BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

Aspects of the present disclosure relate to methods for treating a product for fire resistance, and, more particularly, to methods of treating textile products for fire resistance, and associated apparatuses. Description of Related Art

Some fireproof or otherwise fire retardant textile products rely on the fire-resistant properties of the base fiber to provide the fire- resistant properties of the textile product formed therefrom. One such example includes Nomex®, manufactured by DuPont.

However, many other fire-resistant products are configured to be appl ied to textile products, post-formation. In such instances, however, one possible limitation in the treatment of as-formed textile product for fire resistance, particularly with a liquid fire retardant, is achieving an even and consistent treatment of that textile product. That is, the result of some fire resistance treatment processes involving application of a fire-retardant to an as-formed textile product may be an uneven or otherwise inconsistent coverage of the fire retardant with respect to the textile product. In such instances, such uneven treatment may result in varying levels of fire resistance of the treated textile product which may, in turn, be hazardous to the user of the textile product in the event of a fire against which the textile product is intended to protect the user. Further, such treatment processes may not necessarily be efficient in terms of applying the fire retardant to the textile product, may not include provisions for capturing or recycling excess portions of the fire retardant product, and may not have the capability for preventing or restricting losses of the fire retardant due, for instance, to evaporative processes.

Thus, there exists a need for a process and associated apparatus for evenly and consistently applying a fire retardant, particularly a liquid fire retardant, to an as-formed textile product. In some instances, it may be desirable to have the capability of capturing excess fire retardant and recycling the captured excess in subsequent treatment process cycles, whether in a liquid form or in other forms, such as vapors. BRIEF SUMMARY OF THE DISCLOSURE

The above and other needs are met by aspects of the present disclosure, wherein one such aspect relates to a method of treating a textile product for fire resistance. Such a method comprises wetting a textile product with a liquid fire-retarding solution in a washer device, and then drying the wetted textile product in a dryer device after removal thereof from the washer device.

Another aspect of the present disclosure relates to an apparatus for treating a textile product for fire resistance. Such an apparatus comprises a washer device configured to wet a textile product disposed therein with a liquid fire-retarding solution, and a dryer device configured to receive and dry the wetted textile product after removal thereof from the washer device.

In particular aspects, the liquid fire-retarding solution may be an aqueous fire- retarding solution. It may be preferred that the fire-retarding solution be nontoxic and/or have a neutral pH and/or be non-abrasive, hypoallergenic, and/or have any number of otherwise desirable properties. In some aspects, the fire-retarding solution may comprise any ^¬ one of a boron compound, a borate, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony trioxide, a phosphonium salt, ammonium phosphate, and diammonium phosphate, or various combinations thereof.

In still further aspects, the textile product may comprise a fiber structure configured to absorb, retain, and/or entrap the liquid fire-retarding solution therein. In some instances, at least a portion of the liquid fire-retarding solution may be configured to adhere to a surface of the fiber structure. For example, the textile product may comprise a cotton fiber, a cotton microfibei", and/or a polyester fiber. In any instance, particular advantageous aspects may involve the washer device being configured to wet the textile product until the textile product is fully saturated with the liquid fire-retarding solution.

In yet further aspects, an extractor device is configured to capture excess fire- retarding solution from the washer device and/or the dryer device, with the excess fire- retarding solution being in one of a liquid form and a vapor form, and to direct the captured excess fire-retarding solution to the washer device, for example, in a closed -loop, fire- retarding solution recycling process. In addition, a filter device (i.e., a "lint filter") may be provided with respect to the washer device and/or the dry er device, wherein the filter device may be configured to capture solids from one of the washer device and the dry er device, the solids originating from one of the textile product and the fire-retarding solution. In some instances, the captured solids may be incorporated into other products. Aspects of the present disclosure thus address the identified needs and provide other advantages as otherwise detailed herein,

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 schematically illustrates an apparatus for treating textile products for fire resistance, according to one aspect of the disclosure; and

FIG. 2 schematically illustrates a dryer device for an apparatus for treating textile products for fire resistance, according to one aspect of the disclosure,

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the disclosure are shown, Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

Aspects of the present disclosure are generally directed to apparatuses and methods for treating a textile product for fire resistance. As previously discussed, one possible limitation in the treatment of as-formed textile product for fire resistance, particularly with a liquid fire retardant, is achieving an even and consistent treatment of that textile product. That is, the result of some fire resistance treatment processes may be an uneven or otherwise inconsistent application of the fire retardant to the textile product. In such instances, such uneven treatment may result in varying levels of fire resistance of the treated textile product which may, in turn, be hazardous to the user of the textile product in the event of a fire against which the textile product is intended to protect the user.

As such, one aspect of the present disclosure involves an apparatus for treating textile products for fire resistance, shown as element 100 in FIG. 1 , comprising a washer device 200 configured to wet a textile product 300 disposed therein with a liquid fire- retarding solution, and a dryer device 500 configured to receive and dry the wetted textile product after removal thereof from the washer device 200, The washer device 200 may be, for example, configured to receive the textile products 300 through a loading/unloading opening defined thereby into a washing cavity. One skilled in the art will appreciate that such a washer device 200 may be similar to a clothing washer used in residential applications, or an industrial washer device used in commercial applications. In particular aspects of the present disclosure, the washer device 200 is engaged with a source 400 containing the liquid fire-retarding solution, and is appropriately configured to receive and circulate the fire-retarding solution. That is, the washer device 200 may be particularly configured, for example, to withstand any detrimental effects of the fire-retarding solution upon exposure thereto and/or to be capable of handling the particular viscosity or evaporative characteristics thereof while applying the fire- retarding solution to the textile product 300.

