Description:DESCRIPTION OF INVENTION
FIELD OF INVENTION
The present invention relates in general to fire resistant fabrics.
More particularly, the present invention relates to fire resistant, simple circular knit fabrics for covering articles such as foam and latex mattresses, other foamed covered furniture and also as a protective fabric for lining under military tents and armory.
BACKGROUND OF THE INVENTION
Fire resistant or flame retardant knitted fabric is a type of fabric that has been treated with a chemical finish or coated with a substance that helps to prevent or slow down the spread of flames. This type of fabric is often used in clothing and other textiles that may be exposed to high heat or flames, such as protective gear for firefighters, military personnel, and industrial workers. It is also used in the production of upholstery, curtains, and other household textiles where fire safety is a concern.
There are several different types of flame retardant treatments that can be applied to knitted fabric, including chemical finishes that are applied during the manufacturing process and coatings that are applied after the fabric has been made. The effectiveness of these treatments can vary, and it is important to follow the care instructions provided by the manufacturer to ensure that the flame retardant properties of the fabric are maintained.
Flame retardant knitted fabric is typically tested to ensure that it meets certain safety standards, such as those set by the National Fire Protection Association (NFPA) or the International Association of Plastics Distributors (IAPD). These standards help to ensure that the fabric is able to provide an appropriate level of protection in the event of a fire.
The use of flame-retardant chemicals in furniture and other household items has been a topic of debate in recent years, due to concerns about the potential health effects of these chemicals. Despite this, many mattress manufacturers still use flame retardant chemicals in the production of their products.
One alternative to the use of flame-retardant chemicals is the use of flame-resistant materials in the production of mattress covers. These materials are inherently flame-resistant, meaning that they do not require the use of chemical flame retardants.
The prior art reveals that there have been attempts to develop flame retardant knitted fabrics. Following patent and non-patent literature describes the existing state of the art.
WO2015013825A1 discloses a fire resistant, double knit fabric and methods of manufacturing the same. The fire barrier double knit fabric of the present invention includes a face side having a yard including a fire retardant fiber, and a back side having a yard including a charring yarn. The fabric resistant fabric of the present invention can be made in a stretchable tubular sock that can be used on all mattress widths (one size fits all) or as an open form for upholstering, lamination of mattress ticking.
US20060135014A1 discusses a retrofit cover for fully or partially enclosing a mattress, wherein the cover is formed of a unitary, integrally formed fabric having a fire barrier element. The cover is capable of rendering mattresses, mattress foundations, upholstered furniture article and other articles filled with resilient cushioning materials that were not originally manufactured to meet a full-scale open flame standard capable of passing such newly mandated standard for performance in newly manufactured items. When tested in accordance with the flame resistance test protocols of 16 CFR 1633 or TB 603, the item encased in the retrofit cover has a maximum heat release rate of less than 200 kW and a total energy release of less than 25 MJ in the first five minutes of the test.
The exhaustive literature search conducted to identify prior art indicated that several efforts have been made in the past to develop flame retardant mattress cover. However, the conventional process of manufacturing a fire-retardant mattress cover involves manufacturing of yarns which is costly and complex.
Therefore, in light of foregoing discussion, there exists a need to overcome the drawbacks associated with the existing flame retardant fabrics.
The present invention describes a flame retardant protective knitted fabric manufactured using a simple knitted fabric technology.
OBJECT OF THE INVENTION
It is the primary object of the present invention is to provide a flame retardant protective knitted fabric which essentially is a protective layer for the mattress that can help to prevent the spread of fire in the event of an accident or emergency;
Further objective of the present invention is to reduce the risk of injury or death due to fire in the home, hospitals, hotels especially for individuals who may be more vulnerable to the effects of fire, such as children or the elderly as well as patients under treatment while meeting fire safety regulations and standards;
Further objective of the present invention is to offer a convenient and easy-to-use solution and to increase the fire safety of their home;
Further objective of the present invention is to provide a durable and long-lasting fabric that can withstand repeated washings and regular use.
Further objective of the present invention is to use it as a liner in army tents and armory which are at high risk during war period and in war prone zones.
SUMMARY OF THE INVENTION
Embodiments of the present disclosure present technological improvements as solution to one or more of the above-mentioned technical problems recognized by the inventor in conventional practices and existing state of the art.
The present disclosure seeks to provide a flame retardant knitted fabric manufactured using a simple circular knitting machine.
In accordance with one aspect of the present invention, the said flame retardant protective knitted fabric is made using a modacrylic ring spun yarn and a continuous filament glass fibre yarn in an interlock structure, resulting in a durable and long-lasting product.
In accordance with another aspect of the present invention, the said flame retardant protective knitted fabric could provide an effective and convenient solution for increasing the fire safety of a mattress.
