Nonwoven highloft flame barrier

Abstract

The invention relates to a nonwoven highloft flame barrier well suited for use in mattress, upholstered furniture and other end use applications where a highloft nonwoven material is desired for flame barrier purposes. A preferred nonwoven highloft flame barrier of the invention comprises a blend of fibers, that are inherently fire resistant and essentially nonshrinking to direct flame, with melamine fibers being preferred either alone or in conjunction with, for example, viscose rayon based fibers, fibers extruded from polymers made with halogenated monomers and preferably low-melt binder fibers, which are thermally activated in a highloft manufacturing process to provide low bulk density, resiliency and insulation properties in the end use application. The preferred fiber blends are designed to withstand extended periods of time exposed to open flame with minimal shrinkage of the char barrier; thereby preventing a flames from 'breaking through' the char barrier and igniting underlying materials. Other component fibers can also, optionally, be included such as: natural fibers, to improve product economics in the end use application. The highloft flame barrier of this invention also allows for the manufacture of open flame resistant composite articles, while also permitting the continued use of conventional non-flame retardant dress cover fabrics, conventional non-flame retardant fiberfills and conventional non-flame retardant polyurethane foams.