Nonwoven material and dryer with nonwoven material

Abstract

A non-woven fabric includes flame retardant fibers and binding fibers mixed with the flame retardant fibers. The binding fibers set a thickness of the fabric. Application of a flame to the fabric causes the binding fibers to degrade and the flame retardant fibers to expand such that the thickness of the fabric increases, for example by a factor of two or more. The non-woven fabric can be used in a wide variety of different applications. For example, the non-woven fabric may be used to make seals of a drier, heat shields, fire barriers, and/or vents.

1 . A non-woven fabric comprising:
 flame retardant fibers;   binding fibers mixed with the flame retardant fibers;   wherein the binding fibers set a thickness of the fabric;   wherein application of a 1000° F. flame to the fabric causes the binding fibers to degrade and the flame retardant fibers to expand such that said thickness increases by a factor of at least two.   
     
     
         2 . The non-woven fabric of  claim 1  wherein said thickness increases by a factor of about two to about 6. 
     
     
         3 . The non-woven fabric of  claim 1  wherein the binding fibers are self-extinguishing fibers. 
     
     
         4 . The non-woven fabric of  claim 1  wherein the binding fibers are polyester fibers. 
     
     
         5 . The non-woven fabric of  claim 1  wherein the binding fibers are polyester bi-component fibers. 
     
     
         6 . The non-woven fabric of  claim 1  wherein the flame retardant fibers do not burn when the 1000° F. flame is applied to the fabric. 
     
     
         7 . The non-woven fabric of  claim 1  wherein the flame retardant fibers comprise oxidized Polyacrylonitrile fibers. 
     
     
         8 . The non-woven fabric of  claim 1  wherein the weight percentage of the flame retardant fibers is between 55% and 75% and the weight percentage of binding fibers is between 25% and 45% of the weight of the blanket. 
     
     
         9 . The non-woven fabric of  claim 1  wherein the binding fibers and the flame retardant fibers are not needled together. 
     
     
         10 . The non-woven fabric of  claim 1  wherein said thickness is less than ½″. 
     
     
         11 . The non-woven fabric of  claim 1  wherein said thickness is less than 8 mm and a weight of the fabric is greater than 200 grams per square meter. 
     
     
         12 . The non-woven fabric of  claim 1  wherein said thickness is between about 1 mm and about 6 mm and a weight of the fabric is about 400 grams per square meter. 
     
     
         13 . The non-woven fabric of  claim 1  wherein the thermal resistance across the width of the blanket increases as a result of the application of the flame. 
     
     
         14 . The non-woven fabric of  claim 1  an airflow resistance of the fabric is reduced after the application of a 1000° F. flame to the fabric to cause the binding fibers to degrade and the flame retardant fibers to expand. 
     
     
         15 . The non-woven fabric of  claim 1  an airflow resistance of the fabric decreases after the application of a 1000° F. and the flame retardant fibers expand, while preventing propagation of the flame through the fabric. 
     
     
         16 . The non-woven fabric of  claim 1  wherein application of a 1000 degree F. flame to the fabric for eight hours causes substantially no drawing of the flame retardant fibers. 
     
     
         17 . A non-woven fabric comprising:
 flame retardant fibers;   binding material mixed with the flame retardant fibers;   wherein the binding material sets a thickness of the fabric;   wherein application of a 1000° F. flame to the fabric causes the binding material to degrade and the flame retardant fibers to expand such that said thickness increases by a factor of at least two.   
     
     
         18 . The non-woven fabric of  claim 17  wherein application of a 1000° F. flame to the fabric causes the binding material to transition to a gas state. 
     
     
         19 . The non-woven fabric of  claim 17  wherein the binding material is a self-extinguishing material. 
     
     
         20 . The non-woven fabric of  claim 17  wherein the binding material is polyester. 
     
     
         21 . The non-woven fabric of  claim 17  wherein the flame retardant fibers do not burn when the 1000° F. flame is applied to the fabric. 
     
     
         22 . The non-woven fabric of  claim 17  wherein the flame retardant fibers comprise oxidized Polyacrylonitrile fibers. 
     
     
         23 . The non-woven fabric of  claim 17  wherein said thickness is less than 8 mm and a weight of the fabric is greater than 200 grams per square meter. 
     
     
         24 . The non-woven fabric of  claim 17  wherein application of a 1000 degree F. flame to the fabric for eight hours causes substantially no drawing of the flame retardant fibers. 
     
     
         25 . A method of making a non-woven fabric comprising:
 air laying a mixture flame retardant fibers and binding fibers;   heating and compressing the air laid flame retardant fibers and binding fibers;   cooling the binding fibers to set a thickness of the fabric;   wherein the flame retardant fibers, the binding fibers, a weight per unit area of the fabric, and said thickness are selected such that application of a 1000° F. flame to the fabric causes the binding fibers to degrade and the flame retardant fibers to expand such that said thickness increases by a factor of at least two.   
     
     
         26 . The method of making a non-woven fabric of  claim 25  wherein the mixture of flame retardant fibers and binding fibers are air laid at a thickness greater than ½ inch. 
     
     
         27 . The method of making a non-woven fabric of  claim 26  wherein the air laid flame retardant fibers and binding fibers are heated and compressed from said thickness greater than ½″ to a thickness that is less than or equal to ¼″ and then cooled to set said thickness of said fabric to less than or equal to ¼″. 
     
     
         28 . The method of making a non-woven fabric of  claim 27  wherein a weight of the fabric is greater than 200 grams per square meter. 
     
     
         29 . The method of making a non-woven fabric of  claim 25  wherein the binding fibers are polyester fibers. 
     
     
         30 . The method of making non-woven fabric of  claim 25  wherein the binding fibers are polyester bi-component fibers. 
     
     
         31 . The method of making a non-woven fabric of  claim 25  wherein the flame retardant fibers comprise oxidized Polyacrylonitrile fibers. 
     
     
         32 . The method of making a non-woven fabric of  claim 25  wherein the weight percentage of the flame retardant fibers is between 55% and 75% and the weight percentage of binding fibers is between 25% and 45% of the weight of the blanket. 
     
     
         33 . The method of making a non-woven fabric of  claim 25  wherein an airflow resistance of the fabric decreases after the application of a 1000° F. flame to the fabric to cause the binding fibers to degrade and the flame retardant fibers to expand, while preventing propagation of said flame through the fabric.