Method for forming a flexible, thermal-barrier sheet product, and associated apparatus

1. A method of forming a flexible fire-resistant and thermal resistant sheet product, said method comprising:

securing a first insulation material sheet to a first cover sheet, with lateral stitching using a first stitching material, to form a first sheet product portion including a perimeter;

securing a second insulation material sheet to a second cover sheet, with lateral stitching using the first stitching material, to form a second sheet product portion including a perimeter; and

securing the first sheet product portion to the second sheet product portion, at least about the perimeters thereof and with a plurality of separate and individual point stitches therebetween, the point stitches being comprised of a second stitching material, such that the first insulation material sheet is disposed adjacent to the second insulation material sheet, the first and second sheet product portions cooperating to form the sheet product;

wherein the first stitching material is arranged to form lateral stitching and extending only between the insulation material sheet and the cover sheet of each of the first and second sheet product portion.

2. A method according to claim 1 , wherein securing the first insulation material sheet and securing the second insulation sheet material each comprise securing the first and second insulation material sheets, each comprised of filiform glass fibers, to the respective first and second cover sheets.

3. A method according to claim 1 , comprising interacting at least one of the first and second insulation material sheets and the first and second cover sheets with a fire-retarding solution including one or more of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogen compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate, and combinations thereof.

4. A method according to claim 1 , comprising:

interacting at least one of the first and second insulation material sheets with a fire-retarding solution; and

de-liquefying the at least one of the first and second insulation material sheets to form at least one dry melt-resistant insulation material sheet therefrom.

5. A method according to claim 1 , comprising:

interacting at least one of the first and second cover sheets with a fire-retarding solution; and

de-liquefying the at least one of the first and second cover sheets to form at least one dry ignition-resistant cover sheet therefrom.

6. A method according to claim 1 , comprising:

interacting the first stitching material with a fire-retarding solution; and

de-liquefying the first stitching material to form dry ignition-resistant first stitching material therefrom.

7. A method according to claim 1 , comprising:

interacting the second stitching material with a fire-retarding solution; and

de-liquefying the second stitching material to form dry ignition-resistant second stitching material therefrom.

8. A method according to claim 3 , wherein interacting at least one of the first and second insulation material sheets and the first and second cover sheets with a fire-retarding solution further comprises interacting at least one of the first and second insulation material sheets and the first and second cover sheets with a fire-retarding solution comprising one of an aqueous fire-retarding solution, a nontoxic liquid fire-retarding solution, and a neutral pH liquid fire-retarding solution.

9. A flexible fire-resistant and thermal resistant sheet, said sheet comprising:

a first sheet product layered with and secured to a co-extending second sheet product, each sheet product comprising an insulation material sheet layered with a co-extending cover sheet, the insulation material and cover sheets each having a perimeter corresponding to a perimeter of the respective sheet product, the insulation material sheet being comprised of filiform glass fibers and being layered with the co-extending cover sheet, the insulation material sheet and the cover sheet being secured together with a first stitching material arranged to form lateral stitching and extending only between the insulation material sheet and the cover sheet of each of the first and second sheet products, the layered and co-extending first and second sheet products being arranged such that the perimeters thereof are coincident and such that the insulation material sheet of the first sheet product is disposed directly adjacent to the insulation material sheet of the second sheet product, with the layered and co-extending first and second sheet products being secured together about the coincident perimeters thereof with a second stitching material arranged to form a plurality of separate and individual point stitches extending between the respective cover sheets, and such that the layered and secured together sheet products cooperate to form the flexible fire-resistant and thermal resistant sheet,

wherein one of the first and second insulation material sheets and the first and second cover sheets, and one of the first and second stitching materials is interacted with a fire-retarding solution including one or more of a boron compound, a phosphorus compound, a chlorine compound, a fluorine compound, an antimony compound, a borate compound, a halogen compound, boric acid, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, carbon tetrachloride, urea-potassium bicarbonate, and combinations thereof.

10. A sheet according to claim 9 , wherein the first and second cover sheets are comprised of a material selected from the group consisting of cotton, polyester, poly-cotton, filiform glass fibers, Kraft paper, encasement paper, a fibrous material, an aluminum foil sheet or other metal foil sheet, and combinations thereof.

11. A sheet according to claim 9 , wherein the first and second stitching materials are comprised of a fibrous material selected from the group consisting of cotton, poly-cotton, filiform glass fibers, and combination thereof.