Coated fire barriers made from corespun yarns - coated fibers comprising the sheath of the corespun yarns

Abstract

The invention relates to a fire resistant flame barrier lightweight fabric substrate consisting of a high temperature resistant continuous filament fiberglass core and a low temperature resistant staple fiber sheath treated with a durable or non-durable fire retardant agent prior to yarn formation. The invention also discloses a process for making a fire resistant corespun yarn by treating fibers with fire retardant agent to make the sheath of the corespun yarn.

1 . A fire resistant fabric comprising:
 a fine textured fire resistant flame barrier lightweight fabric substrate formed of a nonlively nonplied fine balanced corespun yarn comprising:   the yarn being air jet spun without any appreciable twist and including a core of high temperature resistant continuous filament fiberglass constituting about 20% to 40% of total weight of the corespun yarn;   a sheath of low temperature resistant staple fibers treated with at least one of a durable or non-durable fire retardant agent prior to the yarn formation process; and   the sheath surrounding and covering said core constituting about 80% to 60% of the total weight of the corespun yarn.   
     
     
         2 . The sheath of  claim 1 , wherein at least some of the sheath fibers are micro-coated with durable or non-durable fire retardant agents. 
     
     
         3 . The sheath of  claim 1 , wherein the fire retardant agent comprises at least one of:
 Ammonium polyphosphate;   Graphite;   Boric acid; or   other environmentally friendly chemicals.   
     
     
         4 . The fire resistant fabric of  claim 3  wherein the retardant agent comprises one of a:
 gas; 
 liquid; and 
 powder. 
 
     
     
         5 . The fire resistant fabric of  claim 1 , wherein said fabric substrate is one of knit or woven construction. 
     
     
         6 . The corespun yarn of  claim 1 , wherein said sheath comprises blends of natural and or man-made fibers comprising at least one of:
 animal;   vegetable;   mineral;   wool;   cotton;   polyester;   modacrylic;   nylon;   rayon;   Lyocell;   Kenaf;   Hemp;   Jute;   acetate; and   blends thereof.   
     
     
         7 . The corespun yarn of  claim 1 , wherein the sheath is comprised of substantially 100% fire retardant micro-coated fibers. 
     
     
         8 . The corespun yarn of  claim 1 , wherein the sheath is comprised of fire retardant micro-coated fibers blended with other non-treated fibers. 
     
     
         9 . The corespun yarn of  claim 1 , wherein the sheath is comprised of fire retardant micro-coated fibers blended with other inherently fire retardant fibers. 
     
     
         10 . A process for making a fire retardant corespun yarn by treating the fibers with fire retardant agent to make the sheath of the corespun yarn comprising:
 preparing a fire retardant composition;   applying the fire retardant composition to the fiber;   drying and or curing the treated fiber; and   forming a yarn from the treated fiber.   
     
     
         11 . The process of  claim 10 , wherein the treated fibers cover the core high temperature resistant fibers to create a sheath of treated fibers. 
     
     
         12 . The process of  claim 10 , wherein the treated fibers are blended with other fibers to create a sheath of treated and untreated fibers. 
     
     
         13 . The process of  claim 10 , wherein the fire retardant composition is applied to the sheath of the corespun yarn and comprises at least one of:
 Ammonium polyphosphate;   Graphite;   Boric Acid; and   other environmentally friendly chemicals.   
     
     
         14 . The process of  claim 10 , wherein the fire retardant composition is applied to at least a surface of the fiber by at least one of:
 mixing;   spraying;   rolling; and   brushing.   
     
     
         15 . The process of  claim 10 , wherein the fiber used to make the sheath of the corespun yarn is immersed in the fire retardant composition. 
     
     
         16 . The process of  claim 10 , wherein the fire retardant composition is reapplied as necessary.