Importance

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Abstract

A lightweight (2.25 to 6 ounce per square yard) fabric mechanically bonded through needle-punching formed of fire-retardant fibers with no post-treatment. The composition of the fibers is typically 75 to 85% fire-retardant cellulose and 15 to 25% fire inhibiting modacrylic fiber with a high limited oxygen index. The cellulosic fiber in particular can be rayon or lyocell saturated with a fire-retardant agent such as diammonium phosphate. The cellulosic fiber acts as a char-former thereby creating a carbonized thermal insulator. The modacrylic is an acrylic modified fiber with additional monomers which reduce fuel value and help limit the available oxygen to the fire cycle. The modacrylic component also serves to add strength to the char-forming fiber by softening and thereby binding to the charring fibers. The fibers are blended together and homogenized into a lightweight fiber web which is stacked in staggered layers to form a low density batting. The batting is then passed through two needle-bonding machines which mechanically entangle the batting fibers to form a dense needle-punched fabric. The fabric is then slit and rolled up into usable form. No additional processes or post-treatments are necessary to impart the fire-retardancy. This material is designed to be used immediately under the outer-ticking or finished surface layer of upholstery and will protect solid materials beneath it from burning. The product is designed to comply with the Federal Regulation 16 C.F.R. 1633 and California Code TB6B603.

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First Claim