology associated with the test is defined in ASTM e 176"Standard Fire Standard Terminology". In general, the test protocol uses a pair of propane burners, designed to simulate the levels of heat flow and durations imposed on a mattress and base by burning the bedding. The burners impose different flows for different times on the top of the mattress and the mattress / base side. During and subsequent to this exposure, measurements of the time-dependent heat release ratio are made from the test specimen. The mattress / base is placed on top of a short bed structure that sits on a grip surface. During the test, the smoke plume is captured by a hood that is instrumented to measure -the heat release cup. For practicality mattresses and individual size bases are tested. After ignition by the burners, the specimen is allowed to burn freely under well ventilated conditions. The test specimen includes a mattress that is placed on the base with T-shaped burners placed to burn the specimen. A burner hits flames on the upper surface of the mattress and is placed 39 mm from the surface of the mattress. The second burner impacts flares vertically on the side of the mattress / base combination and is placed 42 mm from the side of the specimen. The side burner and the top burner are not placed in the same place along the length of the specimen but are deviated from each other along the length approximately 18 to 20 cm. The burners are specially constructed and aligned for the test method. The test specimen is conditioned for 24 hours prior to the test at an ambient temperature of about 12 Celsius (54 Fahrenheit) and a relative humidity of less than 70 percent. The test specimen of the mattress and the base were centered on each other and the flame and grip surface. If the mattress is 1 to 2 cm narrower than the base, the mattress can be changed until the sides of the mattress and the base are aligned vertically. The burners are aligned and spaced from the specimen by the standard. The recording and logging devices are turned on at least one minute before ignition. The burners are lit and the top of the burner is allowed to burn glove 70 seconds while the burner side is allowed to burn for 50 seconds (if possible) and then these are removed from the area. The data collection continues until all signs of burning and embers have ceased or until one hour has passed. Vertical Flame Test. The vertical flame performance of the reinforced nonwoven fabric was measured using ASTM D6413-99. Thickness. The measured thickness of the reinforced fabric of this invention prior to swelling can be measured using ASTM D1777-96 Option 1. However, most of the standard methods of thickness measurement require the application of some type of weight on the sample to be measured. Therefore, to obtain a true thickness reading and not to disturb the "swelling" of swollen samples that had experienced high heat or flame, the thickness results for Example 2 were based on electronic scanning electron microscope (SEM) measurements. samples of cuts. The test samples were cut with a pair of sharp scissors and mounted on the SEM sample strut. Example 1 A reinforced nonwoven fabric was prepared as follows. 90 parts by weight 2.2 dpf, cutting length of 2"discontinuous fiber brand Type 970 Kevlar® and 10 parts 4 dpf, binder fiber Unitika Type 4080 cutting length 2" was mixed as feed from the bales to three cards. The fiber webs from the three cards were collected on a transport belt to create a fiber mat having a basis weight of approximately 37.3mg / m2 (1.1 oz / yd2). An open mesh grid of polyester filament yarn was inserted between two webs formed by the first two cards. The open mesh grid was a Saint Gobain 5 x 10 grid (Type KPMR10510 / P3 having 5 ends / 2.54 centimeters (ends / inch) of polyester 150 denier in the weft direction and 10 ends / 2.54 centimeters (ends / inch) 70 denier polyester in the warp direction) and has a basis weight of 12.54 g / m2. (37 oz / yd2). The resulting structure had two carded veils on one side of the open mesh grid and a veil carded on the other side of the grid. Adhesive powder Griltex 763305 20 EMS was applied to the combined veils and the grid in an amount of carried the total weight of the sheet to 67.82 g / m2 (2 oz / yd2). The combined webs, binder powder, and grid were transported to an oven at 285 ° C to melt the binder fiber and powder. At the exit of the furnace the sheets were compressed between two steel rollers with a space of 0 centimeters (0"), which consolidated the components into a cohesive fabric.The fabric was cooled in this compressed state.The final composition of the fabric was approximately 50% Kevlar® fiber, 6% binder fiber, 19% polyester grid and 25% binder fiber The fabric had a thickness of approximately 23 mils in ASTM D1777-96 Option 1. The fabric had a hold strength of 30 lbs -force in the warp direction and 22 lb.