Flame-retardant waterproof stretchable composite fabric, pillow or mattress protector using said fabric and use of said fabric as a protective screen

Abstract

The composite fabric is suitable as a flame barrier for different articles, such as mattresses, pillows, seats and upholstered furniture and is made from a plurality of joined breathable layers including at least one textile layer and one impervious layer joined including a knitted textile layer made of cellulose fibers of natural renewable origin including at least 50% of cellulose flame-retardant fibers, and the impervious layer including an halogen free plastic material selected among polyurethane or polyester incorporating a known flame-retardant or inhibitor additive.

Claims

1. A flame-retardant waterproof stretchable composite fabric, suitable as a flame barrier for pillows or mattress protectors/encasements, made from a plurality of joined breathable layers comprising at least one textile layer and one impervious layer joined by lamination using an adhesive, wherein: the at least one textile layer is made of 100% cellulose fibres, said cellulose fibres comprising at least 50% of cellulose flame-retardant fibres incorporating a flame-inhibitor additive; the at least one textile layer comprises a knitted structure selected from Single Jersey or Interlock type providing a multidirectional extensibility; wherein: said flame-inhibitor additive is halogen free and selected from the group consisting of Kaolin, calcium carbonate, aluminium hydroxide or an organic phosphorous-based pigment; the impervious layer is of biaxial elastic condition; and the impervious layer comprises a halogen free plastic material selected from polyurethane or polyester incorporating an organophosphorus flame-inhibitor additive, wherein the stretchable composite fabric has at least 85% of elastic recovery in both fabric directions, according to UNE EN 15977 and the fabric takes a persistent flame-retardancy, as set forth in standards EN597, ISO12952 and BS7175.

2. A flame-retardant waterproof stretchable composite fabric, according to claim 1, wherein more than 90% of said 100% cellulose fibres are derived from wood or cotton.

3. A flame-retardant waterproof stretchable composite fabric, according to claim 2 wherein about 85% of said 100% cellulose fibres are cellulose flame-retardant fibres.

4. A flame-retardant waterproof stretchable composite fabric, according to claim 3, wherein it has a weight from 80 to 350 g/m.sup.2.

5. A flame-retardant waterproof stretchable composite fabric, according to claim 4, wherein it has a weight of about 160 g/m.sup.2 in a two layer structure.

6. A flame-retardant waterproof stretchable composite fabric according to claim 5, comprising two of the at least one textile three layers with said impervious layer sandwiched between the two textile layers.

7. A flame-retardant waterproof stretchable composite fabric, according to claim 2, wherein it has a weight from 80 to 350 g/m.sup.2.

8. A flame-retardant waterproof stretchable composite fabric, according to claim 7, wherein it has a weight of about 160 g/m.sup.2 in a two layer structure.

9. A flame-retardant waterproof stretchable composite fabric according to claim 8, comprising two of the at least one textile layers with said impervious layer sandwiched between the two textile layers.

10. A flame-retardant waterproof stretchable composite fabric, according to claim 1, wherein about 85% of said 100% cellulose fibres are cellulose flame-retardant fibres.

11. A flame-retardant waterproof stretchable composite fabric, according to claim 10, wherein it has a weight from 80 to 350 g/m.sup.2.

12. A flame-retardant waterproof stretchable composite fabric, according to claim 11, wherein it has a weight of about 160 g/m.sup.2 in a two layer structure.

13. A flame-retardant waterproof stretchable composite fabric according to claim 12, comprising two of the at least one textile layers with said impervious layer sandwiched between the two textile layers.

14. A flame-retardant waterproof stretchable composite fabric according to claim 1, comprising two of the at least one textile layers with said impervious layer sandwiched between the two textile layers.

15. A flame-retardant waterproof stretchable composite fabric, according to claim 1, wherein the organophosphorus flame inhibitor additive is selected from the group consisting of: tris-(2,3-dibromopropyl) phosphate, triphenyl phosphate (TPP), resorcinol bis(diphenylphosphate) (RDP), bisphenol A diphenyl phosphate (BADP), trio-o-cresyl phosphate, dimethyl methyl phosphonate (DMMP), and phosphinates.

