Fire retardant material and method of making the same

Abstract

This invention is directed to a light weight fire resistant material. The material is constructed of a plurality of oxidized polyacrylonitrile (OPAN) fibers. The fire resistant material having a weight in the range of less than about 9.0 oz/yd2, an Arc Thermal Performance Value of greater than about 8.0 and a Thermal Protection Performance of greater than about 13.0.

What is claimed is: 
     
         1 . A lightweight fire resistant material, the material comprising:
 a plurality of oxidized polyacrylonitrile fibers wherein the fire resistant material has a weight in the range of less than about 9.0 oz/yd2, an Arc Thermal Performance Value of greater than about 8.0 and a Thermal Protection Performance of greater than about 13.0.   
     
     
         2 . The material of  claim 1 , wherein oxidized polyacrylonitrile fibers of the fire resistant material are provided in a length in a range of from about 73 mm to about 76 mm. 
     
     
         3 . The material of  claim 1 , wherein the weight of the fire resistant material is in a range of less than about 7.0 oz/yd2. 
     
     
         4 . The material of  claim 1 , wherein the specific gravity of the oxidized polyacrylonitrile fibers is in a range of from about 1.35 to about 1.47. 
     
     
         5 . The material of  claim 1 , wherein the linear mass density of the oxidized polyacrylonitrile fibers is in a range of from about 1.2 denier to about 3.0 denier. 
     
     
         6 . The material of  claim 1 , wherein the fire resistant material further includes para-aramid fibers. 
     
     
         7 . The material of  claim 6 , wherein the para-aramid fibers have a fiber length in a range of from about 38 mm to about 76 mm. 
     
     
         8 . The material of  claim 1 , wherein the oxidized polyacrylonitrile fibers are present in the fire resistant material in an amount of from about 1% by weight to about 100% by weight. 
     
     
         9 . The material of  claim 1 , wherein the oxidized polyacrylonitrile fibers are present in the fire resistant material in an amount of from about 30% by weight to about 70% by weight. 
     
     
         10 . A method of providing a lightweight fire resistant material, the method comprising the steps of:
 providing a plurality of oxidized polyacrylonitrile fibers; and   weaving the plurality of oxidized polyacrylonitrile fibers together wherein the fire resistant material has a weight in the range of less than about 9.0 oz/yd2, an Arc Thermal Performance Value of greater than about 8.0 and a Thermal Protection Performance of greater than about 13.0.   
     
     
         11 . The method of  claim 10 , wherein oxidized polyacrylonitrile fibers of the fire resistant material are provided in a length in a range of from about 73 mm to about 76 mm. 
     
     
         12 . The method of  claim 10 , wherein the weight of the fire resistant material is in a range of less than about 7.0 oz/yd2. 
     
     
         13 . The method of  claim 10 , wherein the specific gravity of the oxidized polyacrylonitrile fibers is in a range of from about 1.35 to about 1.47. 
     
     
         14 . The method of  claim 10 , wherein the linear mass density of the oxidized polyacrylonitrile fibers is in a range of from about 1.2 denier to about 3.0 denier. 
     
     
         15 . The method of  claim 10 , wherein the fire resistant material further includes para-aramid fibers. 
     
     
         16 . The method of  claim 15 , wherein the para-aramid fibers have a fiber length of from about 38 mm to about 76 mm. 
     
     
         17 . The method of  claim 10 , wherein the oxidized polyacrylonitrile fibers are present in the fire resistant material in an amount of from about 1% by weight to about 100% by weight. 
     
     
         18 . The method of  claim 10 , wherein the oxidized polyacrylonitrile fibers are present in the fire resistant material in an amount of from about 30% by weight to about 70% by weight. 
     
     
         19 . A fire resistant material, the material comprising:
 a plurality of oxidized polyacrylonitrile fibers; and   an amount of chitosan applied to the plurality of oxidized polyacrylonitrile fibers to increase the fire resistance of the fire resistant material.   
     
     
         20 . The material of  claim 19 , where in the amount of chitosan applied is in a range of from about 0.1% to about 10.0% by weight of the fire resistant material. 
     
     
         21 . A method of providing a fire resistant material, the method comprising the steps of:
 providing a plurality of oxidized polyacrylonitrile fibers;   applying an amount of chitosan to the plurality of oxidized polyacrylonitrile fibers to increase the fire resistance of the fire resistant material; and   weaving the plurality of oxidized polyacrylonitrile fibers together.   
     
     
         22 . The method of  claim 21 , wherein the chitosan is applied in an amount in the range of from about 0.1% to about 10.0% by weight of the fire resistant material.