High binder flame-retardant nonwovens

Abstract

The present invention concerns a flame-retardant (FR) nonwoven fabric/article useful in household goods and particularly for mattresses. The nonwoven fabric/article comprises from about 6 to about 40 weight percent of a low melt binder; at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, and FR coated fiber; and optionally a synthetic and/or natural fiber. From this nonwoven fabric/article, many household goods such as drapes, curtains, rugs, bedding, and particularly mattresses may be constructed. The present invention also contemplates a mattress constructed from the nonwoven fabric/article comprising FR rayon fibers, FR acrylic fibers, FR melamine fiber, FR polyester fiber, and FR coated fiber, non-FR fibers, and about 6 to about 40 weight percent of a low melt binder. The mattress from this construction passes the California Test Bulletin 129 stringent conditions for mattresses used in public places. Preferably, the nonwoven fabric/article of the present invention has a batt weight of at least 4 oz./sq. yd. and preferably between 4 oz./sq. yd. and 20 oz./sq. yd.

1 ) A nonwoven article produced from greater than about 25 to about 40 weight percent of a low melt binder; at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester, and FR coated fiber; and optionally a non-bonding synthetic or natural fiber, wherein said nonwoven article has a batt weight of at least 4 oz./sq. yd.  
     
     
         2 ) The nonwoven article of  claim 1 , wherein said non-bonding synthetic fiber is one of rayon, polyester, and a mixture thereof.  
     
     
         3 ) The nonwoven article of  claim 1 , wherein said nonwoven article is produced from at least two of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, and FR resin.  
     
     
         4 ) The nonwoven article of  claim 1 , wherein said low melt binder is one of a bicomponent fiber, a low melting fiber, and a mixture thereof.  
     
     
         5 ) The nonwoven article of  claim 4 , wherein said bicomponent fiber has a polyester component and one of a polyolefin component, a copolyester component, and a mixture thereof.  
     
     
         6 ) The nonwoven article of  claim 4 , wherein said low melting fiber is one of a copolyester fiber, a polyolefin fiber, and a mixture thereof.  
     
     
         7 ) The nonwoven article of  claim 1 , wherein said FR coating is a resin of a phosphorus compound, red phosphorus, phosphorus, or a mixture thereof.  
     
     
         8 ) The nonwoven article of  claim 1 , comprising about 30 weight percent of said low melt binder.  
     
     
         9 ) The nonwoven article of  claim 1 , comprising about 40 weight percent of said low melt binder.  
     
     
         10 ) The nonwoven article of  claim 1 , wherein said natural fiber is one of flax, kenaf, and a mixture thereof.  
     
     
         11 ) A mattress comprising a nonwoven article produced from greater than about 25 to about 40 weight percent of a low melt binder; at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, FR polyester fiber, and FR coated fiber; and optionally a non-bonding synthetic or natural fiber, wherein said nonwoven article has a batt weight of at least 4 oz./sq. yd.