Process of making a fire resistant thread

Abstract

A method for producing a fire resistant thread comprising the steps of: unwinding a first yarn being a fire resistant polymer from a first spool onto a first pirn; unwinding a second yarn being a synthetic and/or natural yarn from a second spool onto a second pirn; unwinding a third yarn being a synthetic and/or natural yarn from a third spool onto a third pirn; unwinding the first yarn, the second yarn and the third yarn from the first pirn, the second pirn and the third pirn; twisting the first yarn, the second yarn and the third yarn each in a first direction; twisting the first yarn, the second yarn and the third yarn together in a second direction to form a three-ply thread; coating the three-ply thread with a bonding agent in order to form the fire resistant thread; and collecting the fire resistant thread.

1 . A method for producing a fire resistant thread comprising the steps of:
 unwinding a first yarn being a fire resistant polymer from a first spool onto a first pirn;   unwinding a second yarn being a synthetic and/or natural yarn from a second spool onto a second pirn;   unwinding a third yarn being a synthetic and/or natural yarn from a third spool onto a third pirn;   unwinding said first yarn, said second yarn and said third yarn from said first pirn, said second pirn and said third pirn;   twisting said first yarn, said second yarn and said third yarn each in a first direction;   twisting said first yarn, said second yarn and said third yarn together in a second direction to form a three-ply thread;   coating said three-ply thread with a bonding agent in order to form said fire resistant thread; and   collecting said fire resistant thread.   
     
     
         2 . The method for producing a fire resistant thread of  claim 1  wherein said fire resistant polymer being selected from the group comprising:
 an aramid, a polyester polyarylate, PBO, melamine formaldehyde, or combinations thereof. 
 
     
     
         3 . The method for producing a fire resistant thread of  claim 1  wherein said second and third yarns being selected from the group comprising:
 cotton, linen, polyamides, polyolefins, polyesters, acrylics, cellulosics, or combinations thereof. 
 
     
     
         4 . The method for producing a fire resistant thread of  claim 1  wherein said first, second and third yarns being continuous multifilament yarns. 
     
     
         5 . The method for producing a fire resistant thread of  claim 1  wherein said fire resistant thread being dyeable. 
     
     
         6 . The method for producing a fire resistant thread of  claim 1  wherein said first, second, and third yarns each having a denier in the range of 50 to 450 and having a filament count in the range of 30 to 75;
 said first yarn, said second yarn and said third yarn each having a twist in a first direction being an “S” direction in the range of 8.0 to 12.0 turns per inch; 
 said first yarn, said second yarn and said third yarn being combined together with a twist in a second direction being a “Z” direction in the range of 4.0 to 8.0 turns per inch to form said three-ply thread. 
 
     
     
         7 . The method for producing a fire resistant thread of  claim 6  wherein said first, second, and third yarns each having a denier in the range of 125 to 250 and having a filament count in the range of 40 to 65;
 said first yarn, said second yarn and said third yarn each having a twist in a first direction being an “S” direction in the range of 9.0 to 10.5 turns per inch; 
 said first yarn, said second yarn and said third yarn being combined together with a twist in a second direction being a “Z” direction in the range of 4.5 to 7.0 turns per inch to form said three-ply thread. 
 
     
     
         8 . The method for producing a fire resistant thread of  claim 7  wherein said first yarn being an aramid continuous multifilament yarn with a denier of 200 and a filament count of 40; and
 said second and third yarns each being a nylon continuous multifilament yarn with a denier of 200 and a filament count of 40; 
 said first yarn, said second yarn and said third yarn each having a twist in a first direction being an “S” direction of 9.2 turns per inch; 
 said first yarn, said second yarn and said third yarn being combined together with a twist in a second direction being a “Z” direction of 5.0 turns per inch to form said three-ply thread. 
 
     
     
         9 . A method for producing a fire resistant thread comprising the steps of:
 unwinding a first yarn being a fire resistant polymer from a first spool;   winding said first yarn onto a first pirn;   unwinding a second yarn being a synthetic and/or natural yarn from a second spool;   winding said second yarn onto a second pirn;   unwinding a third yarn being a synthetic and/or natural yarn from a third spool;   winding said third yarn onto a third pirn;   unwinding said first yarn, said second yarn, and said third yarn from said first pirn, said second pirn and said third pirn;   tensioning and then twisting said first yarn, said second yarn and said third yarn each in a first direction;   tensioning and then twisting said first yarn, said second yarn and said third yarn together in a second direction to form a three-ply thread;   coating said three-ply thread with a bonding agent in order to form said fire resistant thread; and   collecting said fire resistant thread.   
     
