Knit tube flame resistant barriers

Abstract

The invention relates to the use of a flame resistant knit tube, made with either a seamless or seamed circular knit or a seamed or tubular warp knit fabric, used to protect a mattress, foundation, upholstery cushion, pillow, office panel, transportation seat or any other article requiring flame resistant protection. In this invention, a tubular knit fabric is formed utilizing flame resistant yam and then optionally heat-set to prevent curling during subsequent cutting and processing. Heat-setting the knit fabric is especially preferred for circular knit constructions to prevent curling in subsequent processing. The knit tube is then cut to the length of the article to be flame protected, allowing enough additional length to sew a pocket closure on one end and a standard closure on the other end. First, one end of the tubular knit sock is sewn with a pocket closure seam, using a flame resistant thread or a suitable substitute. The open end of the tubular knit sock is then rolled up to the sewn pocket closure end so that it can be easily positioned over the article to be protected from flame. The rolled up knit sock is then unrolled down the length of the article to be flame protected. The second closure seam is then sewn with flame resistant thread, or a suitable substitute, over the open end of the article to completely encapsulate and protect the article. The invention has particular applicability in the formation of fire resistant foam mattresses and foundations that require passage of large open flame tests such as California's Test Bulletin 603 and Test Bulletin 129 and in the formation of fire resistant foam upholstery cushions that require passage of California's Test Bulletin 133 or British Standard 5852 using the crib 5 ignition source.

1 . A flame-resistant barrier material comprising a knitted tubular fabric formed from at least one flame resistant yarn.  
   
   
       2 . The barrier material of  claim 1 , wherein the knitted tubular fabric is heat-set.  
   
   
       3 . The barrier material of  claim 1 , wherein the knitted tubular fabric is a circular or warp knit fabric.  
   
   
       4 . The barrier material of  claim 1 , wherein the flame resistant yarn is a core spun yarn.  
   
   
       5 . The barrier material of  claim 1 , wherein the flame resistant yarn has a Limiting Oxygen Index (LOI) of at least 22 (ASTM D 2863).  
   
   
       6 . The flam resistant barrier material of  claim 1 , wherein one end of the knitted tubular fabric is sewn shut using a flame resistant thread.  
   
   
       7 . The flame resistant barrier material of  claim 1 , wherein the knitted tubular fabric is seamed or seamless.  
   
   
       8 . The flame resistant barrier material of  claim 1 , wherein the flame resistant yarn is an open-end, ring, air-jet, corespun or spun yarn.  
   
   
       9 . The flame resistant barrier material of  claim 1 , wherein the knitted tubular fabric is of a simplex-tricot, double needle bar tricot, V bed, rib, interlock, double knit or Jersey construction.  
   
   
       10 . The flame resistant barrier material of  claim 1 , wherein the flame resistant yarn is selected from the group consisting of melamine, meta and para-aramids, poly(diphenylether)p-aramid, polybenzimidazole, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novoloids, poly(p-phenylene)benzobisoxazole, polyphenylene sulfide, flame resistant viscose rayons, polyethertherketones, polyketones, polyetherimides, chloropolymeric fibers, modacrylics, fluoropolymer fibers and mixtures thereof.  
   
   
       11 . The flame resistant barrier material of  claim 10 , which further includes a non-flame resistant fiber.  
   
   
       12 . The barrier material of  claim 4 , wherein the core spun yarn comprises a dual core of glass fiber filaments and nylon yarn wrapped with a triblend sliver of modacrylic, melamine and polyester staple fibers.  
   
   
       13 . A method of making a flame resistant barrier material which comprises: 
 (a) forming at least one flame resistant yarn into a knitted tubular fabric;    (b) cutting the knitted tubular fabric to a desired length;    (c) optionally, heat-setting the tubular fabric; and    (d) sealing one end of the tubular fabric.    
   
   
       14 . The method of  claim 13 , wherein one end of the knitted tubular fabric is sealed by sewing with a flame resistant thread.  
   
   
       15 . The method of  claim 13 , wherein the knitted tubular fabric is a circular or warp knit fabric.  
   
   
       16 . The method of  claim 13 , wherein the flame resistant yarn is a core spun yarn.  
   
   
       17 . An article requiring flame resistant protection enclosed within the flame resistant barrier material of  claim 1 .  
   
   
       18 . A mattress, foundation, upholstery cushion, pillow, office panel or transportation seat encapsulated within the flame resistant barrier material of  claim 5 .  
   
   
       19 . A method of providing flame resistant protection to an article in need thereof which comprises: 
 preparing a knitted tubular fabric, sealing one end of the tubular fabric, surrounding the article to be protected with the tubular fabric, and sealing a remaining open end of the tubular fabric to encapsulate and protect the article.    
   
   
       20 . The method of  claim 19 , wherein the article in need of fire resistant protection is a mattress, foundation, upholstery cushion, pillow, office panel or transportation seat.