In accordance with another aspect of the present invention, the said flame retardant protective knitted fabric is easy to use and can be washed repeatedly without losing its fire-resistant properties. By providing a protective layer for the mattress, the cover can help to prevent the spread of fire in the event of an accident or emergency, reducing the risk of injury or death due to fire in the home, hospitals and hotels.
The objects and the advantages of the invention are achieved by the process elaborated in the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description illustrates embodiments of the present disclosure and ways in which the disclosed embodiments can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
The present invention provides for flame retardant protective knitted fabric which is designed using circular knitting machine from a fire retardant material, such as modacrylic ring spun yarn or flame retardant Viscose yarn knit together with continuous glass fibre yarn. The material is knitted using a circular knitting machine, which creates a seamless, fitted cover for the mattress.
According to an embodiment of the present invention, the basic Polyurethane foam and/or memory foam in a mattress will be enclosed in a fire-retardant knitted mattress cover which is covered on it like a sock and sewn on both sides and then layer ticking/quilting fabric to ensure the comfort of the user.
The cover is designed to fit snugly over the mattress, since there is a use of knitted fabric which can stretch to accommodate mattresses of different sizes.
The fire-retardant properties of the material used in the cover provide an added layer of protection against fires, helping to reduce the risk of injury or damage in the event of a fire. The seamless, fitted design of the cover also helps to prevent the spread of flames, by preventing air from reaching the mattress and fueling the fire.
According to preferred embodiment of the present invention, the method of manufacture of flame retardant protective knitted fabric comprises the steps of employing an interlock circular knitting machine of 18 gauge and 30 inch diameter 84 feeder; feeding 110 denier glass fiber yarn and 30’s NE modacrylic or FR viscose yarn in the same yarn feeder; using SFE type of Memminger positive feeder (MPF), wherein the glass fiber yarn is passed in controlled tension; arranging the glass fibre yarn and modacrylic or FR viscose yarn alternatively in each SFE MPF, and feeding both one end of the glass fiber yarn and one end of the modacrylic or FR viscose yarn in the same yarn feeder; setting the needles at full clear to knit the fabric.
A flame retardant protective knitted fabric is comprising a modacrylic ring spun yarn and a continuous filament glass fiber yarn in an interlock structure can provide improved flame resistance and durability compared to traditional flame retardant fabrics. The modacrylic yarn, made from a synthetic polymer, is known for its flame-resistant properties, while the continuous filament glass fibre yarn adds strength and durability to the cover.
The interlock structure of the fabric allows for a tight and secure knit, creating a barrier against flames and increasing the overall flame resistance of the cover. The cover resulting from this fabric can be easily installed on a mattress, providing added protection against fires and other potential hazards.
The lab test results of the flame retardant knitted fabric manufactured in accordance to the embodiments of the present invention are mentioned below:
Sr. No. Test Parameters Unit Test Method Test Result
1 Thread Density Per inch ASTM D 3887-96 12 -16
2 Bursting Strength PSI ASTM D 3786 110 - 178
3 Tensile strength N ASTM D 5034-09 75 - 118
4 Vertical flammability - IS 11871 (Method A) No top or either edge flaming;
no flaming or moten debris;
no after flame;
no after glow.
5 450 flammability - IS 11871 (Method B) Specimen did not ignite
6 Air permeability cfm ASTM D 737
Pressure – 125pa
Test area – 38cm2 347 - 588
7 Water permeability mm/s ASTM D 4491 93 - 115

Overall, a flame retardant protective knitted fabric comprising a modacrylic ring spun yarn and a continuous filament glass fibre yarn in an interlock structure offers improved protection against flames and other hazards, while also being easy to install, maintain, and care for.
, Claims:We Claim:
1. A flame retardant protective knitted fabric, the said fabric comprising:
- a spun yarn selected from the group of a modacrylic ring spun yarn as well as a flame-retardant viscose ring spun yarn; and
- a continuous filament glass fiber yarn in an interlock structure;
characterized by tensile strength of 75 – 118N; air permeability of 347 – 588cfm and water permeability of 93 – 115mm/s.
2. The flame retardant protective knitted fabric as claimed in Claim 1, wherein the modacrylic ring spun yarn and the continuous filament glass fiber yarn are knitted in an interlock structure with float stitch.
3. A method for manufacturing a flame retardant protective knitted fabric, the said method comprising the steps of:
- employing an interlock circular knitting machine of 18 gauge and 30 inch diameter 84 feeder;
- feeding 110 denier glass fiber yarn and 30’s NE modacrylic or flame-retardant viscose yarn in the same yarn feeder;
- using SFE type of Memminger positive feeder (MPF), wherein the glass fibre yarn is passed in controlled tension maintaining 2 - 3 rounds of glass fibre yarn in storage space;
- arranging the glass fiber yarn and modacrylic as well as flame retardant viscose yarn alternatively in each SFE MPF, and feeding both one end of the glass fiber yarn and one end of the modacrylic or flame-retardant viscose yarn in the same yarn feeder;
- setting the needles at full clear to knit the fabric.