Fire resistant nonwoven batt having both charring and oxygen-depleting fibers
AssigneeL&P Property Management Company
InventorsSteven E. Ogle, D. Patrick 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.
Claims25
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 consisting of charring fibers polyester carrier fibers and polyester binder fibers;
- forming a second nonwoven fiber batt from a second fiber blend consisting of oxygen-depleting fibers polyester carrier fibers and polyester binder fibers;
- disposing said first and second nonwoven fiber batts relative to onc 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 andlor 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 nanwoven fiber batt, between said inner and outer layers of said bi-layered FR nonwoven fiber ban.
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 consisting of charring fibers, polyester carrier fibers and polyester binder fibers;
- and
- a second nonwoven fiber batt having a second surface, said second nonwoven fiber batt formed from a second fiber blend consisting of oxygen-depleting fibers, polyester carrier fibers and polyester binder 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 bait chars but maintains sufficient structural integrity to trap said oxygen depleting gases, generated by said inner layer of said bi-layer FR nonwoven fiber ban, between said inner and outer layers of said bi-layered FR nonwoven fiber batt.
A method for forming a bi-layered fire resistant (“FR”) nonwoven fiber batt comprising:
- forming a first web from a blend consisting of modacrylic fibers polyester carrier fibers and polyester binder fibers, said first web having first and second side surfaces;
- forming a second web from a blend consisting of FR rayon fibers polyester carrier fibers and polyester binder fibers, said second web having first and second side surfaces;
- disposing said first side surface of said second web to said second side surface of said first web;
- and
- forming a bi-layered FR nonwoven fiber batt from said disposed webs, said first side surface of said first web becoming a lower side surface of said bi-layered FR nonwoven fiber batt, said first web becoming an inner layer of said bi-layered FR nonwoven fiber batt, said second web becoming an outer layer of said bi-layered FR nonwoven fiber batt and said second side surface of said second web becoming an upper side surface of said bi-layered FR nonwoven fiber batt;
- wherein, upon application of flame and/or heat to said upper side surface of 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.
Dependencies are inferred from the claim text.