Progress 10/01/09 to 09/30/10
Outputs
Progress Report Objectives (from AD-416) (1) To produce Flame Retardant (FR) Cotton Blend Flame Barrier Mattress Pads using cotton and other materials. (2) To treat cotton (and lyocell), with chemicals to impart flame retardancy to cotton (lyocell). (3) To prepare an intimate blend of (FR) treated fibers with other inherently flame retardant fibers. (4) To prepare pads for mattresses with the fiber blends, foam, scrim, and adhesives. (5) To evaluate the FR pads and components for flammability and mechanical properties. (6) To determine the best combination of materials, economics, and processing conditions to produce high quality FR mattress pads that conform to the open flame standard. (7) To determine the best candidate(s) for commercially producing FR pads and for mattress burn test. (8) To demonstrate the FR mattress pad(s) protecting mattress (es) by open flame burning tests. Approach (from AD-416) Scientific research on mattresses has been driven primarily by the sleep comfort, cost, and flame retardancy regulations enforced by the state legislature. These regulations are formulated time-to-time based on the statistics published by the U.S. Consumer Product Safety Commission (CPSC) on residential fires. Recent mattress flammability standard addressing the fires by open flames has been implemented by California legislature since January 2005 and there is a proposal to extend this across the country with effect from July 2007. This indicates a high market potential for a viable flame retardant (FR) mattresses. The proposed research is to produce FR mattress pads using cotton and other flame resistant fibers such as Visil (FR Rayon), Trevira (FR PET), Modacrylic and Basofil (Melamine). Flame resistance will be further enhanced by treating the constituent cotton fibers with chemicals such as Borax, Phosphates, and intumescent silicate clay nanocomposites. PE/PET bicomponent fibers and other binders such as Rhoplex, Spunfab will be incorporated in the product. The fabrication of mattress pad involves making an intimate blend of fibers at different proportions in a card; followed a sandwich type construction using flexible foam and scrim, hot air assisted thermo bonding and drying. Effort is on the optimum use of natural fibers, mainly cotton, a biodegradable, renewable resource. The finished product will be characterized for standard flammability tests such as Limited Oxygen Index, Cigarette burn test, Vertical and Horizontal flame tests, and integrity of the after-flame charred product. It is expected that viable products containing cotton, with other FR fibers and additives suitable for making mattresses conforming to the open flames standard can be produced. Based on the laboratory evaluation, promising compositions will be used to make prototype mattress pads, which will be wrapped around the mattress and tested in an outside laboratory according to the proposed (TB 603) standard in the dual burner open flame. The goal of the project is to produce FR mattress pads using cotton with other fibers, in the most economical way. Progress concluded with the 2009 annual report, but was not terminated because of financial management reasons.�See 2009 annual report for last reported progress.
Impacts
(N/A)
Publications
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Progress 09/21/06 to 12/31/09
Outputs
Progress Report Objectives (from AD-416) (1) To produce Flame Retardant (FR) Cotton Blend Flame Barrier Mattress Pads using cotton and other materials. (2) To treat cotton (and lyocell), with chemicals to impart flame retardancy to cotton (lyocell). (3) To prepare an intimate blend of (FR) treated fibers with other inherently flame retardant fibers. (4) To prepare pads for mattresses with the fiber blends, foam, scrim, and adhesives. (5) To evaluate the FR pads and components for flammability and mechanical properties. (6) To determine the best combination of materials, economics, and processing conditions to produce high quality FR mattress pads that conform to the open flame standard. (7) To determine the best candidate(s) for commercially producing FR pads and for mattress burn test. (8) To demonstrate the FR mattress pad(s) protecting mattress (es) by open flame burning tests. Approach (from AD-416) Scientific research on mattresses has been driven primarily by the sleep comfort, cost, and flame retardancy regulations enforced by the state legislature. These regulations are formulated time-to-time based on the statistics published by the U.S. Consumer Product Safety Commission (CPSC) on residential fires. Recent mattress flammability standard addressing the fires by open flames has been implemented by California legislature since January 2005 and there is a proposal to extend this across the country with effect from July 2007. This indicates a high market potential for a viable flame retardant (FR) mattresses. The proposed research is to produce FR mattress pads using cotton and other flame resistant fibers such as Visil (FR Rayon), Trevira (FR PET), Modacrylic and Basofil (Melamine). Flame resistance will be further enhanced by treating the constituent cotton fibers with chemicals such as Borax, Phosphates, and intumescent silicate clay nanocomposites. PE/PET bicomponent fibers and other binders such as Rhoplex, Spunfab will be incorporated in the product. The fabrication of mattress pad involves making an intimate blend of fibers at different proportions in a card; followed a sandwich type construction using flexible foam and scrim, hot air assisted thermo bonding and drying. Effort is on the optimum use of natural fibers, mainly cotton, a biodegradable, renewable resource. The finished product will be characterized for standard flammability tests such as Limited Oxygen Index, Cigarette burn test, Vertical and Horizontal flame tests, and integrity of the after-flame charred product. It is expected that viable products containing cotton, with other FR fibers and additives suitable for making mattresses conforming to the open flames standard can be produced. Based on the laboratory evaluation, promising compositions will be used to make prototype mattress pads, which will be wrapped around the mattress and tested in an outside laboratory according to the proposed (TB 603) standard in the dual burner open flame. The goal of the project is to produce FR mattress pads using cotton with other fibers, in the most economical way. Progress concluded with the 2009 annual report, but was not terminated because of financial management reasons. See 2009 annual report for last reported progress.