16. A pillow or mattress protector obtained from a flame-retardant waterproof stretchable composite fabric made from a plurality of joined breathable layers comprising at least one textile layer and one impervious layer joined by lamination using an adhesive, wherein: the at least one textile layer is made of 100% cellulose fibres, said cellulose fibres comprising at least 50% of cellulose flame-retardant fibres incorporating a flame-inhibitor additive; the at least one textile layer comprises a knitted structure selected from Single Jersey or Interlock type providing a multidirectional extensibility, wherein: said flame-inhibitor additive is halogen free and selected from the group consisting of Kaolin, calcium carbonate, aluminium hydroxide or an organic phosphorous-based pigment; the impervious layer is of biaxial elastic condition; and the impervious layer comprises a halogen free plastic material selected from polyurethane or polyester incorporating an organophosphorus flame-inhibitor additive, wherein the stretchable composite fabric has at least 85% of elastic recovery in both fabric directions, according to UNE EN 15977 and the fabric takes a persistent flame-retardancy, as set forth in standards EN597, ISO12952 and BS7175.

17. A pillow or mattress protector according to claim 16, wherein the organophosphorus flame inhibitor additive is selected from the group consisting of: tris-(2,3-dibromopropyl) phosphate, triphenyl phosphate (TPP), resorcinol bis(diphenylphosphate) (RDP), bisphenol A diphenyl phosphate (BADP), trio-o-cresyl phosphate, dimethyl methyl phosphonate (DMMP), and phosphinates.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a picture showing the after burning performance of the flame-retardant waterproof stretchable composite fabric of this invention, evidencing that no melt, no drip occurs since after burning the textile layer creates a carbonized layer that safeguards the mattress or pillow.

TEST RESULTS OF AN EMBODIMENT OF THE INVENTION

(2) In the following the results of a test on ignability of a bedcover made using the flame-retardant fabric of this invention by smouldering and flaming ignition sources are detailed.

(3) The flame-retardant fabric of the text comprises two layers: a knitted textile layer made of 100% cellulose fibres knitted in a Single Jersey structure (of about 120 g/m.sup.2), 85% of them incorporating an organic phosphorous-based flame-inhibitor, laminated with a polyurethane impervious layer of 25 microns incorporating an organophosphorous flame-inhibitor.

(4) The test follows Standard BS 7175:1989, Section 3. Individual bedcovers (including mattress cases and covers, sheets, pillows, blankets, bedspreads and continental quilt covers) tested with smouldering and flaming ignition sources.

(5) Scope: Methods of assessing the ignitability of individual items of bedcovers. The ignition sources used are the smouldering and/or flaming ignition sources.

(6) Equipment used: Chronometer, Test rig, Anemometer, Ruler.

(7) Conditioning of specimens and cigarette: min 16 h, 205 C. and 65%5% hr

(8) Results obtained:

(9) TABLE-US-00001 Ignited/ Behaviour at Not Ignition source Specified specified time Behaviour on dismanting Ignited Number Position time Initial Repeat Initial Repeat (I/NI) 0 A 60 minutes 0 s 0 s No No NI after Progressive Progressive placement smouldering smouldering of the cigarette 0 B 60 minutes 0 s 0 s No No NI after Progressive Progressive placement smouldering smouldering of the cigarette 1 A 120 s after 0 s 0 s No No NI removal of Progressive Progressive the ignition smouldering smouldering flame 1 B 120 s after 0 s 0 s No No NI removal of Progressive Progressive the ignition smouldering smouldering flame 2 A 120 s after 8 s 12 s No No NI removal of Progressive Progressive the ignition smouldering smouldering flame 2 B 120 s after 0 s 0 s No No NI removal of Progressive Progressive the ignition smouldering smouldering flame 3 A 120 s after 9 s 22 s No No NI removal of Progressive Progressive the ignition smouldering smouldering flame 3 B 120 s after 0 s 0 s No No NI removal of Progressive Progressive the ignition smouldering smouldering flame 4 A 10 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib 4 B 10 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib 5 A 10 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib 5 B 10 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib 6 A 13 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib 6 B 13 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib 7 A 13 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib 7 B 13 minutes 0 s 0 s No No NI after the Progressive Progressive ignition of smouldering smouldering the crib Test conditions: Test atmosphere: (15-30 C.) and (55 20% hr) Pre-treatment: Null Ignition source: Source 0 (smouldering cigarette) tested at Position A (Top) and Position B (Between top and 2.sup.nd fold), Source 1, 2, 3 (Butane gas flame) tested at Position A (Top) and Position B (Below the overhang) and Source 4, 5, 6, 7 (Crib) at Position A (Top) and Position B (Below the overhang) Type of gas: Butane Exposure time of the source: Source 1: 20 1 s Source 2: 40 1 s Source 3: 70 1 s Flame height of the source: Source 1: 35 mm Source 2: 145 mm Source 3: 240 mm Wind speed: <0.2 m/s Remark: The results relate only to the ignitability of the test specimen under the particular conditions of the test and are not intended as a means assessing the full potential fire hazard of the bed covers in use.