-force in the direction of the weft.In a 12-sec vertical burn test, the burn length was 9.39 centimeters (3.7") with a second flame after 5.6 seconds in the warp direction and the burn length was 5.58 centimeters (2.2") with a rear flame of 1.3 sec in the direction of the weft.No flow was observed.It was noted that the heat of the flame caused the thickness of the material in the neighborhood of the flame s and visually increase more than 3x the thickness of the original fabric. The fabric was tested as a fire barrier on one and two sided mattresses in TB 603. For the padded upper mattress panel the fire barrier was placed under a 1.9 cm (3/4") layer of fiber mattress. polyester below the cuti For the boxspring mattress and edges the fire barrier fabric was placed under a 0.48 cm (3/16") layer of foam under the cuti. The mattresses were IBC Celebrity construction. For individual side mattresses, the upper panel padding was constructed of sewn layers that were, in order, a layer of white woven fabric that has a Mosaic style of polyester and polypropylene fibers; a 1.9 cm (3/4") layer of polyester fiber mattress, the fire-blocking fabric of this invention, 3 layers of polyester foam, each layer with a thickness of 1.09 centimeters (7/16"), - and finally a multiple seam backed layer (to keep the seam on the back side of the padding.) The top panel of the single side mattress was constructed from the top panel padding; folded polyurethane foam layer of 3.81 centimeters (1/1/2"); a layer of 1/16"polyurethane foam, and gray felt insulating padding, which was placed against mattress springs 522 Highpro.The bottom panel of the mattress was constructed, outwardly from the springs of the mattress. mattress, with gray felt insulation against the springs, a layer of polyurethane foam of 4.44 centimeters (1- / 3/4"); and an outer skid filler, which was constructed from a non-woven fabric of 135.6 g / m2 (4 oz / yd2) made of 25% Kevlar® aramid fiber and 75% Visil® 33AP cellulose fiber. The quilting edge was constructed of sewn layers that were, in order, a layer of white woven cuticle that has a Mosaic style of polyester and polypropylene fibers; a layer of 0.48 centimeters (3/16") of polyurethane foam, the fire-blocking fabric of this invention, and finally a backing layer with multiple seams (to keep the seam on the back side of the padding). mattresses were quilted with non-FR yarn, the seams were sewn with Kevlar® aramid yarn, and the FR polyester tape was used with the seams.The upper panel of the box spring used with the mattress had a non-slip padding on the surface , which was a nonwoven fabric of 135.64 g / m2 (4 oz / yd2) made of 25% Kevlar® aramid fiber and 75% Visil® 33AP cellulose fiber secured to the cardboard. The sides were approximately 2.54 centimeters (1") and the top was secured to the edge with a continental edge of 5.08 (2") .The edge used in the box spring was the same as that used on the mattress.The seams were sewn using Kevlar® aramid yarn and polyester tape r FR was used with the seams.

For double-sided mattresses, both upper and lower panel padding was constructed in the same way as the upper panel padding for the single-sided mattress. The padding rivet was also constructed in the same way as for the individual side mattress and the panels were quilted and sewn in a similar way for the individual side mattress. The box springs were prepared in the same way as for the individual side mattress. Both single side and double side mattresses were burned in TB 603 and met the criterion of peak heat release of less than 200kW in 30 minutes from burner ignition. Example 2 This example illustrates the foaming behavior of the reinforced fabric of this invention. A reinforced non-woven fabric was prepared similar to Example 1. The fabric had an initial thickness of 0.32 mm (12 mils). Samples of the fabric were placed in a heated oven operating at different temperatures and the time was recorded when the initial overrun of the sample was visually observed. Visual monitoring of the samples continued and the time for essentially total swelling of the samples varied with temperature, with essentially complete swelling occurring in approximately five minutes for the sample tested at 150 ° C until approximately 1.5 minutes for the sample tested at 250 ° C. The samples remained in the oven for a total of 15 minutes and the thickness of the final swelling was recorded. In addition, a sample was kept in flame and this immediately sponged up to its maximum thickness. Its final thickness increased up to 9.38 mm, an increase of 29 times. The final swelling thickness was measured by transverse sectioning of the foamed cloth and measuring the thickness using SEM. TABLE Sample Temp Duration Time Thickness # • c (min) Spin (mm) Initial (sec) A Control - 0.32 1 150 15 90 1.04 2 200 15 30 2.09 3 225 15 Immediate 3.94 4 250 15 Immediate 4.62 It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims (1)

