Fire resistant panel and methods of fire blocking an article

Abstract

Flame retardant panels and methods of manufacture generally include a batting material including a layer having a top surface and a bottom surface, the layer comprising a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface; and a binder material.

1 . A fire resistant batting material, comprising:
 a layer having a top surface and a bottom surface, the layer comprising a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface, wherein the substantially vertically oriented flame retardant treated fibers are fire retardant treated lyocell fibers having a substantially uniform fire retardant throughout a cross section thereof; and   a binder material, wherein the substantially vertically oriented flame retardant treated fibers are greater than 50 percent of the layer.   
     
     
         2 . (canceled) 
     
     
         3 . The fire resistant batting material of  claim 1 , wherein the lyocell fibers have an average length of 1.5 to 3.0 inches. 
     
     
         4 . (canceled) 
     
     
         5 . (canceled) 
     
     
         6 . The fire resistant batting material of  claim 1 , wherein the fire resistant batting material has a basis weight of 5 to 18 ounces per square yard. 
     
     
         7 . The fire resistant batting material of  claim 1 , wherein a loading of the fire retardant material of the substantially vertically oriented flame retardant fibers treated is in an amount effective to meet a flammability standard defined in 16 CFR Part 1633 (2007). 
     
     
         8 . The fire resistant batting material of  claim 1 , wherein the fire retardant material of the substantially vertically oriented flame retardant treated fibers comprises halogenated compounds, phosphorous containing compounds, sulfate containing compounds, metal hydroxides, borates, silicon based compounds, melamine based compounds, phosphonic acid derivatives, intumescent compounds, and mixtures thereof. 
     
     
         9 . The fire resistant batting material of  claim 1 , wherein the batting material has a thickness greater than 0.5 inches to 3 inches. 
     
     
         10 . The fire resistant batting material of  claim 1 , wherein the substantially vertically oriented flame retardant treated lyocell fibers are treated with ammonium polyphosphate. 
     
     
         11 . (canceled) 
     
     
         12 . The fire resistant batting material of  claim 1 , wherein the substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface are in the form of pleats. 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . A mattress comprising the fire resistant batting material of  claim 1 . 
     
     
         16 . A method of fire blocking an article, comprising:
 combining layers comprising a fabric ticking, a layer of batting material, and an optional stitch backing layer, wherein the layer of batting material comprises a top surface, a bottom surface, a plurality of substantially vertically oriented flame retardant treated lyocell fibers extending from the top surface to the bottom surface, and a binder material;   sewing the layers together to form a composite; and   incorporating the composite into the article.   
     
     
         17 . The method of  claim 16 , further comprising a foam layer intermediate the layer of batting material and the optional stitch backing layer. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . The method of  claim 16 , wherein the layer of the batting material has a thickness of 0.5 to 3.0 inches. 
     
     
         21 . The method of  claim 16 , wherein the layer of the batting material has a basis weight of 5 to 18 oz/yd 2 . 
     
     
         22 . The method of  claim 16 , wherein the composite is quilted. 
     
     
         23 . The method of  claim 16 , wherein the fibers of the substantially vertically oriented flame retardant fibers have an average length of 0.5 to 3.0 inches. 
     
     
         24 . The method of  claim 16 , wherein the fire retardant material of the substantially vertically oriented flame retardant fibers comprises halogenated compounds, phosphorous containing compounds, metal hydroxides, borates, silicon based compounds, melamine based compounds, phosphonic acid derivatives, intumescent compounds, and mixtures thereof. 
     
     
         25 . The method of  claim 16 , wherein a loading of the fire retardant material in and/or on the substantially vertically oriented flame retardant treated is in an amount effective to meet the flammability standard defined in 16 CFR 1633 (2007). 
     
     
         26 . The method of  claim 16 , wherein the substantially vertically oriented flame retardant treated fibers are greater than 50 percent of the layer. 
     
     
         27 . The method of  claim 16 , wherein the binder material is a bi-component polyester having a surround melting point of less than 130° C. 
     
     
         28 . The method of  claim 16 , wherein fire retardant treated lyocell fibers comprise ammonium polyphosphate. 
     
     
         29 . The method of  claim 16 , wherein plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface are in the form of pleats.