Impacts
(N/A)
Publications
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Progress 10/01/08 to 09/30/09
Outputs
Progress Report Objectives (from AD-416) (1) To produce Flame Retardant (FR) Cotton Blend Flame Barrier Mattress Pads using cotton and other materials. (2) To treat cotton (and lyocell), with chemicals to impart flame retardancy to cotton (lyocell). (3) To prepare an intimate blend of (FR) treated fibers with other inherently flame retardant fibers. (4) To prepare pads for mattresses with the fiber blends, foam, scrim, and adhesives. (5) To evaluate the FR pads and components for flammability and mechanical properties. (6) To determine the best combination of materials, economics, and processing conditions to produce high quality FR mattress pads that conform to the open flame standard. (7) To determine the best candidate(s) for commercially producing FR pads and for mattress burn test. (8) To demonstrate the FR mattress pad(s) protecting mattress (es) by open flame burning tests. Approach (from AD-416) Scientific research on mattresses has been driven primarily by the sleep comfort, cost, and flame retardancy regulations enforced by the state legislature. These regulations are formulated time-to-time based on the statistics published by the U.S. Consumer Product Safety Commission (CPSC) on residential fires. Recent mattress flammability standard addressing the fires by open flames has been implemented by California legislature since January 2005 and there is a proposal to extend this across the country with effect from July 2007. This indicates a high market potential for a viable flame retardant (FR) mattresses. The proposed research is to produce FR mattress pads using cotton and other flame resistant fibers such as Visil (FR Rayon), Trevira (FR PET), Modacrylic and Basofil (Melamine). Flame resistance will be further enhanced by treating the constituent cotton fibers with chemicals such as Borax, Phosphates, and intumescent silicate clay nanocomposites. PE/PET bicomponent fibers and other binders such as Rhoplex, Spunfab will be incorporated in the product. The fabrication of mattress pad involves making an intimate blend of fibers at different proportions in a card; followed a sandwich type construction using flexible foam and scrim, hot air assisted thermo bonding and drying. Effort is on the optimum use of natural fibers, mainly cotton, a biodegradable, renewable resource. The finished product will be characterized for standard flammability tests such as Limited Oxygen Index, Cigarette burn test, Vertical and Horizontal flame tests, and integrity of the after-flame charred product. It is expected that viable products containing cotton, with other FR fibers and additives suitable for making mattresses conforming to the open flames standard can be produced. Based on the laboratory evaluation, promising compositions will be used to make prototype mattress pads, which will be wrapped around the mattress and tested in an outside laboratory according to the proposed (TB 603) standard in the dual burner open flame. The goal of the project is to produce FR mattress pads using cotton with other fibers, in the most economical way. Significant Activities that Support Special Target Populations Significant progress was accomplished in resistance to small open flame ignition of residential mattresses, and thereby, compliance of the Federal regulation, CFR 1633 (effective July 2007) with the use of a fire- blocking cotton barrier nonwoven highloft (thickness and cushioning). Two cotton-rich mattress pads/highlofts (~300g/m2) were developed by intimate blending of cotton, flame resistant (FR) fiber, and bicomponent fiber in the weight ratio of 50:20:15 respectively. Optimal thermal bonding was achieved at 175 degrees C and 3 minutes. Pads were finished with FR formulations by the pad-dry-cure technique. Physical strength and flammability properties were determined, and char properties were observed for structural integrity. It was demonstrated that a cost effective recipe for constructing mattress pads that pass the latest flammability tests is possible. As planned, these pads/highlofts were produced by blending cotton with other commercially available fibers, binders, and followed by chemical treatments to achieve maximum performance at low cost. The highloft so produced is a good candidate for mattress highlofts, upholstered furniture, and pillows. The FR performance increases for the FR pads with chemical loading of 20%. FR clay treated cotton does not burn, but functions as a char-reinforcing grid. Jones Fiber Products, Inc. (the largest cotton fiber user/manufacturer of FR greige (unbleached) cotton nonwovens in the USA) conducted burn tests on two of the Southern Regional Research Center (SRRC) samples of FR cotton nonwovens. They conducted the open flame test of California Technical Bulletin 117 Draft 2/2002 with the following two modifications: (1) the flame source is BS 5852: 1990 source 3 of 350 +/- 10 mL/min of butane gas, and (2) the test is for 30 minutes to simulate the entire duration of 16 CFR 1633. The test results were very good for both specimens in compliance with the regulations (report: June 29, 2009). These FR greige cotton barrier fabrics (FR non-durable to washing) were produced by coating with economical environmentally benign formulation with diammonium phosphate/urea as flame retardants. The elemental analysis spectra of FR treated greige cotton show uniform distribution of nitrogen and phosphorous on cotton. The progress of the collaborative research was monitored by discussion in personal meetings, over phone, e- mails, mailings, and receiving the required fibers and the samples. Impact: Jones Fiber Products, Inc. has signed a confidentiality agreement with the Agricultural Research Service (ARS) to exploit the present findings in their plants. Findings have been disseminated through a refereed publication, conference proceedings, and presentations. FR finished highlofts would capture additional markets for highlofts for mattress and upholstered furniture manufacturers. FR highlofts would provide great fire protection. The mattresses/upholstered furniture using these FR barrier highlofts are protected from fire flashover, permitting 30+ minutes for the occupants to escape to safety. This will increase the market share of greige/discounted cotton.
Impacts
(N/A)
Publications
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Progress 10/01/07 to 09/30/08
Outputs
Progress Report Objectives (from AD-416) (1) To produce Flame Retardant (FR) Cotton Blend Flame Barrier Mattress Pads using cotton and other materials. (2) To treat cotton (and lyocell), with chemicals to impart flame retardancy to cotton (lyocell). (3) To prepare an intimate blend of (FR) treated fibers with other inherently flame retardant fibers. (4) To prepare pads for mattresses with the fiber blends, foam, scrim, and adhesives. (5) To evaluate the FR pads and components for flammability and mechanical properties. (6) To determine the best combination of materials, economics, and processing conditions to produce high quality FR mattress pads that conform to the open flame standard. (7) To determine the best candidate(s) for commercially producing FR pads and for mattress burn test. (8) To demonstrate the FR mattress pad(s) protecting mattress (es) by open flame burning tests. Approach (from AD-416) Scientific research on mattresses has been driven primarily by the sleep comfort, cost, and flame retardancy regulations enforced by the state legislature. These regulations are formulated time-to-time based on the statistics published by the U.S. Consumer Product Safety Commission (CPSC) on residential fires. Recent mattress flammability standard addressing the fires by open flames has been implemented by California legislature since January 2005 and there is a proposal to extend this across the country with effect from July 2007. This indicates a high market potential for a viable flame retardant (FR) mattresses. The proposed research is to produce FR mattress pads using cotton and other flame resistant fibers such as Visil (FR Rayon), Trevira (FR PET), Modacrylic and Basofil (Melamine). Flame resistance will be further enhanced by treating the constituent cotton fibers with chemicals such as Borax, Phosphates, and intumescent silicate clay nanocomposites. PE/PET bicomponent fibers and other binders such as Rhoplex, Spunfab will be incorporated in the product. The fabrication of mattress pad involves making an intimate blend of fibers at different proportions in a card; followed a sandwich type construction using flexible foam and scrim, hot air assisted thermo bonding and drying. Effort is on the optimum use of natural fibers, mainly cotton, a biodegradable, renewable resource. The finished product will be characterized for standard flammability tests such as Limited Oxygen Index, Cigarette burn test, Vertical and Horizontal flame tests, and integrity of the after-flame charred product. It is expected that viable products containing cotton, with other FR fibers and additives suitable for making mattresses conforming to the open flames standard can be produced. Based on the laboratory evaluation, promising compositions will be used to make prototype mattress pads, which will be wrapped around the mattress and tested in an outside laboratory according to the proposed (TB 603) standard in the dual burner open flame. The goal of the project is to produce FR mattress pads using cotton with other fibers, in the most economical way. Significant Activities that Support Special Target Populations Significant progress was made in achieving resistance to small open flame ignition of residential mattresses and thereby compliance of the Federal regulation, CFR 1633 (effective: July, 2007) with the use of a fire blocking cotton barrier nonwoven. Two cotton-rich mattress pads (~300g/m2) were developed by intimate blending of cotton, flame resistant (FR) fiber, and bicomponent fiber in the weight ratio of 50:20:15 respectively. Optimal thermal-bonding was achieved at 175C and 3 minutes. Pads were finished with FR formulations by the pad-dry-cure technique. Physical strength and the flammability properties of the pads were determined. Char properties after the flammability burn tests of pads were observed for structural integrity and behavior. The FR performance increases for the FR pads with chemical loading of 20%. FR clay treated cotton does not burn, but functions as a char-reinforcing grid. The progress of the collaborative research was monitored by a site visit and discussion in personal meetings, over phone, e-mails, mailings and receiving the required fibers and the samples.
Impacts
(N/A)
Publications
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Progress 10/01/06 to 09/30/07
Outputs
Progress Report Objectives (from AD-416) (1) To produce Flame Retardant (FR) Cotton Blend Flame Barrier Mattress Pads using cotton and other materials. (2) To treat cotton (and lyocell), with chemicals to impart flame retardancy to cotton (lyocell). (3) To prepare an intimate blend of (FR) treated fibers with other inherently flame retardant fibers. (4) To prepare pads for mattresses with the fiber blends, foam, scrim, and adhesives. (5) To evaluate the FR pads and components for flammability and mechanical properties. (6) To determine the best combination of materials, economics, and processing conditions to produce high quality FR mattress pads that conform to the open flame standard. (7) To determine the best candidate(s) for commercially producing FR pads and for mattress burn test. (8) To demonstrate the FR mattress pad(s) protecting mattress (es) by open flame burning tests. Approach (from AD-416) Scientific research on mattresses has been driven primarily by the sleep comfort, cost, and flame retardancy regulations enforced by the state legislature. These regulations are formulated time-to-time based on the statistics published by the U.S. Consumer Product Safety Commission (CPSC) on residential fires. Recent mattress flammability standard addressing the fires by open flames has been implemented by California legislature since January 2005 and there is a proposal to extend this across the country with effect from July 2007. This indicates a high market potential for a viable flame retardant (FR) mattresses. The proposed research is to produce FR mattress pads using cotton and other flame resistant fibers such as Visil (FR Rayon), Trevira (FR PET), Modacrylic and Basofil (Melamine). Flame resistance will be further enhanced by treating the constituent cotton fibers with chemicals such as Borax, Phosphates, and intumescent silicate clay nanocomposites. PE/PET bicomponent fibers and other binders such as Rhoplex, Spunfab will be incorporated in the product. The fabrication of mattress pad involves making an intimate blend of fibers at different proportions in a card; followed a sandwich type construction using flexible foam and scrim, hot air assisted thermo bonding and drying. Effort is on the optimum use of natural fibers, mainly cotton, a biodegradable, renewable resource. The finished product will be characterized for standard flammability tests such as Limited Oxygen Index, Cigarette burn test, Vertical and Horizontal flame tests, and integrity of the after-flame charred product. It is expected that viable products containing cotton, with other FR fibers and additives suitable for making mattresses conforming to the open flames standard can be produced. Based on the laboratory evaluation, promising compositions will be used to make prototype mattress pads, which will be wrapped around the mattress and tested in an outside laboratory according to the proposed (TB 603) standard in the dual burner open flame. The goal of the project is to produce FR mattress pads using cotton with other fibers, in the most economical way. Significant Activities that Support Special Target Populations This report serves to document research conducted under a Specific Cooperative Agreement between the Agricultural Research Service (ARS) and the University of Tennessee, Knoxville (UTK). Additional details of research can be found in the report for the in-house project 6435-41000- 094-00D, "Value-Added and High-Volume Cotton Products and Processes." In the first phase, the collaborators at UTK acquired sufficient quantity of each of the fibers and chemicals, namely, grey cotton fiber, commercial grade flame retardant (FR) fibers (Basofil, Visil, Omnisil), low melt bicomponent binder fiber, and FR chemicals (such as boric acid, ammonium phosphate, and nanoclay) for the work. Mattress pads (target weight: ~300g/m2) were then developed by intimate blending of cotton, FR fiber, and bicomponent fiber using laboratory carding and through air bonding processes. These pads were then finished with FR formulation by the conventional pad-dry-cure technique. Different formulations were studied. Physical strength and the flammability (Limited Oxygen Index Meter) properties of these pads were determined as �satisfactory� to act as barrier fabric for the mattress. Energy Dispersive X-ray (EDX) techniques confirmed the presence of various elements (on the pads) that are responsible for imparting flammability to the pads. In addition, scanning electron microscopy (SEM) and differential scanning calorimetry (DSC) studies were carried out to understand the nature of bonds between the chemical and the fiber. In the next step, these pads will be subjected to standard flammability test: California Technical Bulletin TB604 intended for use in determining the flame resistance of filled bed clothing or top-of-the-bed items (such as mattress pads, comforters, and pillows) and flame propagation when subjected to a small open flame. UTK has plans to establish the test. The progress of the collaborative research is monitored by discussions over phone, e-mails, mailing the required fabrics. A site visit is planned in August, 2007. A poster presentation was made at the Fiber Society meeting in May, 2007. A paper will be presented at the upcoming INTC2007 meeting in Atlanta, GA, September, 2007, and another paper at AATCC 2007 IC & E in Charleston, SC, October 2-4, 2007.
Impacts
(N/A)
Publications
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