Lightweight nonwoven fire retardant barrier

Abstract

A non-woven flame retardant barrier comprising a binder; and a plurality of charring fibers combinable with the binder. The charring fibers include treated viscose fibers, wherein the charring fibers are substantially free of polymers made from halogenated monomers, consist essentially of fibers exclusively having a denier of from 1.5 to 3.5, and provide a fire-blocking web upon exposure to a heat source. The barrier has a basis weight of approximately from 0.25 to 0.65 osf.

What is claimed is: 
     
         1 . A non-woven flame retardant barrier comprising low denier charring fibers in amounts sufficient for a mattress containing the barrier to comply with Cal. AB 603, wherein the barrier is substantially free of polymers made from halogenated monomers and has a basis weight of from 0.25 to 0.75 osf. 
     
     
         2 . The nonwoven barrier of  claim 1 , having a basis weight of from 0.25 to 0.65. 
     
     
         3 . The non-woven barrier of  claim 1 , wherein the low denier charring fibers have a denier of less than about 3.5. 
     
     
         4 . The non-woven barrier of  claim 1 , wherein the low denier charring fibers comprise viscose fibers. 
     
     
         5 . The non-woven barrier of  claim 4 , wherein the low denier charring fibers comprise treated or modified viscose fibers. 
     
     
         6 . The non-woven barrier of  claim 1 , wherein the low denier charring fibers comprise treated or modified natural fibers. 
     
     
         7 . The non-woven barrier of  claim 1 , wherein the low denier charring fibers are treated with at least one of ammonium sulfate, ammonium phosphate, and boric acid. 
     
     
         8 . The non-woven barrier of  claim 1 , wherein the low denier charring fibers comprise at least one of cotton, rayon, and kenaf. 
     
     
         9 . The non-woven barrier of  claim 1 , further comprising high denier charring fibers in amounts that do not prevent compliance with Cal. AB 603, wherein the low denier charring fibers and the high denier charring fibers comprise a blend. 
     
     
         10 . A non-woven flame retardant barrier comprising low denier charring fibers substantially free of polymers made from halogenated monomers and having a basis weight of from 0.25 to 0.75 osf, wherein the low denier charring fibers are present in amounts effective to create a fire-blocking web for a mattress in compliance with Cal. AB 603. 
     
     
         11 . The nonwoven barrier of  claim 10 , having a basis weight of from 0.25 to 0.65. 
     
     
         12 . The non-woven barrier of  claim 10 , wherein the low denier charring fibers have a denier of less than about 3.5. 
     
     
         13 . The non-woven barrier of  claim 10 , wherein the low denier charring fibers comprise viscose fibers. 
     
     
         14 . The non-woven barrier of  claim 13 , wherein the low denier charring fibers comprise treated or modified viscose fibers. 
     
     
         15 . The non-woven barrier of  claim 10 , wherein the low denier charring fibers comprise treated or modified natural fibers. 
     
     
         16 . The non-woven barrier of  claim 10 , wherein the low denier charring fibers are treated with at least one of ammonium sulfate, ammonium phosphate, and boric acid. 
     
     
         17 . The non-woven barrier of  claim 10 , wherein the low denier charring fibers comprise at least one of cotton, rayon, and kenaf. 
     
     
         18 . A non-woven flame retardant barrier comprising a blend of low denier charring fibers and higher denier charring fibers, wherein
 there is more low denier charring fibers than higher denier charring fibers,   the barrier is substantially free of polymers made from halogenated monomers,   the barrier has a basis weight of from 0.25 to 0.75 osf, and   when used in a mattress, the barrier creates a fire-blocking web for a mattress in compliance with Cal. AB 603.   
     
     
         19 . The nonwoven barrier of  claim 18 , having a basis weight of from 0.25 to 0.65. 
     
     
         20 . The non-woven barrier of  claim 18 , wherein the higher denier charring fibers comprise high denier charring fibers. 
     
