Drapeable and launderable light weight flame retardant barrier fabrics

Abstract

Flame retardant (FR) nonwoven fabrics and methods of producing same are provided. An FR nonwoven fabric includes FR rayon and either FR polyester or FR polypropylene or any blend thereof. The FR nonwoven fabric has a basis weight less than 3 ounces per square yard, and is devoid of non-FR binder material. The FR nonwoven fabric displays substantial flame retardant properties after five home launderings in accordance with protocols set forth in AATCC Test Method 135-1995. The FR nonwoven fabric is configured to maintain flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 604 of the State of California Department of Consumer Affairs (TB-604), and to maintain flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in National Fire Protection Agency 701-1989 test method.

1 . A flame retardant (FR) nonwoven fabric, comprising between about 10% and 90% FR rayon and between about 10% and 90% FR polyester, wherein the FR nonwoven fabric has a basis weight less than 3 ounces per square yard, and wherein the FR nonwoven fabric is devoid of non-FR binder material.  
   
   
       2 . The FR nonwoven fabric of  claim 1 , wherein the FR nonwoven fabric is manufactured using a process selected from the group consisting of hydroentangling, stitch bonding, needle punching, and thermal bonding.  
   
   
       3 . The FR nonwoven fabric of  claim 1 , wherein the FR nonwoven fabric displays substantial flame retardant properties after five home launderings in accordance with protocols set forth in AATCC Test Method 135-1995.  
   
   
       4 . The FR nonwoven fabric of  claim 1 , wherein the FR nonwoven fabric maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 604 of the State of California Department of Consumer Affairs (TB-604).  
   
   
       5 . The FR nonwoven fabric of  claim 1 , wherein the FR nonwoven fabric maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in National Fire Protection Agency 701-1989 test method.  
   
   
       6 . A flame retardant (FR) nonwoven fabric, comprising between about 10% and 90% FR rayon and between about 10% and 90% FR polypropylene, wherein the FR nonwoven fabric has a basis weight less than 3 ounces per square yard, and wherein the FR nonwoven fabric is devoid of non-FR binder material.  
   
   
       7 . The FR nonwoven fabric of  claim 6 , wherein the FR nonwoven fabric is manufactured using a process selected from the group consisting of hydroentangling, stitch bonding, needle punching, and thermal bonding.  
   
   
       8 . The FR nonwoven fabric of  claim 6 , wherein the FR nonwoven fabric displays substantial flame retardant properties after five home launderings in accordance with protocols set forth in AATCC Test Method 135-1995.  
   
   
       9 . The FR nonwoven fabric of  claim 6 , wherein the FR nonwoven fabric maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 604 of the State of California Department of Consumer Affairs (TB-604).  
   
   
       10 . The FR nonwoven fabric of  claim 6 , wherein the FR nonwoven fabric maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in National Fire Protection Agency 701-1989 test method.  
   
   
       11 . A method of producing flame retardant (FR) nonwoven fabric, comprising: 
 blending FR polypropylene fibers and FR rayon fibers;    forming a web of the blended polypropylene and rayon fibers, wherein the web has a basis weight less than 3 ounces per square yard; and    heating the web to a temperature sufficient to cause adjacent polypropylene fibers to bond together.    
   
   
       12 . The method of  claim 11 , further comprising calendaring the heated web via a patterned calendar roll.  
   
   
       13 . The method of  claim 11 , wherein the FR polypropylene fibers are 2 denier, 2 inch fibers and wherein the FR rayon fibers are 1.5 denier, 2 inch fibers.  
   
   
       14 . The method of  claim 11 , wherein blending FR polypropylene fibers and FR rayon fibers comprises blending between about 10% and 90% FR rayon fibers and between about 10% and 90% FR polypropylene fibers.  
   
   
       15 . A method of producing flame retardant (FR) nonwoven fabric, comprising: 
 blending FR polyester fibers and FR rayon fibers;    forming a web of the blended polyester and rayon fibers, wherein the web has a basis weight less than 3 ounces per square yard; and    heating the web to a temperature sufficient to cause adjacent polyester fibers to bond together.    
   
   
       16 . The method of  claim 15 , further comprising calendaring the heated web via a patterned calendar roll.  
   
   
       17 . The method of  claim 15 , wherein the FR polyester fibers are 2 denier, 2 inch fibers and wherein the FR rayon fibers are 1.5 denier, 2 inch fibers.  
   
   
       18 . The method of  claim 15 , wherein blending FR polyester fibers and FR rayon fibers comprises blending between about 10% and 90% FR rayon fibers and between about 10% and 90% FR polyester fibers.  
   
   
       19 . A method of producing flame retardant (FR) nonwoven fabric, comprising: 
 blending FR polypropylene fibers and FR rayon fibers;    forming a first web of the blended polypropylene and rayon fibers, wherein the fibers are oriented in a machine direction;    forming a second web of the blended polypropylene and rayon fibers, wherein the fibers are oriented in a cross direction; and    bonding the first and second webs together to form a composite web having a basis weight less than 3 ounces per square yard.    
   
   
       20 . The method of  claim 19 , wherein the FR polypropylene fibers are 2 denier, 2 inch fibers and wherein the FR rayon fibers are 1.5 denier, 2 inch fibers.  
   
   
       21 . The method of  claim 19 , wherein bonding the first and second webs together comprises stitch bonding the first and second webs.  
   
   
       22 . The method of  claim 19 , wherein bonding the first and second webs together comprises spunlacing the first and second webs.  
   
   
       23 . The method of  claim 19 , wherein bonding the first and second webs together comprises needlepunching the first and second webs.  
   
   
       24 . A method of producing flame retardant (FR) nonwoven fabric, comprising: 
 blending FR polyester fibers and FR rayon fibers;    forming a first web of the blended polyester and rayon fibers, wherein the fibers are oriented in a machine direction;    forming a second web of the blended polyester and rayon fibers, wherein the fibers are oriented in a cross direction; and    bonding the first and second webs together to form a composite web having a basis weight less than 3 ounces per square yard.    
   
   
       25 . The method of  claim 24 , wherein the FR polyester fibers are 2 denier, 2 inch fibers and wherein the FR rayon fibers are 1.5 denier, 2 inch fibers.  
   
   
       26 . The method of  claim 24 , wherein bonding the first and second webs together comprises stitch bonding the first and second webs.  
   
   
       27 . The method of  claim 24 , wherein bonding the first and second webs together comprises spunlacing the first and second webs.  
   
   
       28 . The method of  claim 24 , wherein bonding the first and second webs together comprises needlepunching the first and second webs.