Flame-retardant cellulosic nonwoven fabric

Abstract

The present invention is directed to a hydroentangled flame retardant nonwoven fabric, and more specifically, to a cellulosic flame retardant fabric comprising a self extinguishing fiber so as to minimize the total percentage of fabric weight lost upon burning in accordance with technical bulletin 604. Use of natural fiber fabrics in bedding components is desirable due to the softness and durability associated with the fabrics; however, natural fiber, such as cellulose, is highly flammable and therefore lacks the ability to provide the proper flammability protection often sought out in bedding components. In accordance with the present invention, a small amount of self-extinguishing fiber, such as a modacrylic fiber, was blended with the natural fiber and hydroentangled to form a nonwoven composite fabric that is soft, flame retardant, and suitable for bedding articles.

1 . A flame retardant nonwoven fabric consisting essentially of a hydroentangled fiber blend consisting essentially of from 60% to less than 65% lyocell fiber and from more than 35% to 40% self-extinguishing modacrylic fiber, wherein said fabric exhibits a basis weight loss of no more than 3% after 360 seconds when tested in compliance with Technical Bulletin 604 using a bag in bag construct. 
   
   
       2 . (canceled) 
   
   
       3 . A flame retardant nonwoven fabric as in  claim 1 , wherein said fabric further comprises at least one additional layer selected from the group consisting of an additional nonwoven, a woven, a scrim, and a polymer film. 
   
   
       4 . A flame retardant bedding article consisting essentially of a hydroentangled fiber blend consisting essentially of from 60% to less than 65% lyocell fiber and from more than 35% to 40% self-extinguishing modacrylic fiber, wherein said fabric exhibits a basis weight loss of no more than 3% after 360 seconds when tested in compliance with Technical Bulletin 604 using a bag in bag construct. 
   
   
       5 . A flame retardant nonwoven fabric as in  claim 1 , wherein said fabric comprises a three-dimensionally imaged nonwoven fabric. 
   
   
       6 . A flame retardant nonwoven fabric consisting essentially of a hydroentangled fiber blend consisting essentially of 60-65% lyocell fiber and 40-35% self-extinguishing modacrylic fiber, wherein said fabric exhibits a basis weight loss of between 0.5%-5% after 360 seconds when tested in compliance with Technical Bulletin 604 using a sewn in construct. 
   
   
       7 . A flame retardant nonwoven fabric as in  claim 6 , wherein said fabric exhibits a basis weight loss of between 1%-4% after 360 seconds when tested in compliance with Technical Bulletin 604 using a sewn in construct.