Fire resistant nonwoven batt having both charring and oxygen-depleting fibers
AssigneeL&P Property Management Company
InventorsSteven Ogle, D. Steagall
Life of this patent
Estimating the term…
Abstract
Disclosed are uni-layer and bi-layer FR nonwoven fiber batts formed of various blends of charring fibers such as FR treated rayon, oxygen-depleting fibers such as modacrylic fibers and nonwoven fibers such as carrier fibers and binder fibers and associated methods for forming the same. Variously, the uni-layer and bi-layer FR nonwoven fiber batts may include layers formed entirely of blends of charring fibers and nonwoven fibers, layers formed entirely of blends of oxygen-depleting fibers and nonwoven fibers and/or layers formed of blends of charring fibers, oxygen-depleting fibers and nonwoven fibers.
Claims76
A method for forming a bi-layer fire resistant (“FR”) nonwoven fiber batt comprising:
- forming a first, barrier, web from a first fiber blend;
- forming a second, oxygen-depleting, web from a second fiber blend;
- disposing a first surface of said first, barrier, web to a second surface of said second, oxygen-depleting, web to form said FR batt
A method of forming a bi-layered, fire resistant (“FR”) nonwoven fiber batt, comprising:
- forming a first nonwoven fiber batt from a first fiber blend at least partially comprised of charring fibers;
- forming a second nonwoven fiber batt from a second fiber blend at least partially comprised of oxygen-depleting fibers;
- disposing said first and second nonwoven fiber batts relative to one another such that said second nonwoven fiber batt forms an inner layer of said bi-layered FR nonwoven fiber batt and said first nonwoven fiber batt forms an outer layer of said bi-layered FR nonwoven fiber batt;
- wherein, upon application of flame and/or heat to said bi-layered FR nonwoven fiber batt, said inner layer of said bi-layered FR nonwoven fiber batt generates oxygen depleting gases while said outer layer of said bi-layered FR nonwoven fiber batt chars but maintains sufficient structural integrity to trap said oxygen depleting gases, generated by said inner layer of said bi-layer FR nonwoven fiber batt, between said inner and outer layers of said bi-layered FR nonwoven fiber batt.
A method for forming a uni-layer fire resistant (“FR”) nonwoven fiber batt, comprising:
- forming a blend of charring fibers, oxygen-depleting fibers and binder fibers;
- and
- forming said uni-layer FR nonwoven fiber batt from said blend.
A method for forming a uni-layer fire resistant (“FR”) nonwoven fiber batt, comprising:
- forming a blend comprised of a first amount of charring fibers, a second amount of oxygen depleting fibers and a third amount of binder fibers, said first, second and third amounts selected based upon a desired basis weight for said uni-layer FR nonwoven fiber batt, a desired percentage, by volume, of charring fibers in said blend, a desired percentage, by volume, of oxygen-depleting fibers in said blend and a desired percentage, by volume, of binder fibers in said blend;
- and
- forming said uni-layer nonwoven fiber batt from said blend.
A bi-layer fire resistant (“FR”) nonwoven fiber batt comprising:
- a first, barrier, web having a first surface, said first, barrier, web formed from a first fiber blend;
- and
- a second, oxygen-depleting, web having a second surface, said second, oxygen-depleting, web formed from a second fiber blend;
- said first surface of said first, barrier, web in contact with said second surface of said second, oxygen-depleting web.
A bi-layered, fire resistant (“FR”) nonwoven fiber batt, comprising:
- a first nonwoven fiber batt having a first surface, said first nonwoven fiber batt formed from a first fiber blend at least partially comprised of charring fibers;
- and
- a second nonwoven fiber batt having a second surface, said second nonwoven fiber batt formed from a second fiber blend at least partially comprised of oxygen-depleting fibers, said first surface of said first nonwoven fiber batt in contact with and oriented relative to said second surface of said second nonwoven fiber batt such that said first nonwoven fiber batt forms an outer layer of said bi-layered FR nonwoven fiber batt and said second nonwoven fiber batt forms an inner layer of said bi-layered FR nonwoven fiber batt;
- wherein, upon application of flame and/or heat to said bi-layered FR nonwoven fiber batt, said inner layer of said bi-layered FR nonwoven fiber batt generates oxygen-depleting gases while said outer layer of said bi-layered FR nonwoven fiber batt chars but maintains sufficient structural integrity to trap said oxygen depleting gases, generated by said inner layer of said bi-layer FR nonwoven fiber batt, between said inner and outer layers of said bi-layered FR nonwoven fiber batt.
A uni-layer fire resistant (“FR”) nonwoven fiber batt, comprising a blend of charring fibers, oxygen-depleting fibers and binder fibers.
Dependencies are inferred from the claim text.