Fire retardant nylon fibers and methods for making them

Abstract

Provided are nylon fibers having fire retardant agents dispersed therein and methods for manufacturing such fibers. The fire-retardant agents may comprise Tris(tribromophenyl) triazine and/or antimony trioxide. Fabrics made from such fibers are also provided.

What is claimed is: 
     
         1 . A layered fabric comprising:
 (i) a first layer comprising a plurality of fire-retardant nylon fibers having dispersed within internal regions thereof a fire-retardant composition comprising:
 a. a brominated (Br) organic fire-retardant; and 
 b. a synergist,
 wherein the fire-retardant composition comprises from about 0.1% to about 10% brominated organic fire-retardant; and from about 0.1% to about 10% synergist, 
 wherein a major portion thereof is Nylon-6 polymer and/or Nylon-6,6 polymer, 
 wherein the fiber is essentially free of brominated polystyrenes; and 
 
   (ii) a second layer comprising a laminate bonded to the first layer.   
     
     
         2 . The layered fabric of  claim 1 , wherein the brominated organic fire-retardant is selected from the group consisting of tris(tribromophenyl) triazine; tris(tribromoneopentyl)phosphate; pentabromobenzyl acrylate (PBB-MA); poly(pentabromobenzyl acrylate) (PBB-PA); brominated trimethylphenyl indan; and tetrabromobisphenyl A-bis(2,3-dibromopropyl ether). 
     
     
         3 . The layered fabric of  claim 1 , wherein the brominated organic fire-retardant is a brominated aryl fire-retardant. 
     
     
         4 . The layered fabric of  claim 1 , wherein the brominated organic fire-retardant comprises tris(tribromophenyl) triazine. 
     
     
         5 . The layered fabric of  claim 1 , wherein the synergist is selected from the group consisting of antimony (Sb) trioxide, antimony pentoxide, sodium antimonite, calcium metaborate, aluminum hydroxide (ATH), and barium borate. 
     
     
         6 . The layered fabric of  claim 1 , wherein the synergist is antimony trioxide. 
     
     
         7 . The layered fabric of  claim 1 , wherein the brominated organic fire-retardant is tris(tribromophenyl) triazine; and the synergist is antimony trioxide. 
     
     
         8 . The layered fabric of  claim 7 , wherein the antimony trioxide and the tris(tribromophenyl) triazine are present in an amount sufficient to provide a weight ratio of elemental Sb and Br (Sb:Br) of from about 1:3 to about 1:10, and wherein the aggregate weight of elemental Sb and Br in the fiber is from about 0.1% to about 20% by weight of the total weight of the fiber. 
     
     
         9 . The layered fabric of  claim 1 , wherein the antimony trioxide and the tris(tribromophenyl) triazine are present in the fibers of the first layer in a weight ratio of from about 2:1 to about 5:1. 
     
     
         10 . The layered fabric of  claim 1 , wherein the first layer comprises at least about 50% Nylon-6 polymer and/or Nylon-6,6 polymer. 
     
     
         11 . The layered fabric of  claim 1 , wherein the laminate comprises a coating or an impregnation selected from the group consisting of a silicone coating, a polyurethane coating, a water-repellant coating, a durable water-repellant (DWR), a water-soluble particle, a UV stabilizer, a light absorber or reflector, an antimicrobial agent, an antistatic agent, a hand-altering agent, an anti-soiling agent, a colorant, and any combinations thereof. 
     
     
         12 . The layered fabric of  claim 1 , wherein the laminate is disposed as an outer layer of a multi-ply laminate. 
     
     
         13 . The layered fabric of  claim 1 , further comprising from about 0.1% to about 10% inorganic halogenated fire-retardant. 
     
     
         14 . The layered fabric of  claim 13 , wherein the inorganic halogenated fire-retardant is tris(tribromoneopentyl)phosphate. 
     
     
         15 . The layered fabric of  claim 1 , wherein the layered fabric comprises:
 a fiber of the plurality of fire-retardant nylon fibers having a tensile strength within 20% of the tensile strength of an otherwise identical nylon fiber that does not comprise said fire-retardant composition;   a moisture vapor transport rate (MVTR) of greater than 100 gms/m2/day;   an air porosity of about 0.1 ft 3 /min to about 50 ft 3 /min; or   a hand and/or a drape of no more than +1 compared to an otherwise identical fabric that does not comprise said fire-retardant composition.   
     
     
         16 . A method of producing the layered fabric of  claim 1 , comprising:
 (i) heating a mixture of solid pellets of Nylon-6 polymer, wherein said pellets having tris(tribromophenyl) triazine dispersed therein, and Nylon-6,6 polymer to form a molten mixture comprising Nylon-6 and Nylon-6,6 polymers and tris (tribromophenyl) triazine; and   (ii) forming a plurality of fire-retardant nylon fibers from the molten mixture,
 wherein the plurality of fire-retardant nylon fibers form the first layer; 
   (iii) bonding a second layer comprising a laminate to the first layer to form the layered fabric.   
     
     
         17 . The method of  claim 16 , wherein the laminate comprises a coating or an impregnation selected from the group consisting of: a silicone coating, a polyurethane coating, a water-repellant coating, a durable water-repellant (DWR), a water-soluble particle, a UV stabilizer, a light absorber or reflector, an antimicrobial agent, an antistatic agent, a hand-altering agent, an anti-soiling agent, a colorant, and any combinations thereof. 
     
     
         18 . The method of  claim 16 , wherein forming the first layer, the plurality of fire-retardant nylon fibers form threads or yarns. 
     
     
         19 . The method of  claim 18 , wherein forming the first layer comprises weaving yarns spun from the plurality of fire-retardant nylon fibers. 
     
     
         20 . The method of  claim 16 , wherein bonding occurs by knife blading, roll coating, transfer coating.