Flame resistant fabric useful as a batting in mattresses and upholstery

Abstract

Flame resistant fabrics useful as battings such as in mattresses and upholstery contain cellulose fibers (which retain at least 10 percent of their weight when heated in air to 700° C. at a rate of 20° C. per minute) and animal wool.

1 . A flame resistant fabric comprising: 
 (a) cellulose containing fibers which retain at least 10 percent of their weight when heated in air to 700° C. at a rate of 20° C. per minute, and    (b) wool,    wherein (b) is present in a range from 15 to 70% by weight on a basis of (a) and (b).    
   
   
       2 . The fabric of  claim 1  wherein wool is present in a range from 15 to 70% by weight on a basis of the cellulosic fiber and wool.  
   
   
       3 . The fabric of  claim 1  with a thermal performance temperature in a range from 125° C. to 500° C.  
   
   
       4 . The fabric of  claim 3  with a thermal performance temperature in a range from 200° C. to 400° C.  
   
   
       5 . The fabric of  claim 1  with a compression at least 40% measured at 24 hours in accordance with modified ASTM D6571-01.  
   
   
       6 . The fabric of  claim 1  wherein the cellulose containing fiber contains silicic acid.  
   
   
       7 . The fabric of  claim 1  with a density in a range from 0.3 to 6.0 pounds per cubic foot (5 to 96 kilograms per cubic meter).  
   
   
       8 . The fabric of  claim 1  having a basis weight in a range from 3 to 18 ounces per square yard (102 to 610 grams per square yard).  
   
   
       9 . The fabric of  claim 9  having a basis weight in a range from 4 to 12 ounces per square yard (136 to 407 grams per square yard).  
   
   
       10 . The fabric of  claim 1  when tested in a mattress according to the State of California test standard TB603 results in a peak rate of heat release less than 200 kw during the 30 minute test duration and a total heat release less than 20 MJ within 10 minutes of test start.  
   
   
       11 . The fabric of  claim 1  which additionally contains a heat resistant fiber.  
   
   
       12 . The fabric of  claim 11  wherein the heat resistant fiber is aramid, polybenzazole, polybenzimidazole or polyimide.  
   
   
       13 . The fabric of  claim 12  wherein the aramid is poly(paraphenylene terephthalamide).  
   
   
       14 . The fabric of  claim 1  present as a batting in an article of manufacture.  
   
   
       15 . The fabric of  claim 1  present in a mattress.  
   
   
       16 . The fabric of  claim 1  present in furniture.  
   
   
       17 . A method of joining a flame resistant fabric with an additional fabric comprising: 
 (a) contacting directly or through an adhesive the flame resistant fabric with the additional fabric;    (b) joining both fabrics wherein the flame resistant fabric is defined as in  claim 1 .    
   
   
       18 . The method of  claim 17  wherein the joining is by sewing.