Thermally Protective Flame Retardant Fabric

Abstract

A thermally protective, flame retardant fabric includes a substrate treated with a combination of a flame retardant agent and an intumescent agent. The substrate includes non-thermoplastic fibers or a blend of non-thermoplastic fibers and thermoplastic fibers having a basis weight ranging from 2.0 to 15.0 ounces per square yard. The fabric has a contact thermal protective performance value of at least 4.5 and a contact thermal protective performance efficiency greater than 1.1. Applications of the fabric include protective garments, articles of furniture, vehicle components, building components, electrical components, decorative components, appliances, and containers.

1 . A fabric comprising a non-woven substrate treated with a combination of a flame retardant agent and an intumescent agent, the substrate comprising cellulosic fibers and at least one thermoplastic fiber, wherein the fabric has a thickness ranging from 0.01 to 0.15 inches and a contact thermal protective performance value of at least 4.5. 
     
     
         2 . The fabric of  claim 1 , wherein the substrate has a basis weight ranging from 2.0 to 15.0 ounces per square yard. 
     
     
         3 . (canceled) 
     
     
         4 . The fabric of  claim 1 , wherein the fabric has a contact thermal protective performance efficiency greater than 1.1. 
     
     
         5 . The fabric of  claim 1 , wherein the substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard. 
     
     
         6 . The fabric of  claim 1 , wherein the substrate has a basis weight ranging from 5.0 to 6.5 ounces per square yard. 
     
     
         7 - 8 . (canceled) 
     
     
         9 . The fabric of  claim 1 , wherein the substrate comprises a nonwoven fabric chosen from needlepunched, spunbonded, thermalbonded, spunlaced, resin bonded, stitch bonded, and meltblown fabrics. 
     
     
         10 - 11 . (canceled) 
     
     
         12 . The fabric of  claim 1 , wherein the substrate is treated by a method comprising applying a flame retardant chemical to the substrate, followed by applying a finish comprising an intumescent coating to the substrate. 
     
     
         13 . (canceled) 
     
     
         14 . The fabric of  claim 1 , wherein the substrate is treated by a method comprising applying a finish to the substrate, wherein the finish comprises an intumescent, flame retardant coating. 
     
     
         15 . (canceled) 
     
     
         16 . The fabric of  claim 1 , wherein the substrate comprises at least one temperature resistant fiber. 
     
     
         17 . The fabric of  claim 16 , wherein the cellulosic fibers are chosen from rayon, lyocell, cotton, and woodpulp. 
     
     
         18 . The fabric of  claim 16 , wherein the at least one temperature resistant fiber is chosen from glass, kevlar, asbestos, carbon, polyphenylene benzobisoxazole, polybenzimidazole, para-aramids, meta-aramids, fluorocarbons, polyphenylene sulfides, melamines, and polyimides. 
     
     
         19 - 22 . (canceled) 
     
     
         23 . A protective garment constructed from the fabric claimed in  claim 1 . 
     
     
         24 . (canceled) 
     
     
         25 . An article of furniture constructed from the fabric claimed in  claim 1 . 
     
     
         26 . (canceled) 
     
     
         27 . A vehicle component constructed from the fabric claimed in  claim 1 . 
     
     
         28 - 38 . (canceled) 
     
     
         39 . A method of forming a thermally protective, flame retardant fabric, the method comprising: applying a flame retardant chemical to a nonwoven substrate comprising cellulosic fibers and at least one thermoplastic fiber; applying a finish comprising an intumescent coating to the substrate; and drying the substrate. 
     
     
         40 - 41 . (canceled) 
     
     
         42 . The method of  claim 39 , wherein the flame retardant chemical is applied to the substrate in an amount ranging from 5 to 100% solids by weight based on the weight of the fabric. 
     
     
         43 . The method of  claim 42 , wherein the flame retardant chemical is applied to the substrate in an amount ranging from 35 to 85% solids by weight based on the weight of the fabric. 
     
     
         44 . (canceled) 
     
     
         45 . The method of  claim 39 , wherein the finish is applied to the substrate in an amount ranging from 5 to 200% solids by weight based on the weight of the fabric. 
     
     
         46 . The method of  claim 45 , wherein the finish is applied to the substrate in an amount ranging from 15 to 50% solids by weight based on the weight of the fabric. 
     
     
         47 . (canceled) 
     
     
         48 . The method of  claim 39 , wherein the substrate has a basis weight ranging from 2.0 to 15.0 ounces per square yard. 
     
     
         49 . The method of  claim 48 , wherein the substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard. 
     
     
         50 . The method of  claim 49 , wherein the substrate has a basis weight ranging from 5.0 to 6.5 ounces per square yard. 
     
     
         51 . The method of  claim 39 , wherein the fabric has a thickness ranging from 0.01 to 0.15 inches. 
     
     
         52 . (canceled) 
     
     
         53 . A fabric formed using the method of  claim 39 , wherein the fabric has a contact thermal protective performance value of at least 4.5. 
     
     
         54 - 55 . (canceled) 
     
     
         56 . A fabric formed using the method of  claim 39 , wherein the fabric has a contact thermal protective performance efficiency greater than 1.1. 
     
     
         57 . A method of forming a thermally protective, flame retardant fabric, the method comprising: applying a finish to a nonwoven substrate comprising cellulosic fibers and at least one thermoplastic fiber, wherein the finish comprises an intumescent, flame retardant coating; and drying the substrate. 
     
     
         58 - 59 . (canceled) 
     
     
         60 . The method of  claim 57 , wherein the finish is applied to the substrate in an amount ranging from 15 to 130% solids by weight based on the weight of the fabric. 
     
     
         61 . (canceled) 
     
     
         62 . The method of  claim 57 , wherein the substrate has a basis weight ranging from 2.0 to 15.0 ounces per square yard. 
     
     
         63 . The method of  claim 62 , wherein the substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard. 
     
     
         64 . The method of  claim 63 , wherein the substrate comprises fibers having a basis weight ranging from 5.0 to 6.5 ounces per square yard. 
     
     
         65 . The method of  claim 57 , wherein the fabric has a thickness ranging from 0.01 to 0.15 inches. 
     
     
         66 . (canceled) 
     
     
         67 . A fabric formed using the method of  claim 57 , wherein the fabric has a contact thermal protective performance value of at least 4.5. 
     
     
         68 - 69 . (canceled) 
     
     
         70 . A fabric formed using the method of  claim 57 , wherein the fabric has a contact thermal protective performance efficiency greater than 1.1.