     
         10 . The method for producing a fire resistant thread of  claim 9  wherein said first yarn being wound onto said first pirn in a cocoon shape;
 said second yarn being wound onto said second pirn in a cocoon shape; and 
 said third yarn being wound onto said third pirn in a cocoon shape. 
 
     
     
         11 . The method for producing a fire resistant thread of  claim 9  wherein said fire resistant polymer being selected from the group comprising:
 an aramid, a polyester polyarylate, PBO, melamine formaldehyde, or combinations thereof. 
 
     
     
         12 . The method for producing a fire resistant thread of  claim 9  wherein said second yarn and said third yarn being selected from the group comprising:
 cotton, linen, polyamides, polyolefins, polyesters, acrylics, cellulosics, or combinations thereof. 
 
     
     
         13 . The method for producing a fire resistant thread of  claim 9  wherein said first, second and third yarns being continuous multifilament yarns. 
     
     
         14 . The method for producing a fire resistant thread of  claim 9  wherein said fire resistant thread being dyeable. 
     
     
         15 . The method for producing a fire resistant thread of  claim 9  wherein said first and second yarns each having a denier in the range of 50 to 450 and having a filament count in the range of 30 to 75;
 said first yarn, said second yarn and said third yarn each being tensioned to prevent any loops or breaks in the yarn and having a twist in a first direction being an “S” direction in the range of 8.0 to 12.0 turns per inch; and 
 said first yarn, said second yarn and said third yarn being tensioned together to prevent any loops or breaks in the yarns and then combined together with a twist in a second direction being a “Z” direction in the range of 4.0 to 8.0 turns per inch to form said three-ply thread. 
 
     
     
         16 . The method for producing a fire resistant thread of  claim 15  wherein said first, second, and third yarns each having a denier in the range of 125 to 250 and having a filament count in the range of 40 to 65;
 said first yarn, said second yarn and said third yarn each being tensioned to prevent any loops or breaks in the yarns and having a twist in a first direction being an “S” direction in the range of 9.0 to 10.5 turns per inch; and 
 said first yarn, said second yarn and said third yarn being tensioned together to prevent any loops or breaks in the yarns and then combined together with a twist in a second direction being a “Z” direction in the range of 4.5 to 7.0 turns per inch to form said three-ply thread. 
 
     
     
         17 . The method for producing a fire resistant thread of  claim 16  wherein said first yarn being an aramid continuous multifilament yarn with a denier of 200 and a filament count of 40;
 said second and third yarns each being a nylon continuous multifilament yarn with a denier of 200 and a filament count of 40; 
 said first yarn, said second yarn and said third yarn each being tensioned to prevent any loops or breaks in the yarns and having a twist in a first direction being an “S” direction of 9.2 turns per inch; and 
 said first yarn, said second yarn and said third yarn being tensioned together to prevent any loops or breaks in the yarns and then combined together with a twist in a second direction being a “Z” direction of 5.0 turns per inch to form said three-ply thread. 
 
     
     
         18 . The method for producing a fire resistant thread of  claim 9  wherein said first yarn being an aramid continuous multifilament yarn; and
 said second yarn and said third yarn each being a nylon continuous multifilament yarn. 
 
     
     
         19 . The method for producing a fire resistant thread of  claim 9  wherein said coating step being comprised of the following steps:
 running said three-ply thread from a supply creel; 
 passing said three-ply thread through a first set of stretch rollers; 
 passing said three-ply thread through a dipping tank which contains a bonding agent; 
 passing said three-ply thread through a squeegee roller to remove excess bonding agent; 
 passing said three-ply thread through a first oven to dry said three-ply thread; 
 passing said three-ply thread through a second oven to dry said three-ply thread; 
 passing said three-ply thread through a third oven to dry said three-ply thread; 
 passing said three-ply thread through a second set of stretch rollers; 
 applying a lubricant to said three-ply thread resulting in said fire resistant thread; and 
 collecting said fire resistant thread on a spool. 
 
     
     
         20 . The method for producing a fire resistant thread of  claim 19  wherein said first oven having a temperature in the range of 132° C. to 143° C.;
 said second oven having a temperature in the range of 143° C. to 154° C.; and 
 said third oven having a temperature in the range of 154° C. to 166° C.