FIRE RETARDANT NYLON FIBERS AND METHODS FOR MAKING THEM
Provided are nylon fibers having fire retardant agents dispersed therein and methods for manufacturing such fibers. The fire-retardant agents may comprise Tris(tribromophenyl) triazine and/or antimony trioxide. Fabrics made from such fibers are also provided.
1 . A layered fabric comprising:
(i) a first layer comprising a plurality of fire-retardant nylon fibers having dispersed within internal regions thereof a fire-retardant composition comprising:
a. a brominated (Br) organic fire-retardant; and
b. a synergist,
wherein the fire-retardant composition comprises from about 0.1% to about 10% brominated organic fire-retardant; and from about 0.1% to about 10% synergist,
wherein a major portion thereof is Nylon-6 polymer and/or Nylon-6,6 polymer,
wherein the fiber is essentially free of brominated polystyrenes; and
(ii) a second layer comprising a laminate bonded to the first layer.
2 . The layered fabric of claim 1 , wherein the brominated organic fire-retardant is selected from the group consisting of tris(tribromophenyl) triazine; tris(tribromoneopentyl)phosphate; pentabromobenzyl acrylate (PBB-MA); poly(pentabromobenzyl acrylate) (PBB-PA); brominated trimethylphenyl indan; and tetrabromobisphenyl A-bis(2,3-dibromopropyl ether).
3 . The layered fabric of claim 1 , wherein the brominated organic fire-retardant is a brominated aryl fire-retardant.
4 . The layered fabric of claim 1 , wherein the brominated organic fire-retardant comprises tris(tribromophenyl) triazine.
5 . The layered fabric of claim 1 , wherein the synergist is selected from the group consisting of antimony (Sb) trioxide, antimony pentoxide, sodium antimonite, calcium metaborate, aluminum hydroxide (ATH), and barium borate.
6 . The layered fabric of claim 1 , wherein the synergist is antimony trioxide.
7 . The layered fabric of claim 1 , wherein the brominated organic fire-retardant is tris(tribromophenyl) triazine; and the synergist is antimony trioxide.
8 . The layered fabric of claim 7 , wherein the antimony trioxide and the tris(tribromophenyl) triazine are present in an amount sufficient to provide a weight ratio of elemental Sb and Br (Sb:Br) of from about 1:3 to about 1:10, and wherein the aggregate weight of elemental Sb and Br in the fiber is from about 0.1% to about 20% by weight of the total weight of the fiber.
9 . The layered fabric of claim 1 , wherein the antimony trioxide and the tris(tribromophenyl) triazine are present in the fibers of the first layer in a weight ratio of from about 2:1 to about 5:1.
10 . The layered fabric of claim 1 , wherein the first layer comprises at least about 50% Nylon-6 polymer and/or Nylon-6,6 polymer.
11 . The layered fabric of claim 1 , wherein the laminate comprises a coating or an impregnation selected from the group consisting of a silicone coating, a polyurethane coating, a water-repellant coating, a durable water-repellant (DWR), a water-soluble particle, a UV stabilizer, a light absorber or reflector, an antimicrobial agent, an antistatic agent, a hand-altering agent, an anti-soiling agent, a colorant, and any combinations thereof.
12 . The layered fabric of claim 1 , wherein the laminate is disposed as an outer layer of a multi-ply laminate.
13 . The layered fabric of claim 1 , further comprising from about 0.1% to about 10% inorganic halogenated fire-retardant.
14 . The layered fabric of claim 13 , wherein the inorganic halogenated fire-retardant is tris(tribromoneopentyl)phosphate.
15 . The layered fabric of claim 1 , wherein the layered fabric comprises:
a fiber of the plurality of fire-retardant nylon fibers having a tensile strength within 20% of the tensile strength of an otherwise identical nylon fiber that does not comprise said fire-retardant composition;
a moisture vapor transport rate (MVTR) of greater than 100 gms/m2/day;
an air porosity of about 0.1 ft 3 /min to about 50 ft 3 /min; or
a hand and/or a drape of no more than +1 compared to an otherwise identical fabric that does not comprise said fire-retardant composition.
16 . A method of producing the layered fabric of claim 1 , comprising:
(i) heating a mixture of solid pellets of Nylon-6 polymer, wherein said pellets having tris(tribromophenyl) triazine dispersed therein, and Nylon-6,6 polymer to form a molten mixture comprising Nylon-6 and Nylon-6,6 polymers and tris (tribromophenyl) triazine; and
(ii) forming a plurality of fire-retardant nylon fibers from the molten mixture,
wherein the plurality of fire-retardant nylon fibers form the first layer;
(iii) bonding a second layer comprising a laminate to the first layer to form the layered fabric.
17 . The method of claim 16 , wherein the laminate comprises a coating or an impregnation selected from the group consisting of: a silicone coating, a polyurethane coating, a water-repellant coating, a durable water-repellant (DWR), a water-soluble particle, a UV stabilizer, a light absorber or reflector, an antimicrobial agent, an antistatic agent, a hand-altering agent, an anti-soiling agent, a colorant, and any combinations thereof.
18 . The method of claim 16 , wherein forming the first layer, the plurality of fire-retardant nylon fibers form threads or yarns.
19 . The method of claim 18 , wherein forming the first layer comprises weaving yarns spun from the plurality of fire-retardant nylon fibers.
20 . The method of claim 16 , wherein bonding occurs by knife blading, roll coating, transfer coating.