Thermally protective flame retardant fabric

Abstract

The present invention provides a fabric consisting of a single layer of a non-woven substrate treated with a flame retardant finish. The non-woven substrate comprises cellulosic fibers and polyester fibers and has a basis weight ranging from 2.0 to 15.0 ounces per square yard. The fabric has a thickness ranging from 0.01 to 0.15 inches.

What is claimed is: 
     
         1 . A fabric consisting of a single layer of a non-woven, needlepunched substrate,
 wherein the non-woven, needlepunched substrate comprises cellulosic fibers and polyester fibers,   wherein the non-woven, needlepunched substrate is treated with an intumescent, flame retardant finish comprising one or more compounds comprising phosphorous and/or nitrogen,   wherein the non-woven, needlepunched substrate has a basis weight ranging from 2.0 to 15.0 ounces per square yard, and   wherein the fabric has a thickness ranging from 0.01 to 0.15 inches.   
     
     
         2 . The fabric of  claim 1 , wherein the fabric has a contact thermal protective performance value of at least 6.5. 
     
     
         3 . The fabric of  claim 1 , wherein the fabric has a contact thermal protective performance value of at least 9.0. 
     
     
         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 non-woven, needlepunched substrate has a basis weight ranging from 5.0 to 6.5 ounces per square yard. 
     
     
         6 . The fabric of  claim 1 , wherein the fabric has a contact thermal protective performance value of at least 4.5. 
     
     
         7 . The fabric of  claim 1 , wherein the fabric has a thickness ranging from 0.04 to 0.09 inches. 
     
     
         8 . The fabric of  claim 1 , wherein the fabric has a thickness ranging from 0.01 to 0.05 inches. 
     
     
         9 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard. 
     
     
         10 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard. 
     
     
         11 . The fabric of  claim 1 , wherein the cellulosic fibers comprise cotton, rayon and/or lyocell fibers. 
     
     
         12 . The fabric of  claim 1 , wherein the cellulosic fibers comprise rayon fibers. 
     
     
         13 . The fabric of  claim 1 , wherein the cellulosic fibers comprise lyocell fibers. 
     
     
         14 . A protective garment constructed from the fabric claimed in  claim 1 . 
     
     
         15 . The protective garment of  claim 14 , wherein the protective garment is chosen from fire retardant suits, fire retardant gloves and welding suits. 
     
     
         16 . An article of furniture constructed from the fabric claimed in  claim 1 . 
     
     
         17 . The article of furniture of  claim 16 , wherein the article of furniture is chosen from mattresses, chairs, sofas, and seats. 
     
     
         18 . A vehicle component constructed from the fabric claimed in  claim 1 . 
     
     
         19 . The vehicle component of  claim 18 , wherein the vehicle component is chosen from vehicle seats, vehicle beds, vehicle doors, vehicle bodies, mobile homes, trailers, insulation, and fuel tank exterior liners. 
     
     
         20 . The fabric of  claim 1 , wherein the intumescent, flame retardant finish is applied to the non-woven, needlepunched substrate in an amount ranging from 15 to 130 percent solids, based upon the weight of the non-woven, needlepunched substrate. 
     
     
         21 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 2.0 to 8.0 ounces per square yard and a thickness ranging from 0.04 to 0.09 inches. 
     
     
         22 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 2.0 to 8.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches. 
     
     
         23 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard and a thickness ranging from 0.04 to 0.09 inches. 
     
     
         24 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 3.0 to 8.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches. 
     
     
         25 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard and a thickness ranging from 0.04 to 0.09 inches. 
     
     
         26 . The fabric of  claim 1 , wherein the non-woven, needlepunched substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches. 
     
     
         27 . The fabric of  claim 1 , wherein the intumescent, flame retardant finish comprises one or more compounds comprising phosphorous and nitrogen. 
     
     
         28 . The fabric of  claim 1 , wherein the cellulosic fibers comprise rayon and/or lyocell fibers and wherein the non-woven, needlepunched substrate has a basis weight ranging from 2.0 to 5.0 ounces per square yard and a thickness ranging from 0.01 to 0.05 inches. 
     
     
         29 . The fabric of  claim 28 , wherein the fabric has a contact thermal protective performance value of at least 4.5. 
     
     
         30 . The fabric of  claim 28 , wherein the fabric has a contact thermal protective performance efficiency of greater than 1.1.