Flame resistant fabrics having a high synthetic content and process for making
AssigneeMilliken & Company
InventorsShulong Li, Richard A. Mayernik
Life of this patent
Estimating the term…
Abstract
Provided herein are flame resistant fabrics having a thermoplastic fiber content of as much as 65% (where no more than 5% of the fibers are non-thermoplastic synthetic fibers). The flame resistant properties are imparted by treating the fabric with one or more flame retardant chemicals and then by curing the treated fabric at high temperatures. Optionally, softeners, stain release agents, soil repellent agents, permanent press resins, and the like may be added to the bath of flame retardant chemicals. Alternately, the treated fabric may be subjected to mechanical treatment to increase softness. The fabrics produced by the present process exhibit improved performance and tear strength, as compared to conventionally treated fabrics.
Claims15
A flame resistant fabric, said flame resistant fabric comprising:
- a fabric substrate, wherein said fabric substrate has cellulosic fibers and thermoplastic fibers, said cellulosic fibers being present in an amount between about 50% and about 70% of the weight of said fabric and said thermoplastic fibers being present in an amount between about 30% and about 50% of the weight of said fabric;
- and
- a finish applied to said fabric substrate, wherein said finish comprises a softening agent and a pentavalent phosphorous compound, the pentavalent phosphorous compound being a product produced by first heat-curing and then oxidizing a reaction mixture comprising (i) urea and (ii) a compound selected from the group consisting of tetrahydroxymethyl phosphonium salts and tetrahydroxymethyl phosphonium condensates, the tetrahydroxymethyl phosphonium condensate being produced by reacting a tetrahydroxymethyl phosphonium salt with a compound selected from the group consisting of urea, guanazole, and biguanide;
- wherein at least a portion of said cellulosic fibers have the pentavalent phosphorous compound polymerized therein.
A flame resistant fabric, said flame resistant fabric comprising:
- a fabric substrate, wherein said fabric substrate has cellulosic fibers and thermoplastic fibers, said cellulosic fibers being present in an amount between about 35% and about 70% of the weight of said fabric and said thermoplastic fibers being present in an amount between about 30% and about 65% of the weight of said fabric;
- and
- a finish applied to said fabric substrate, wherein said finish comprises an aromatic brominated compound and a pentavalent phosphorous compound, the pentavalent phosphorous compound being a product produced by first heat-curing and then oxidizing a reaction mixture comprising (i) urea and (ii) a compound selected from the group consisting of tetrahydroxymethyl phosphonium salts and tetrahydroxymethyl phosphonium condensates, the tetrahydroxymethyl phosphonium condensate being produced by reacting a tetrahydroxymethyl phosphonium salt with a compound selected from the group consisting of urea, guanazole, and biguanide;
- wherein at least a portion of said cellulosic fibers have the pentavalent phosphorous compound polymerized therein.
A method of making a flame retardant fabric, said method comprising:
- (a) forming a fabric, said fabric comprising a first plurality of yarns in a first direction and a second plurality of yarns in a second direction substantially perpendicular to said first direction, wherein said fabric has a cellulosic fiber content of between about 50% by weight of said fabric and about 70% by weight of said fabric and a thermoplastic fiber content of between about 30% by weight of said fabric and about 50% by weight of said fabric;
- (b) applying to said fabric a finishing composition, said finishing composition comprising a softening agent, urea, and a tetrahydroxymethyl phosphonium condensate, the tetrahydroxymethyl phosphonium condensate being produced by reacting a tetrahydroxymethyl phosphonium salt with a compound selected from the group consisting of urea, guanazole, and biguanide;
- and
- (c) curing said finish on said fabric by subjecting said fabric to temperatures between about 150° C. and about 190° C.;
- (d) oxidizing said cured fabric using a peroxide to convert said tetrahydroxymethyl phosphonium condensate into a pentavalent phosphate compound;
- (e) immersing said cured fabric in a caustic solution that neutralizes the peroxide of step (d);
- and
- (f) immersing said cured fabric in a solution containing a reducing agent.
Dependencies are inferred from the claim text.