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  Textile woven and knit fabrics with enhanced flame retardancy and comfort for bedclothing productsUSPTO Application #: 20060211319Title: Textile woven and knit fabrics with enhanced flame retardancy and comfort for bedclothing products Abstract: Textile woven and knit fabrics with inherent flame resistant properties for use in household filled bedclothing applications, such as mattress ticking. In one embodiment, the yarn used to weave or knit the fabric comprises from about 25 to about 60 weight % modacrylic fiber and from about 40 to about 75 weight % cellulosic fiber. In another embodiment, the yarns used to knit the fabrics can comprise from about 25 to about 75 weight % modacrylic fiber, from about 20 to about 50 weight % of cellulosic fibers, and from about 5 to about 55 weight % of other materials such as polyester fibers/filaments and/or glass filaments. Preferably, the woven fabrics have a spun yarn count from about 20/1 ecc to about 40/1 ecc, while the knit fabrics have a spun yarn count from 10/1 ecc to 30/1 ecc for the face side layer, a yarn count of 4/1 ecc to 10/1 ecc as well as 4/2 ecc to 10/2 ecc for the filling layer, and a yarn count of 20/1 ecc to 40/1 ecc (more preferably 30/1 ecc to 40/1 ecc) as well as a filament yarn count of 100 denier to 300 denier for the back side layer. The textile woven fabric may be suitable for filled bedclothing products such as comforters, bed spreads, pillow and mattress covers, and pillow and mattress pad ticking. The textile knit fabric may be suitable for mattress ticking applications. (end of abstract) Agent: Kenyon & Kenyon LLP - New York, NY, US Inventors: Osamu Masuda, Yoshio Nakahori USPTO Applicaton #: 20060211319 - Class: 442181000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material) The Patent Description & Claims data below is from USPTO Patent Application 20060211319. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] The present application claims the benefit, under 35 U.S.C. .sctn. 119(e), of U.S. Provisional Application No. 60/662,643, filed on Mar. 17, 2005, and U.S. Provisional Application No. 60/696,991, filed on Jul. 5, 2005. FIELD OF THE INVENTION [0002] The present invention relates to textile woven and knit fabrics with fire retardant properties for use in household filled bedclothing applications. More particularly, the fabric may be suitable in flame resistant fiber filled bedclothing products such as comforters, bed spreads, pillow and mattress covers, and pillow and mattress pad ticking. BACKGROUND [0003] Flame resistant fabrics have been developed and used in the textile industry in applications such as protective apparel, upholstery, and draperies. In some cases, the woven fabrics, which may be synthetic or natural fibers or a blend thereof, are topically coated with a flame resistant chemical. When used in residential household products (such as mattresses), however, these fabrics exhibit diminished flame retardant properties over time, especially when subjected to numerous washings in the presence of a detergent. Moreover, most of these coated fabrics are stiff or abrasive to the human touch and may be undesirable in residential household applications such as for use in bedclothing products. [0004] In other cases, the fabric possesses inherent flame and heat resistant properties. For example, INDURA.RTM. developed by Westex, Inc., NOMEX.RTM. developed by Dupont, and LENZING FR.RTM. developed by Lenzing AG are well known in the protective apparel industry as fabrics with inherent flame resistant properties and high temperature applications. However, because these fabrics are generally harsh to the touch and are relatively expensive, they may be undesirable and not cost effective in residential household applications such as for use in filled bedclothing products. In addition, these fabrics are generally not available in the color white or cream, which is a further drawback in the filled bedclothing products industry. Other flame retardant fabrics, such as polyester based flame retardant fabric, may not be suitable for filled bedclothing applications as this type of fabric is prone to melting and dripping. SUMMARY OF THE INVENTION [0005] It is an object of the invention to provide a textile woven fabric with inherent flame resistant properties for use in household filled bedclothing applications, and to provide a textile knit fabric with inherent flame resistant properties for use in household filled bedclothing applications. [0006] In an embodiment of the invention, a textile woven fabric with inherent flame resistant properties for use in household filled bedclothing applications is provided. In one aspect, the yarn used to weave the fabric comprises from about 25 to about 60 weight % modacrylic fiber and from about 40 to about 75 weight % cellulosic fiber. Preferably, the woven fabric has a spun yarn count from about 20/1 ecc to about 40/1 ecc. The textile woven fabric may be suitable for filled bedclothing products such as comforters, bed spreads, pillow and mattress covers, and pillow and mattress pad ticking. [0007] In another embodiment of the invention, a fabric knitted from a yarn which comprises about 25 to about 60 weight % of modacrylic fiber and about 40 to about 75 weight % of cellulosic fiber is provided. In still another embodiment, the yarn used to knit the fabric comprises about 25 to about 75 weight % of modacrylic fiber, about 20 to about 50 weight % of cellulosic fibers, and about 5 to about 55 weight % of other materials such as polyester fibers/filaments and/or glass filaments. Preferably, the knit fabric has a spun yarn count from 10/1 ecc to 30/1 ecc for the face side layer, and a yarn count of 4/1 ecc to 10/1 ecc as well as 4/2 ecc to 10/2 ecc for the filling layer. Preferably, the knit fabric has a yarn count of 20/1 ecc to 40/1 ecc (more preferably 30/1 ecc to 40/1 ecc) as well as a filament yarn count of 100 denier to 300 denier for the back side layer. Machinery which can be used to make the knit fabrics commercially can be, e.g., from Terrot Strickmaschinen GmbH, preferably a model UCC 548 38 inch/20 gg. [0008] Because of its knit structured nature, the fabric of these knitted embodiments of the invention is very stretchable and may mold against and conform to VISICO.RTM. elastic foams. Hence, sleep comfort will be maintained compared to conventional woven ticking fabrics. Due to the vertically structured construction of the fabrics, cushioning comfort can be achieved in addition to the fire retardant and moldability properties. The textile knit fabric is particularly suitable for mattress ticking applications. