Flame-retardant nonwovens

Abstract

The present invention concerns a flame retardant (FR) nonwoven fabric useful in household goods and particularly for mattresses. The nonwoven fabric comprises from about 6 to 25 weight % of a low melt binder, and least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin and optionally synthetic and/or natural fiber. From this nonwoven fabric, many household goods such as drapes, curtains, rugs, bedding and particularly mattresses may be constructed. The present invention also contemplates a mattress constructed from the nonwoven fabric comprising FR rayon fibers, FR acrylic fibers, FR resin, and non FR polyester fibers, and about 6 to about 25 weight % low melt binder. The mattress from this construction passes the California Test Bulletin 129 stringent conditions for mattresses used in public places. Preferably the nonwoven fabric has a batt weight of at least 5 oz./sq. yd. and preferably between 5 oz./sq. yd. and 20 oz./sq. yd.

What is claimed is:  
     
         1 ) A nonwoven article produced from about 6 to about 25 weight % low melt binder; at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin; and optionally nonbonding synthetic or natural fiber, wherein said nonwoven article has a weight of at least 5 oz./sq. yd.  
     
     
         2 ) The nonwoven article of  claim 1 , wherein said nonbonding synthetic fiber is rayon, polyester, or a mixture thereof.  
     
     
         3 ) The nonwoven article of  claim 1 , wherein article is produced from at least two of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin.  
     
     
         4 ) The nonwoven article of  claim 1 , wherein said low melt binder is a bicomponent fiber or a low melting fiber.  
     
     
         5 ) The nonwoven article of  claim 4 , wherein said bicomponent fiber has a polyester component, and a polyolefin or copolyester component.  
     
     
         6 ) The nonwoven article of  claim 4 , wherein said low melting fiber is copolyester or polyolefin fiber.  
     
     
         7 ) The nonwoven article of  claim 1 , wherein said FR resin is a phosphorus compound, red phosphorus, or phosphorus compatible with said nonbonding synthetic fiber.  
     
     
         8 ) The nonwoven article of  claim 1 , having about 50 weight % rayon, about 35 weight % polyester, and about 15 weight % bicomponent fiber, totaling 100 weight %, and about 21 weight % FR resin, based on said 100 weight %.  
     
     
         9 ) The nonwoven article of  claim 1 , having about 30 weight % FR acrylic, about 25 weight % FR melamine, about 30 weight % rayon, and about 15 weight % bicomponent fiber, totaling 100 weight %, and about 14 weight % FR resin, based on said 100 weight %.  
     
     
         10 ) The nonwoven article of  claim 1 , having about 30 weight % FR acrylic, about 25 weight % FR melamine, about 30 weight % rayon, and about 15 weight % bicomponent fiber, totaling 100 weight %, and about 20 weight % FR resin, based on said 100 weight %.  
     
     
         11 ) The nonwoven article of  claim 1 , having about 30 weight % FR acrylic, about 25 weight % FR melamine, about 30 weight % FR rayon, and about 15 weight % bicomponent fiber, totaling 100 weight %, and about 15 weight % FR resin, based on said 100 weight %.  
     
     
         12 ) The nonwoven article of  claim 1 , having about 30 weight % FR acrylic, about 25 weight % polyester, about 30 weight % FR rayon, and about 15 weight % bicomponent fiber, totaling 100 weight %, and about 14 weight % FR resin, based on said 100 weight %.  
     
     
         13 ) The nonwoven article of  claim 1 , having about 80 weight % rayon, about 20 weight % bicomponent fiber, totaling 100 weight %, and about 24 weight % FR resin based on said 100 weight %.  
     
     
         14 ) The nonwoven article of  claim 1 , having about 40 weight % FR acrylic, about 40 weight % FR melamine, and about 20 weight % bicomponent fiber, totaling 100 weight %.  
     
     
         15 ) The nonwoven article of  claim 1 , having about 40 weight % FR rayon, about 45 weight % polyester, and about 15 weight % bicomponent fiber, totaling 100 weight %.  
     
     
         16 ) The nonwoven article of  claim 1 , having about 30 weight % FR acrylic, about 25 weight % FR melamine, about 30 weight % FR rayon, and about 15 weight % bicomponent fiber, totaling 100 weight %.  
     
     
         17 ) The nonwoven article of  claim 1 , having about 30 weight % FR acrylic, about 30 weight % FR rayon, about 25 weight % polyester, and about 15 weight % bicomponent fiber, totaling 100 weight %.  
     
     
         18 ) The nonwoven article of  claim 1 , wherein said natural fiber is flax or kenaf.  
     
     
         19 ) A nonwoven article produced from: a low melt binder; at least two of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin; and optionally a nonbonding synthetic fiber, wherein said nonwoven article has a weight of at least 5 oz./sq. yd.  
     
     
         20 ) A nonwoven article produced from: about 6 to about 25 weight % low melt binder; at least two of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin; and a nonbonding synthetic or natural fiber, wherein said nonwoven article has a weight of at least 5 oz./sq. yd.  
     
     
         21 ) A nonwoven article produced from synthetic fiber, natural fibers and about 6 to about 25 weight % low melt binder, and an FR resin, wherein said nonwoven article has a weight of at least 5 oz./sq. yd.  
     
     
         22 ) The nonwoven article of  claim 21 , wherein said synthetic fiber is rayon, polyester, or a mixture thereof.  
     
     
         23 ) The nonwoven article of  claim 21 , wherein said synthetic fiber is from about 15 weight % to about 55 weight % of said article.  
     
     
         24 ) The nonwoven article of  claim 21 , wherein said natural fiber is flax, kenaf, or a mixture of these.  
     
     
         25 ) The nonwoven article of  claim 21 , wherein said natural fiber is from about 40 weight % to about 60 weight % of said article.  
     
     
         26 ) The nonwoven article of  claim 21 , wherein said low melt binder is a bicomponent fiber or a low melting fiber.  
     
     
         27 ) The nonwoven article of  claim 26 , wherein said bicomponent fiber has a polyester component, and a polyolefin or copolyester component.  
     
     
         28 ) The nonwoven article of  claim 26 , wherein said low melting fiber is copolyester or polyolefin fiber.  
     
     
         29 ) A mattress, said mattress having a nonwoven batt comprising about 6 to about 25 weight % low melt binder, and at least one of FR rayon fiber, FR acrylic fiber, FR melamine fiber, or FR resin, wherein said nonwoven batt has a weight of at least 5 oz./sq. yd.  
     
     
         30 ) The mattress of  claim 29 , wherein said mattress has FR rayon fibers, FR acrylic fibers, FR resin, and non FR polyester fibers.