Graphite and nanoclay flame retardant fabrics

Abstract

A flame resistant textile fabric includes a coating having an expandable graphite, or a combination of an expandable graphite and a nanoclay, disposed on one or both of its first and second surfaces. The flame resistant textile fabrics may be used to make one or more components of a mattress, such as a filler cloth, or fabric fire barrier.

What is claimed is: 
     
         1 . A flame resistant textile fabric, comprising a first surface, a second surface opposite the first surface, and a coating disposed on at least one of the first and second surfaces, wherein the coating includes an expandable graphite. 
     
     
         2 . The flame resistant textile fabric of  claim 1 , wherein the coating includes a nanoclay. 
     
     
         3 . The flame resistant textile fabric of  claim 1 , wherein the expandable graphite present in the coating is in a range from about 5% to about 75% by weight, based on the total weight of solids in the coating. 
     
     
         4 . The flame resistant textile fabric of  claim 2 , wherein a combination of the expandable graphite and the nanoclay present in the coating is in a range from about 5% to about 75% by weight, based on the total weight of solids in the coating. 
     
     
         5 . The flame resistant textile fabric of  claim 1 , wherein the expandable graphite includes particle having a particle size in a range of from about 297 microns (about 80 mesh) to about 37 microns (about 400 mesh). 
     
     
         6 . The flame resistant textile fabric of  claim 5 , wherein the expandable graphite includes particle having a particle size of about 100 microns (about 140 mesh). 
     
     
         7 . The flame resistant textile fabric of  claim 1 , wherein the expandable graphite includes particles having a particle size in a range of from 75 to 95 microns, with no more than ten percent (10%) of the particles of the expandable graphite having a particle size of 100 microns (about 140 mesh) or larger. 
     
     
         8 . The flame resistant textile fabric of  claim 7 , wherein the coating includes a latex binder. 
     
     
         9 . The flame resistant textile fabric of  claim 7 , wherein the coating is derived from a flowable coating material which includes the expandable graphite is a suspension prior to deposition on the fabric. 
     
     
         10 . The flame resistant textile fabric of  claim 7 , wherein the fabric is a woven flame resistant textile fabric. 
     
     
         11 . The flame resistant textile fabric of  claim 7 , wherein the fabric is a nonwoven flame resistant textile fabric.