CLAIMS Having described the invention as above, the content of the following claims is claimed as property: 1. A non-woven fabric reinforced to block fire to an article, characterized in that it comprises an open mesh grid having a first side and a second side , the first side has heat-resistant organic fibers, crimps compressed thereon, the fibers maintained in a state compressed by a thermoplastic binder, wherein when the fabric is exposed to heat or flame, the fabric is able to increase its thickness by minus three times. The reinforced non-woven fabric according to claim 1, characterized in that the fabric is capable of increasing its thickness by at least five times when the fabric is exposed to heat or flame. The reinforced non-woven fabric according to claim 1, characterized in that the fabric is capable of increasing its thickness by at least ten times when the fabric is exposed to heat or flame. The reinforced non-woven fabric according to claim 3, characterized in that the fibers are maintained in a compressed state by the combination of the thermoplastic binder and the thermoplastic open mesh grid. The reinforced non-woven fabric according to claim 1, characterized in that it aionally comprises heat-resistant, crimped organic fibers compressed on the second side of the grid, the fibers are maintained in a state compressed by a thermoplastic binder. The reinforced non-woven fabric according to claim 1, characterized in that the open mesh grid comprises thermoplastic material. The reinforced nonwoven fabric according to claim 1, characterized in that the thermoplastic binder is binder fiber. The reinforced non-woven fabric according to claim 7, characterized in that the thermoplastic binder comprises a combination of binder fiber and binder powder. The reinforced non-woven fabric according to claim 1, characterized in that the heat-resistant organic fiber is a para-aramid fiber. The reinforced nonwoven fabric according to claim 9, characterized in that the thermoplastic binder is a combination of polyester binder powder and polyester binder fibers, and the open mesh grid is made of the same or different polyester polymer. 11. A fire-blocking article characterized in that it comprises the reinforced non-woven fabric according to claim 1. 12. A fire-blocking mattress characterized in that it comprises the reinforced non-woven fabric according to claim 1. 13. A process for manufacturing a reinforced non-woven fabric that is heat-filled or flame-retardant to block fire to an article, characterized in that it comprises the steps of: a) forming a mat comprising heat-resistant organic fiber and binder fiber, b) contacting the mat with the first side of an open mesh grid, the grid having the first and second sides, to form a fabric assembly, c) applying binder powder to the fabric assembly, d) heating the fabric assembly to activate the binder fiber and the binder powder, e) compressing the fabric assembly to a compressed state, and f) cooling the fabric assembly in a compressed state to form a reinforced nonwoven fabric. 1 . The process in accordance with the claim 13, characterized in that it has the aional step prior to step c) of contacting the second side of the open mesh grid with a second fiber mat comprising heat resistant organic fiber and binder fiber. 15. A fire-blocking pag characterized in that it comprises an outer fabric ply or a cover fabric layer; one or more layers of non-woven reinforced fire-blocking fabric, a layer of foam pag or fiber mattress, and optionally a stitched backing layer; wherein the reinforced non-woven fire-blocking fabric comprises an open-mesh grid having heat-resistant, crimped organic fibers compressed thereon, the fibers held in a state compressed by a thermoplastic binder. 16. A method for blocking fire to an article with a layer of reinforced non-woven fabric which is sponge in heat or flame, characterized in that it comprises the steps of a) combining a layer of reinforced non-woven fabric, a cuti fabric or upholstery layer , and optionally a quilting layer, b) sewing the layers together to form a fire-blocking fabric padding, c) incorporating the fire-blocking fabric padding within the article, the reinforced non-woven fabric layer comprising a mesh grid open having a first side and a second side, the first side having heat-resistant organic fibers, crimped, compressed thereon, the fibers maintained in a state compressed by a thermoplastic binder, wherein when the fabric cushion is exposed to heat or flame, the reinforced nonwoven fabric layer is able to increase its thickness by at least three times. 17. The method for blocking fire to an article according to claim 16, characterized in that the article is a mattress. The method for blocking fire to an article according to claim 16, characterized in that the additionally reinforced nonwoven fabric comprises heat-resistant, crimped organic fibers compressed on the second side of the grid, the fibers held in a compressed state by a thermoplastic binder.

1 . The method for blocking fire to an article according to claim 18, characterized in that the article is a mattress.