FIRE-RESISTANT GLASS FIBER KNIT FABRIC

Abstract

Disclosed is a fire resistant knit fabric skeleton having a plurality of knit loops formed of corespun glass fibers, with every other course in the knit further containing a bare glass fiber, such that alternating courses of the knit fabric are either entirely corespun glass fiber or a combination of corespun glass fiber and bare glass fiber. The fabrics a unique mix of favorable properties such as excellent fire resistance and strength, improved coating adhesion, a lower basis weight, and high cross machine direction extensibility.

Claims

1. A knit fabric comprising successive courses of corespun glass fibers, wherein every other course of said fabric comprises a bare glass fiber in combination with said corespun glass fiber.

2. The fabric of claim 1, wherein the fabric comprises a circular knit fabric.

3. The fabric of claim 1, wherein the fabric comprises a lockstitch fabric.

4. The fabric of claim 1, wherein the fabric has a basis weight of about 5 to about 7 ounces per square yard.

5. The fabric of claim 1, wherein the fabric has a basis weight of about 5.5 ounces per square yard.

6. The fabric of claim 1, wherein the fabric comprises a lockstitch fabric and has a basis weight of about 5.5 ounces per square yard.

7. The fabric of claim 1, said fabric consisting entirely of corespun glass fibers and bare glass fibers.

8. The fabric of claim 1, wherein the corespun glass fibers comprise about 60 to about 80% by weight of the fabric.

9. The fabric of claim 1, wherein the corespun glass fibers comprise about 68 to about 78% by weight of the fabric.

10. The fabric of claim 1, wherein the corespun glass fibers comprise about 72 to about 75% by weight of the fabric.

11. The fabric of claim 1, wherein the bare glass fibers comprise about 20 to about 40% by weight of the fabric.

12. The fabric of claim 1, wherein the bare glass fibers comprise about 22 to about 32% by weight of the fabric.

13. The fabric of claim 1, wherein the bare glass fibers comprise about 25 to about 28% by weight of the fabric.

14. The fabric of claim 1, wherein the fabric comprises a lockstitch fabric having a basis weight of about 5.5 ounces per square yard and wherein the corespun glass fibers comprise about 68 to about 78% by weight of the fabric.

15. The fabric of claim 1, further comprising a coating on at least one side of the fabric.

16. The fabric of claim 1, further comprising a halogenated polymer coating on one side of the fabric.

17. The fabric of claim 1, further comprising foam laminated to at least one side of the fabric.

18. The fabric of claim 1, further comprising a textile laminated to at least one side of the knit fabric.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is an enlarged plan view of the front side or face of the fire resistant fabric according to a preferred embodiment of the invention; and

[0017] FIG. 2 is a plan view of the back side of the fabric of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND OPERATION OF THE INVENTION

[0018] The preferred fabric of the invention is a circular knit fabric containing bare glass fibers and corespun glass fibers. The bare glass fibers are fibers having a glass filament and no sheath or coating. The corespun glass fibers are fibers having a glass filament as a core and a sheath of non-glass fiber. Such corespun fibers are well known and discussed above in the aforementioned Publication Nos. 2016/0183694 and 2007/0004302, and U.S. Pat. Nos. 4,690,859, 5,540,980, and 4,987,026. The disclosures of these references are incorporated herein in their respective entireties.

[0019] The fabric preferably has a basis weight of between about 5 ounces per square yard and about 6 ounces per square yard, and is most preferably about 5.5 ounces per square yard. The corespun glass fibers comprise between 60 wt. % and 80 wt. % of the fabric, more preferably between 68 and 78 wt. %, and most preferably between 72 and 75 wt. %. The bare glass fibers may be from 20 wt. % to 40 wt. % of the fabric, more preferably between 22 and 32 wt. % and most preferably between 25 and 27 wt. %. The fabric skeleton described herein may be further processed by methods known in the art for particular applications, such as coating the skeleton with halogenated polymers or other fire resistant compositions, laminating the skeleton to foams or textiles, etc. In particular, the fabric skeleton of the invention has improved coating adhesion as compared to fabrics made of all corespun glass fibers or alternating course of corespun fibers and bare glass fibers.

[0020] The fabric of the invention may be made by any known knitting process that will produce the desired pattern. In making the fabric, every other feed includes a bare glass fiber and a corespun glass fiber and alternates with feeds that contain only corespun glass fiber. Thus, for example, feeds 1, 3 and 5 can include bare glass and corespun glass fibers whereas feeds 2, 4 and 6 can contain only corespun glass fiber. Stated another way, in making the fabrics of the invention all feeds include corespun glass yarns, whilst every other feed also includes a bare glass fiber.

[0021] The fabrics disclosed herein meet the requirements of the ASTM D6413 Vertical Flame Test. By selecting appropriate components, laminated structures made using the fabrics of the invention are capable of meeting FTPC Part 8 of IMO Res. A.652(16): Test for Upholstered Furniture. The fabrics disclosed herein have an extensibility (measured in the cross machine direction) of at least 100% under a static load of 10 pounds (4.54 kg) and preferably at least 125% under such load. This extensibility makes the fabrics particularly well-suited for use in upholstery and other applications requiring a high degree of drape or conformity.

[0022] With reference to FIGS. 1 and 2, a preferred embodiment of the fire resistant fabric of the invention is illustrated therein. The fabric 10 comprises a plurality of loops characteristic of a knit fabric. The fabric illustrated in FIGS. 1 and 2 is a weft knit fabric known as a lockstitch (due to its formation being defined by a lockstitch pattern), which is a more robust knit as compared to, for example, a jersey knit, and is thus the preferred construction of the fabric of the invention. Other knit patterns, however, may also be used. As seen the Figures, the fabric 10 comprises corespun glass fibers 14 wherein every other course or feed includes a bare glass fiber 12.

[0023] The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims.