1. RESEARCH DEGREE PROPOSAL
(To be typewritten by the Applicant)
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Project Title:
Non woven fabric manufacturing and application of flame retardant finish.
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Project Objectives: (Purpose of proposed investigation)
Formation of Web using carding machine.
Formation of batt by parallel dry led method using carding machine.
Application of chemical bonding using chemical adhesives to produce non woven fabric.
Drying of complete batt by Oven drying method.
Testing physical properties of non woven manufactured fabric.
Application of flame retardant on non woven fabric.
Testing of flame ret ardency using vertical flame retardant tester.
3.
Scope and Background of Research:
The scope of the non woven fabric is very wide as compred to woven and knitt fabric,
because 60% of non woven fabric is used for disposable product in the world and china produce
one millon tonn of non woven fabric per annum. china is the bigest producer of non woven fabric.
The application of non woven
fabric is the following,
a. Automotive ( for automobile seat cover etc)
b.Medical
(surgical clothes, gloves,mask etc)
c.Hygiene and personal care
d. Home furnishing (sofa set, bed sheet etc)
e.Houshold ( door trim panel carpets etc)
f.Agriculture
g.Stationary
The finishing of fabrics with flame retardants can reduce the tendency to burn the fabric reduce
the tendency to propagate the flame. The flame retardants may char the fuel, quench the reaction of
combustion, absorb heat or emit cooling gases or replace oxygen. Flame retardants are durable or
nondurable. Durable retardants include decabromodiphenyl oxide, antimony oxide, phosphates,
brominated esters, PVC and other chlorinated binders. Nondurables include borates, boric acids, zinc
borate, sulfamic acid sulfamates, ammonium phosphates, urea, etc. Hydrated alumina and zinc borate act
as smoke supressants. Problems in the application include odor, yellowing, loss of tensile strength,
stiffening, skin irritation and color change or loss The second part of the research is the flame
retardentapplication which also many uses in the field of textile. it use for gloves ie flame
resistant,in steel industry jackets and clothes which are fire resistant,becausethe flame
retarden may char the fuel,quench the reaction of combstion, absorb heat or emit coolig
gases or replace oxygen. the flame retardent may durable and non durable.

2. 4.
Research Methodology:
The method of formation of non woven fabric is as follow,
we use the drylaid method for formation of non woven fabric
and this method use the carding machine, procedure of formation
of non woven fabric through carding machine is that,
a.first formation of web by passing the fiber through carding machine
b.secondly the web bonding by bonding chemical, pressing,and thermal
c.finally finish treatment (flame retardent finish is apply on the fabric

3. 5.
Project Significance and Value:
The value and significance of the project is that the non woven fabric is high
market value in the world because their formation is easy as compared to
woven and knitt fabric and also their use in the world is more for many
purposes such as house furnishing, seat covers, bed sheet airo plain seat cove surgical
purposes, and also the flame retardent finished non woven fabric is use for gloves, flame
resistant fabric which is use in industry. Nowadays, in the medical field nonwovens are used in a
variety of applications such as barrier products (drapes, gowns and germ-eliminating products),
wound care applications, face masks, wipes. In a price-sensitive healthcare segment, some
institutions have found nonwovens to be a less expensive choice than woven products in certain
applications [1]. Since microorganisms can grow and survive on textile materials, particularly on
medical textiles, from days to several weeks the healthcare workers and patients become more
aware of the risk of cross contamination, so the demand for cost-effective and convenient protection
has risen.
6. Literature Review
, This invention relates to composite reinforced nonwoven fabrics of the disposable type that have highstrength properties and a high degree of drape. Nonwoven materials, made by a variety of methods, are
speci?cally designed to meet requirements of particular end uses. A number of nonwoven products, such
as apparel inter linings and needle-punched carpets, are reusable and usually quite durable. Recently,
certain nonwoven fabrics have gained widespread

4. use in the manufacture of disposable work garments, disposa
ble bed linens, disposable surgical drapes, disposable cleaning
cloths, and the like. Nonwoven fabrics for such uses should be
relatively inexpensive and should have high-strength proper
ties. in addition, they should be very pliable, that is, they
should possess a high degree of drapability.(1)
The textile fabric of the present invention can per
form satisfactorily as a ?re blocking sheet when the
fabric contains at least three of the hydraulically nee
dled nonwoven fabric layers of aramid ?bers. More
than seven of the nonwoven layers do not add signi?
cant further protection. Preferably, four to six layers are
used. The fastened-together layers of the fabric of the
invention can include a layer of woven fabric of flame
resistant ?bers, especially as an outer layer, to impart
greater dimensional stability and abrasion resistance to
the over-all fabric.(2)
The present invention is directed to the ?eld of non
woven fabrics, in general, and is directed to a single
layer non-woven fabric suitable for use _as a cotton bale
covering having high strength and resistance to tears
and abrasion, in particular. The fabric of the present
invention can be produced at a rate faster than woven
products and without the contamination problems en
countered with products manufactured from woven
products and especially those using polymeric yarns.
The present invention is also directed to a process for
producing such a non-woven fabric.
For many years, the cotton industry has sought a
solution to the problem of wrapping cotton bales to
protect the bales from contamination and damage dur
ing shipping. Some wraps commonly used are jute or
burlap. These have the disadvantage of being loosely
woven, admitting contaminants into the cotton bale,
and are susceptible to tears, rips and holes that expose
the wrapped cotton to contamination during storage
and shipping.
Other wraps include woven polypropylene, the pre
dominate bale wrapping material. These wraps, how
ever, ?brillate in use, the polypropylene strands becom
ing closely entwined with the raw cotton and thereby
contaminating it. Such contamination cannot be sepa
rated, and is extremely difficult to detect in raw ?ber.
Moreover, polypropylene wraps are not biodegradable
or recyclable and have few end uses. An example of this
type of woven wrap is disclosed in U.S. Pat. No.
4,557,958 (Barkis) wherein woven polypropylene or
polyethylene fabric is infused with a series of stripes of
thermoplastic resin to prevent fraying when the fabric is
cut.
Non-woven cotton bale covers are disclosed in U.S.
Pat. No. 3,647,139 (Manasian) and U.S. Pat. No.
3,647,061 (Kaupin).(3)

5. Nonwoven fabrics are widely employed as barrier materials in protective clothing, but without any active functions.
Such defensive protection is insufficient in providing biological and chemical protection. This research aims at
developing an integrated manufacturing process that can produce functional synthetic fibers and nonwoven fabrics
directly. The research involves the study of controlled graft polymerization reactions in reactive extrusion process
and the development of self-decontaminating nonwoven fabrics for biological and chemical protective clothing. The
research team will accomplish the following objectives in three years: 1) development of integrated manufacturing
technologies of functionalizing synthetic fibers and polymers through a controlled radical graft polymerization; and
2) preparation of self-decontaminating synthetic fibers and nonwoven fabrics using the new process. The integration
of chemical modification and fiber extrusion during the manufacturing process will enable the production of
functional fibers and nonwoven fabrics simultaneously (4)
NON-WOVEN FLAME BLOCKING FABRIC AND
METHOD
BACKGROUND OF THE INVENTION
[0001] This invention relates to a non-Woven ?ame
blocker fabric that Will not ignite or burn upon exposure to
open ?ame and the resultant heat but instead forms a
reinforced char barrier that prevents a ?ame from igniting
any ?ammable substrate.
[0002] Non-Woven ?bers and fabrics possessing ?ame
retardant properties have been manufactured and sold for at
least tWenty-?ve years. These prior ?ame-retardant fabrics,
While resistant to ?ame, are lacking in structural integrity,
hoWever, having virtually Zero puncture, tear, cross direc
tion, and machine direction strength prior to eXposure to
?ame. Of greater concern, the ?ame-retardant materials
produced in these previous methods are virtually reduced to
dust When eXposed to an open ?ame, having no tensile
strength upon charring. These fabrics Were limited in their
end uses, and ?ame retardant materials produced by this
method Were used primarily in incontinent pad sheets and
medical or emergency services clothing materials. Thus,
fabrics such as disclosed in U.S. Pat. Nos.: 6,132,476,
5,609,950, 5,766,746, and 4,151,322, are incapable of form
ing a reinforced char barrier Which prevents a ?ame from
igniting any ?ammable substrate.
[0003] The formation of a char barrier Was a focus of the
disclosure U.S. Pat. No. 5,645,926 Horrocks, et al., disclos
ing a ?exible ?re-resistant material comprising a mixture of
organic intumescent ?ller and organic and/or inorganic
?bers adapted to produce a char barrier upon eXposure to
heat that retains structural integrity. A disadvantage of
Horrocks is its requirement for the use of an intumescent
?ller material tending to result in a thicker product. Speci?
cally, intumescent materials sWell and char When eXposed to
?ame, making the application of intumescent ?llers in
composite structures for protecting substrate materials dis
advantageous. Furthermore, Horrocks did not attempt to
provide reinforcement for imparting structural integrity to
the char barrier.(5)
7. Details of Any External Collaboration:
External requirment for project completion is the following,
a. Padder machine for the formation of web (web formation)
b. finishing chemicals such as bonding chemicals for the bonding of

6. web of fibers (web to web bonding)
c. also the flame retardent finish ( for flame retardency)
. Durable retardants include decabromodiphenyl oxide, antimony oxide, phosphates, brominated esters,
PVC and other chlorinated binders. Nondurables include borates, boric acids, zinc borate, sulfamic acid
sulfamates, ammonium phosphates, urea, etc. Hydrated alumina and zinc borate act as smoke supressants.
The present invention relates to the use of ionic liquids as flame retardants. The compoundsof the
invention may be used as flame retardants in various materials without causingdamage to the
environment and or health of humans or animals. Ionicliquid flameretardants maybe applied
alone or in combination with traditional flame retardants. Ionicliquid flame retardants can be
applied to finish textile, plastic, leather, paper, rubber, or aswild fire flame retardants.
8. REFERENCES
2. Loren M. Collins; Mount Pleasant(2004) NON-WOVEN FLAME BLOCKING FABRIC and
methods, Pub. N0.: US 2004/0242107 A1
1. [72] lnventor Robert W. Dnvison
Wilmington, Del.
[21] Appl. No. 7,932
[22] Filed Feb. 2, 1970
[45] Patented Dec. 21, 1971
[73] Assignee Hercules Incorporated
Wilmington, Del.
2. [54] FIRE-BLOCKING TEXTILE FABRIC [56] References Cited
[75] Inventors: Michael A. Blaustein, Wilmington; U'S' PATENT DOCUMENTS
Dennis A. Nollen, Hockessin; Loretta 4,120,914 10/1978 Behnke et a1. .................... .. 524/538
A. G. Page, Newark, all Of Del. 4,198,494 4/1980 Burchel ......................... .. 525/143
4,255,817 3/1981 Hcim ............ .. . 428/920
[73] Assignee: E. I. Du Pont de Nemours and 4,284,680 8/1981 Awano et a1. . . 428/287
Company, Wilmington, DeL 4,463,465 8/1984 Parker et a1. .. 428/921
4,473,614 9/ 1984 Hockmeyer . . . . . . . . , . . .. 428/921
[21] App], NO_: 893,531 4,482,603 11/1984 Yoshida et a1. . . . . . . . .. 428/287
4,529,644 7/1985 Awano et a1. .................... .. 428/287
[22] Med: Aug‘ 21’ 1986
3. NON-WOVEN FABRIC SUITABLE FOR USE [58] Field of Search .................... .. 206/835; 428/34.1,
AS A COTTON BALE COVERING AND 428/35.6, 102, 105, 113, 280, 281, 283, 288, 297,
PROCESS FOR PRODUCING SAID FABRIC 402, 300; 28/110; 112/438, 62.2; 156/148
Primary Examiner-James J. Bell
l 7 51 Inventors : Low's Rachman’ Lubbock , Tex .; Attorney, Agent, or Fi_ rm-Mason, Fenw1_ ck& Lawrence
Jerome M. Rachman, New York,
NY. [57] ABSTRACT
A single layer non-woven fabric suitable for use as a
cotton bale covering that is a single layer batt formed of
cross-lapped ?ber, having a structure compacted by
needle tacking, and being thermally bonded by ther
mally set low melt thermoplastic material intermixed
throughout the batt, and stitch bonded throughout the
[73] Assignees: Lorraine Rachman; Paul B. Rachman;
Barron S. Rachman, all of New York,

7. NY.
[21] Appl. No.2 221,538
[22] Filed; Jul_ 19, 1938
4. Integrated Production of Functional Fibers and Nonwoven Fabrics
Project Leader: Gang Sun
Graduate Students: Mohammad Badrossamay, Dong Wang
University of California, Davis, CA 95616
5 . (54) NON-WOVEN FLAME BLOCKING FABRIC (52) US. Cl. ....................... .. 442/403; 442/136; 442/332;
AND METHOD 442/404; 442/406; 442/414;
442/415; 264/165
(76) Inventor: Loren M. Collins; Mount Pleasant; SC
(Us) (57) ABSTRACT
Correspondence Address:
CRAVEN & REID, LLC
12 E. STONE AVENUE
GREENVILLE, SC 29609 (US)
(21) Appl. No.: 10/448,601
(22) Filed: May 30, 2003