Fiberglass corespun fabrics for use in flame resistant drywall installations

Abstract

Provided is a flame resistant drywall installation, especially those designed to meet ASTM E119. The installations comprise the use of fiberglass corespun flame resistant (FR) woven and fiberglass corespun stitchbonded nonwoven fabrics. The preferred forms of the woven and stitchbonded fabric used in this invention include: WOVEN FABRIC: A 3-8 opsy woven fabric consisting of fiberglass corespun yarns as described below. STITCHBONDED FABRIC: A 4-10 nonwoven batting of 100% cotton, 100% rayon, 100% lyocell, cotton/non-FR fiber blends, rayon/non-FR fiber blends or lyocell/non-FR fiber blends stitched with fiberglass corespun yarns as described below. Fiberglass corespun weaving and stitching yarns, for use in the invention, include those known in the textile industry as Alessandra® yarn (U.S. Pat. Nos. 6,146,759; 6,287,690; 6,410,140; 6,606,846; 6,553,749 by McKinnon Land LLC) and Firegard® yarn (by Springs Industries). The two fabric types mentioned above are used in tandom, between layers of conventional gypsum style drywall paneling to obtain a higher flame rating than would otherwise be able to be obtain in a layered drywall construction which does not include these fabrics. Conventional latex paint or flame resistant coating materials can be used to adhere the fabrics between the drywall paneling.

1 . A flame resistant drywall installation comprising fiberglass corespun flame resistant woven and fiberglass corespun stitchbonded nonwoven fabrics bonded between the drywall panel layers. 
     
     
         2 . The installation of  claim 1 , wherein latex paint is used to bond the fabrics between the drywall panel layers. 
     
     
         3 . The installation of  claim 1 , wherein the fiberglass corespun flame resistant woven fabric is comprised of 10/1 cotton count Alessandra FR yarns. 
     
     
         4 . The installation of  claim 3 , wherein the yarns are woven into a 44×34 twill construction with a basis weight of between 3.0 and 8.0 opsy. 
     
     
         5 . The installation of  claim 4 , wherein the basis weight is about 5.0 opsy. 
     
     
         6 . The installation of  claim 1 , wherein the fiberglass corespun stitchbonded nonwoven fabric is comprised of cotton batting stitched with 14/1 cotton count Alessandra FR yarn. 
     
     
         7 . The installation of  claim 6 , wherein the basis weight of the cotton batting is between 4.0 and 10 opsy. 
     
     
         8 . The installation of  claim 7 , wherein the cotton batting basis weight is about 6 opsy. 
     
     
         9 . The installation of  claim 3 , wherein the yarn contains a char forming and/or oxygen depleting fiber wrapped around a fiberglass core. 
     
     
         10 . The installation of  claim 9 , wherein the char forming fiber is selected from the group consisting of melamines, para-aramides, polybenzimidazoles, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novaloids, poly(p-phenylene benzobisoxazole), poly (p-phenylene benzothiazoles), polyphenylene sulfide, viscose rayons, polyetheretherketones, polyketones and combinations thereof 
     
     
         11 . The installation of  claim 9 , wherein the oxygen depleting fiber is selected from the group consisting of chloropolymeric fibers; modacrylics; fluoropolymeric fibers; poly(ethylene-chlorotrifluoroethylene); polyvinylidene fluoride fibers; polyperfluoroalkoxy, polyfluorinated ethylene-propylene; and combinations thereof. 
     
     
         12 . The installation of  claim 6 , wherein the yarn contains a char forming and/or oxygen depleting fiber wrapped around a fiberglass case. 
     
     
         13 . The installation of  claim 12 , wherein the char forming fiber is selected from the group consisting of melamines, para-aramides, polybenzimidazoles, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novaloids, poly(p-phenylene benzobisoxazole), poly (p-phenylene benzothiazoles), polyphenylene sulfide, viscose rayons, polyetheretherketones, polyketones and combinations thereof. 
     
     
         14 . The installation of  claim 12 , wherein the oxygen depleting fiber is selected from the group consisting of chloropolymeric fibers; modacrylics; fluoropolymeric fibers; poly(ethylene-chlorotrifluoroethylene); polyvinylidene fluoride fibers; polyperfluoroalkoxy, polyfluorinated ethylene-propylene; and combinations thereof. 
     
     
         15 . The installation of  claim 9 , wherein the char forming and/or oxygen depleting fiber is blended with cotton, wool, silk, mohair, cashmere, kenof, sisal, nylons, polyesters, polyolefins, rayons, lyocells, acrylics, cellulose acetates or polyactides. 
     
     
         16 . The installation of  claim 12 , wherein the char forming and/or oxygen depleting fiber is blended with cotton, wool, silk, mohair, cashmere, kenof, sisal, nylons, polyesters, polyolefins, rayons, lyocells, acrylics, cellulose acetates or polyactides. 
     
     
         17 . The installation of  claim 1 , wherein a flame resistant coating is used to bond the fabrics between the drywall panel layers. 
     
     
         18 . The installation of  claim 17 , wherein the flame resistant coating is comprised of ethylene/vinyl chlorides copolymers with or without standard acrylic or styrene acrylonitrile polymers; while optionally including materials such as nitrogen phosphorous flame retardant, a phosphate flame retardant, aluminum trihydrate, magnesium hydroxide, calcium hydroxide, calcium carbonate, antimony trioxide, and mixtures thereof.