# US 10,246,806 B2 · Economical fire barrier nonwoven

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- Number: US 10,246,806 B2
- Document ID: US10246806B2
- Status: Granted
- Kind: B2
- Application number: 15/132,623
- Filed: 2016-04-19
- Published: 2016-12-08
- Granted: 2019-04-02
- Earliest claimed: 2015-06-04
- Assignees: Tintoria Piana US, Inc.
- Applicants: Tintoria Piana US, Inc.
- Inventors: Sang-hoon Lim; Andrea Piana
- Web page: https://patentgrep.com/patent/US10246806B2

## CPC

- D04H 3/013: Regenerated cellulose series
- D04H 1/425: Cellulose series
- D04H 1/4258: Regenerated cellulose series
- D04H 1/43828: {sheath-core}
- D04H 1/43835: {Mixed fibres, e.g. at least two chemically different fibres or fibre blends}
- D04H 1/542: Adhesive fibres
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)

## Abstract

Provided herein is a new fire barrier nonwoven composed of flame retardant (FR) cellulosic fiber(s) and untreated cellulosic fiber(s) and optionally a binder fiber and methods of making the same, wherein the FR cellulosic fiber contains FR chemical(s) or FR compound(s) that have melting point or decomposition temperature at 400° C. (752° F.) or below. The FR performance of the new nonwoven provided herein is comparable to the conventional FR nonwoven (FR cellulosic fiber/binder fiber), but has advantages in cost effectiveness.

## Claims

### Claim 1

A fire barrier nonwoven, comprising:
10-80 wt % of at least one flame retardant (FR) cellulosic fiber, wherein said at least one FR cellulosic fiber contains or is treated with FR chemicals or FR compounds having a melting point or decomposition temperature at 400° C. (752° F.) or below; and
10-80 wt % of at least one untreated cellulosic fiber, said at least one untreated cellulosic fiber being the same or different cellulosic fiber used to make said FR cellulosic fiber,
wherein said at least one untreated cellulosic fiber is selected from the group consisting of cotton, kapok, flax, ramie, kenaf, abaca, coir, hemp, jute, sisal, pineapple, rayon, lyocell, and bamboo, and
wherein said at least one FR cellulosic fiber and said at least one untreated cellulosic fiber are assembled together as a fiber barrier nonwoven material.

### Claim 2 (depends on 1)

The fire barrier nonwoven of claim 1 further comprising one or more fibers which are different from said at least one FR cellulosic fiber and said at least one untreated cellulosic fiber.

### Claim 3 (depends on 2)

The fire barrier nonwoven of claim 2 wherein said one or more fibers which are different from said at least one FR cellulosic fiber and said at least one untreated cellulosic fiber include one or more of metal fibers, high performance fibers, polyester fibers, and colored fibers.

### Claim 4 (depends on 3)

The fire barrier of claim 3 wherein said high performance fibers are selected from glass fibers, aramid fibers, and basalt fibers.

### Claim 5 (depends on 1)

The fire barrier nonwoven of claim 1 wherein said fire barrier nonwoven material is assembled together by a bonding material which bonds fibers together.

### Claim 6 (depends on 5)

The fire barrier nonwoven of claim 5 wherein said bonding material is formed from melted binder fibers or melted surface portions of binder fibers.

### Claim 7 (depends on 5)

The fire barrier nonwoven of claim 5 wherein said bonding material is formed from a chemical reaction involving at least one of said at least one FR cellulosic fiber and said at least one untreated cellulosic fiber.

### Claim 8 (depends on 1)

The fire barrier nonwoven of claim 1 wherein said fire barrier nonwoven material is assembled from a mechanical interconnection involving at least one of said at least one FR cellulosic fiber and said at least one untreated cellulosic fiber.

### Claim 9 (depends on 1)

The fire barrier nonwoven of claim 1 wherein one or more of said at least one FR cellulosic fiber and said at least one untreated cellulosic fiber constitute at least 40 wt % of said fire barrier nonwoven material.

### Claim 10 (depends on 1)

The fire barrier nonwoven of claim 1 wherein said FR chemicals or FR compounds are selected from the group consisting of phosphorus-containing FR chemicals or compounds, sulfur-containing FR chemicals or compounds, halogen-containing FR chemicals or compounds, and boron-containing FR chemicals or compounds.

### Claim 11 (depends on 1)

The fire barrier nonwoven of claim 1 wherein said at least one FR cellulosic fiber is an FR-treated cellulosic fiber selected from the group consisting of cotton, kapok, flax, ramie, kenaf, abaca, coir, hemp, jute, sisal, pineapple, rayon, lyocell, and bamboo.

### Claim 12

A nonwoven for forming a fire barrier nonwoven, comprising:
10-80 wt % of at least one flame retardant (FR) cellulosic fiber, wherein said at least one FR cellulosic fiber contains or is treated with FR chemicals or FR compounds having a melting point or decomposition temperature at 400° C. (752° F.) or below;
10-80 wt % of at least one untreated cellulosic fiber, said at least one untreated cellulosic fiber being the same or different cellulosic fiber used to make said FR treated cellulosic fiber, wherein said at least one untreated cellulosic fiber is selected from the group consisting of cotton, kapok, flax, ramie, kenaf, abaca, coir, hemp, jute, sisal, pineapple, rayon, lyocell, and bamboo; and
at least 5 wt % of at least one binder fiber which has a melting temperature below 185° C.

### Claim 13 (depends on 12)

The nonwoven of claim 12 further comprising one or more fibers which are different from said at least one FR cellulosic fiber, said at least one untreated cellulosic fiber, and said at least one binder fiber.

### Claim 14 (depends on 12)

The nonwoven of claim 12 nonwoven wherein said at least one FR cellulosic fiber is an FR-treated cellulosic fiber selected from the group consisting of cotton, kapok, flax, ramie, kenaf, abaca, coir, hemp, jute, sisal, pineapple, rayon, lyocell, and bamboo.

### Claim 15 (depends on 12)

The nonwoven of claim 12 wherein said at least one binder fiber constitutes 10-30 wt % of the nonwoven.

### Claim 16 (depends on 12)

The nonwoven of claim 12 wherein said at least one untreated cellulosic fiber comprises one or more of rayon and cotton.

### Claim 17 (depends on 16)

The nonwoven of claim 16 wherein said at least one FR cellulosic fiber comprises rayon.

### Claim 18 (depends on 12)

The nonwoven of claim 12 wherein said at least one FR cellulosic fiber constitutes 10-65 wt % of said nonwoven, wherein said at least one untreated cellulosic fiber comprises 10-60 wt % of said nonwoven, and wherein said at least one binder fiber constitutes 10-30 wt % of the nonwoven.

### Claim 19 (depends on 1)

The fire barrier nonwoven of claim 1 wherein said at least one untreated cellulosic fiber comprises one or more of rayon and cotton.

### Claim 20 (depends on 19)

The fire barrier nonwoven of claim 19 wherein said at least one FR cellulosic fiber comprises rayon.

### Claim 21 (depends on 1)

The fire barrier nonwoven of claim 1 further comprising at least one binder fiber which constitutes 10-30 wt % of the nonwoven.