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 shows the test result for Example 1 of the open flame protocol California Text Bulletin TB604. DETAILED DESCRIPTION [0010] In one embodiment of the invention, a textile woven fabric with inherent flame resistant properties for use in household filled bedclothing applications is provided. The textile woven fabric comprises a modacrylic fiber and a cellulosic fiber. It is generally believed that upon exposure to open flame, the modacrylic/cellulosic blend fabric expands to form a char barrier that deprives fire of fuel causing the flame to extinguish before they reach the underlying fiber filled material. [0011] In another embodiment of the invention, a textile knit fabric with inherent flame resistant properties for use in mattress ticking applications is provided. The textile knit fabric comprises a modacrylic fiber and a cellulosic fiber. In yet another embodiment, the textile knit fabric comprises a modacrylic fiber and a cellulosic fiber with a minor blend of other materials such as a polyester material and/or a glass filament. Without intending to be bound by any theory, it is believed that upon exposure to open flame, the modacrylic/cellulosic blend fabric expands to form a char barrier that deprives fire of fuel causing the flame to extinguish before reaching the underlying materials, such as polyester or polyester blended batting or various kinds of foam materials. [0012] As used herein the terms "flame retardant" and "flame resistant" are used interchangeably and generally describe fabrics which, when ignited by a flame source, resist and/or prevent the spread of flames and/or heat. [0013] The modacrylic fibers of the woven and knit fabrics of the present invention comprise inherently flame retardant materials. Preferably, the modacrylic fibers comprise polymers with halogenated monomers which generate oxygen depleting gases during thermal decomposition. The cellulosic fibers of the present invention need not be inherently flame retardant materials, and need not be treated with topical fire resistant chemical or coating, such as, for example, boric acid or ammonia phosphate based coatings commonly used as fire resistant coatings. Preferably, the cellulosic fibers are non-flame retardant cotton/rayon. [0014] It is believed that the modacrylic fibers generate oxygen depleting gases when ignited by a flame source. The oxygen depleting gases may prevent ignition of the underlying or encased ignitable non-flame retardant batting fabrics or fiber fills, which are commonly conventional polyester fibers or various kinds of foams. The oxygen depleting gases are further believed to coat the cellulosic fiber thereby protecting it from flames and also accelerating char formations in the cellulosic fiber. It is further believed that the char acts as a shield or barrier to prevent the underlying ignitable products from ignition. [0015] In the textile knit fabric embodiments of the invention, the knit fabrics may be manufactured by known techniques. Preferred machinery which can be used to make the knit fabrics is commercially available from Terrot Strickmaschinen GmbH, preferably model UCC 548 38 inch/20 gg. Equipment which can knit 85 inch or wider width in one knitting run is preferred. This type of machinery also enables the manufacture of three layered knit fabrics, having a face layer, a filling layer, and a back surface layer. This type also enables one to make jacquard patterns. [0016] In preferred embodiments of the textile woven fabric of the invention, the yarn used to weave the fabric comprises from about 25 to about 60 weight % modacrylic fiber and from about 40 to about 75 weight % cellulosic fiber. In more preferred embodiments, the yarn comprises from about 35 to about 50 weight % modacrylic fiber and from about 50 to about 70 weight % cellulosic fiber. More preferably, the woven fabric comprises 35 weight % modacrylic fiber and 65 weight % blended cotton. It is believed that this range of fiber blend is optimal in that it allows the woven fabric to pass regulatory open flame test protocol, such as the California Flame Resistance of Filled Bedclothing TB604 test, while maintaining cost effectiveness. Embodiments of the textile woven fabric of the present invention used as cover materials for filled bedclothing are expected to pass the California TB604 test. It is further expected that when exposed to open flame, woven fabrics with these fiber blends would withstand the flames with minimal shrinkage of the char barrier thereby preventing the flames from penetrating the char barrier and igniting the underlying material. [0017] Preferably, the woven fabric of the invention has a spun yarn count from about 20/1 ecc to about 40/1 ecc. More preferably, the spun yarn count is about 35/1 ecc. In one embodiment, the woven fabric has a weight from about 50 g/m.sup.2 to about 400 g/m.sup.2. These are generally representative of this particular commodity zone in the retail industry and is expected to be cost effective. [0018] The present invention contemplates the woven fabrics described herein for applications in the filled bedclothing industry, such as in comforters, bed spreads, pillow and mattress covers, and pillow and mattress pad ticking. More specifically, the woven fabrics may be used as cover material or ticking fabric in a fiber-filled bedclothing product such as pillows, comforters, and mattress pads. Moreover, it is believed that the woven fabrics of the present invention are particularly suited as flame retardant materials for the filled bedclothing industry because they have inherent flame retardant properties, are supple (especially as compared to materials that are composed of 100% cellulosic fiber), low in cost, and may be produced in the color white. In addition, the woven fabric may be manufactured readily as it does not require special spinning technology nor special weaving and dyeing/finishing technology beyond those conventionally used in the industry. Embodiments of the woven fabrics of the present invention thus allow for the manufacture of open flame resistant products for use with conventional non-flame resistant fiber fills in a cost effective manner. Continue reading... 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