     
         21 . The non-woven barrier of  claim 18 , wherein the low denier charring fibers have a denier of less than about 3.5. 
     
     
         22 . The non-woven barrier of  claim 18 , wherein the low denier charring fibers comprise treated or modified natural fibers. 
     
     
         23 . The non-woven barrier of  claim 18 , wherein the low denier charring fibers are treated with at least one of ammonium sulfate, ammonium phosphate, and boric acid. 
     
     
         24 . The non-woven barrier of  claim 18 , wherein the low denier charring fibers comprise at least one of cotton, rayon, and kenaf. 
     
     
         25 . A non-woven flame retardant barrier comprising low denier charring fibers, binder and filler, wherein
 the barrier is substantially free of polymers made from halogenated monomers and has a basis weight of from 0.25 to 0.75 osf, and   the binder and filler comprise up to 40% of the fibers.   
     
     
         26 . The nonwoven barrier of  claim 25 , having a basis weight of from 0.25 to 0.65. 
     
     
         27 . The non-woven barrier of  claim 25 , wherein the low denier charring fibers comprise at least one of cotton, rayon, and kenaf. 
     
     
         28 . The non-woven barrier of  claim 25 , wherein the low denier charring fiber is present in amounts sufficient for a mattress containing the barrier to comply with Cal. AB 603. 
     
     
         29 . The non-woven barrier of  claim 28 , further comprising higher denier charring fibers. 
     
     
         30 . The nonwoven barrier of  claim 29 , wherein the low denier charring fibers and the higher denier charring fibers comprise a blend. 
     
     
         31 . An article of manufacture comprising the non-woven barrier of  claim 25 , wherein the article is for use in a partition, automobile, aircraft, appliance, bedding, or furniture. 
     
     
         32 . The article of  claim 31 , wherein the article is a thermal or acoustic insulator. 
     
     
         33 . The article of  claim 31 , for use in an automobile. 
     
     
         34 . The article of  claim 31 , wherein the article is a mattress that meets the requirements of Cal. AB 603. 
     
     
         35 . The article of  claim 31 , further comprising at least one additional layer to form a composite material. 
     
     
         36 . The article of  claim 35 , wherein the non-woven barrier is in a layer extending along a surface. 
     
     
         37 . The article of  claim 36 , further comprising a fabric covering the surface. 
     
     
         38 . An article of manufacture comprising the non-woven barrier of  claim 1 , wherein the article is for use in a partition, automobile, aircraft, appliance, bedding, or furniture. 
     
     
         39 . The article of  claim 38 , wherein the article is a thermal or acoustic insulator. 
     
     
         40 . The article of  claim 38 , for use in an automobile. 
     
     
         41 . The article of  claim 38 , further comprising at least one additional layer to form a composite material. 
     
     
         42 . The article of  claim 41 , wherein the non-woven barrier is in a layer extending along a surface. 
     
     
         43 . The article of  claim 42 , further comprising a fabric covering the surface. 
     
     
         44 . A non-woven flame retardant barrier comprising low denier charring fibers, binder and filler, wherein
 the barrier is substantially free of polymers made from halogenated monomers and has a basis weight of from 0.25 to 0.75 osf, and   the low denier charring fibers comprise at least about 60% of the fibers.   
     
     
         45 . The nonwoven barrier of  claim 44 , having a basis weight of from 0.25 to 0.65. 
     
     
         46 . The non-woven barrier of  claim 44 , wherein the lower denier charring fibers comprise at least one of cotton, rayon, and kenaf. 
     
     
         47 . The non-woven barrier of  claim 44 , wherein the low denier charring fiber is present in amounts sufficient for a mattress containing the barrier to comply with Cal. AB 603. 
     
     
         48 . The non-woven barrier of  claim 47 , further comprising higher denier charring fibers. 
     
     
         49 . The nonwoven barrier of  claim 48 , wherein the low denier charring fibers and the higher denier charring fibers comprise a blend.