Thermally protective flame retardant fabric
View Patent ↗A thermally protective, flame retardant fabric includes a substrate treated with a combination of a flame retardant agent and an intumescent agent. The substrate includes non-thermoplastic fibers or a blend of non-thermoplastic fibers and thermoplastic fibers having a basis weight ranging from 2.0 to 15.0 ounces per square yard. The fabric has a contact thermal protective performance value of at least 4.5 and a contact thermal protective performance efficiency greater than 1.1. Applications of the fabric include protective garments, articles of furniture, vehicle components, building components, electrical components, decorative components, appliances, and containers.
1. A fabric consisting of a single layer of a non-woven substrate,
wherein the non-woven substrate comprises cellulosic fibers, polyester fibers and aramid fibers,
wherein the non-woven substrate is treated with an intumescent, flame retardant finish comprising one or more compounds comprising phosphorous and/or nitrogen,
wherein the non-woven substrate has a basis weight ranging from 2.0 to 15.0 ounces per square yard,
wherein the non-woven substrate is a non-woven stitchbonded substrate, and
wherein the fabric has a thickness ranging from 0.01 to 0.15 inches.
2. The fabric of claim 1 , wherein the fabric has a contact thermal protective performance value of at least 6.5.
3. The fabric of claim 1 , wherein the fabric has a contact thermal protective performance value of at least 9.0.
4. The fabric of claim 1 , wherein the fabric has a contact thermal protective performance efficiency greater than 1.1.
5. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 5.0 to 6.5 ounces per square yard.
6. The fabric of claim 1 , wherein the fabric has a contact thermal protective performance value of at least 4.5.
7. The fabric of claim 1 , wherein the fabric has a thickness ranging from 0.04 to 0.09 inches.
8. The fabric of claim 1 , wherein the fabric has a thickness ranging from 0.01 to 0.05 inches.
9. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard.
10. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard.
11. The fabric of claim 1 , wherein the cellulosic fibers comprise cotton, rayon and/or lyocell fibers.
12. The fabric of claim 1 , wherein the cellulosic fibers comprise rayon fibers.
13. The fabric of claim 1 , wherein the cellulosic fibers comprise lyocell fibers.
14. A protective garment constructed from the fabric claimed in claim 1 .
15. The protective garment of claim 14 , wherein the protective garment is chosen from fire retardant suits, fire retardant gloves and welding suits.
16. An article of furniture constructed from the fabric claimed in claim 1 .
17. The article of furniture of claim 16 , wherein the article of furniture is chosen from mattresses, chairs, sofas, and seats.
18. A vehicle component constructed from the fabric claimed in claim 1 .
19. The vehicle component of claim 18 , wherein the vehicle component is chosen from vehicle seats, vehicle beds, vehicle doors, vehicle bodies, mobile homes, trailers, insulation, and fuel tank exterior liners.
20. The fabric of claim 1 , wherein the intumescent, flame retardant finish is applied to the non-woven substrate in an amount ranging from 15 to 130 percent solids, based upon the weight of the non-woven substrate.
21. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 2.0 to 8.0 ounces per square yard and a thickness ranging from 0.04 to 0.09 inches.
22. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 2.0 to 8.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches.
23. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard and a thickness ranging from 0.04 to 0.09 inches.
24. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches.
25. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard and a thickness ranging from 0.04 to 0.09 inches.
26. The fabric of claim 1 , wherein the non-woven substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches.
27. The fabric of claim 1 , wherein the intumescent, flame retardant finish comprises one or more compounds comprising phosphorous and nitrogen.
28. The fabric of claim 1 , wherein the cellulosic fibers comprise rayon and/or lyocell fibers and wherein the non-woven substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches.
29. The fabric of claim 28 , wherein the fabric has a contact thermal protective performance value of at least 4.5.
30. The fabric of claim 28 , wherein the fabric has a contact thermal protective performance efficiency of greater than 1.1.