Because of the particular nature of the fire-retarding solution, as well as, for example, the cost and/or availability thereof, it may also be desirable for the washer device 200 to be configured to recycle any excess amounts of the fire-retarding solution following application thereof to the textile products 300 (i.e., using an appropriate extractor device). That is, the washer device 200 may be configured to collect any excess portions of the fire-retarding solution initially introduced into the washer device 200 for application to the textile products 300 therein. In one favorable aspect, the washer device 200 is configured to wet the textile products 300 therein, until the textile products are fully saturated with the fire-retarding solution. In some instances, the washer device 200 may be configured to agitate the textile products 300 in conjunction with the introduction of the fire-retarding solution. Following such wetting of the textile products 300, the washer device 200 may be configured to drain and collect any excess portions of the fire-retarding solution (i.e., in a liquid form), including any such portions removed from the textile products 300 from a spin cycle. In addition, the washer device 200 may also be configured to recover any vapors associated with the fire- retarding solution. Upon recovery of the excess portions, including liquids and vapors, the recovered fire-retarding solution may be strained, filtered, or otherwise purified, and then reintroduced to the source 400, or directly back into the washer device 200 to treat subsequent textile products 300, In other instances, the textile products 300 may be processed with the fire-retarding solution multiple times in order to ensure full saturation.

Upon sufficient wetting of the textile products 300 in the washer device 200, the textile products 300 may be removed therefrom and introduced to the dryer device 500 for drying the textile products 300. The dryer device 500 may be configured, for example, to tumble dry the textile products 300 with heated air (i.e., heated with combusted natural gas or other suitable fuel source). In other aspects, the dryer device 500 may be configured to implement a variety of heating/drying methods for drying the textile products 300, such as, for example, microwave or infrared drying techniques, as will be appreciated by one skilled in the art. As with the washer device 200, the dryer device 500 may also be configured to recover any liquids and/or vapors associated with the fire-retarding solution removed from the textile products 300 via the drying process. Upon recovery of the excess portions, including liquids and vapors, the recovered fire-retarding solution may be strained, filtered, or otherwise purified, and then reintroduced to the source 400, or directly back into the washer device 200 to treat subsequent textile products 300.

As such, according to one aspect, the washer device 200 and/or dryer device 500 may be configured to implement a closed-loop, fire-retarding solution recycling process, where the fire-retarding solution is substantially or entirely prevented from leaving the system 100 as a waste product. In addition, in some instances, the washer device 200 and/or the dry er device 500 may also include a filter device (i.e., a "lint filter" in the dryer device 500 or a solids trap in the washer device 200), wherein the filter device may be configured to capture solids from one of the washer device 200 and the dryer device 500, the solids originating from one of the textile product 300 and the fire-retarding solution. For example, the solids may comprise lint or other fibers originating from the textile product 300, or residue of the fire-retarding solution remaining after evaporation of the liquid portion thereof. In some instances, the captured solids may be incorporated into other products while providing fire- resistance properties therefor.

In some aspects of the present disclosure, the washer device 200 may be configured to wet the textile product 300 with an aqueous fire-retarding solution. It may be preferred, in some instances, that the fire-retarding solution be nontoxic and/or have a neutral pH and/or be non-abrasive, hypoallergenic, and/or have any number of otherwise desirable properties affecting human / animal and/or environmental safety, while maintaining the necessary efficacy. It may be further preferred, in some instances, that the treated textile product having the fire- retarding solution applied thereto be nontoxic, exhibit a neutral pH. be hypoallergenic, and/or have any number of otherwise desirable properties affecting human / animal and/or environmental safety, while maintaining the necessary efficacy, upon exposure to heat and/or flame. In some aspects, the fire- retarding solution may comprise any one of a boron compound, a borate, an inorganic hydrate, a bromine compound, aluminum hydroxide, magnesium hydroxide, hydromagnesite, antimony tri oxide, a phosphonium salt, ammonium phosphate, and diammonium phosphate, or various combinations thereof. In this regard, one skilled in the art will appreciate that various fire-retarding or fire resistant substances, either currently known or later developed or discovered, may be applicable to the disclosed processes and apparatuses herein within the scope of the present disclosure. In still further aspects, the textile product may comprise a fiber structure configured to absorb, retain, and/or entrap the liquid fire-retarding solution therein. In some instances, at least a portion of the liquid fire-retarding solution may be configured to adhere to a surface of the fiber structure. For example, the textile product 300 may comprise a cotton fiber and/or a polyester fiber. That is, the textile product 300 may be comprised of 100% cotton, 100% polyester, or any combination thereof. In yet other aspects, a cotton microfiber structure may be implemented. In such instances, treatment of the textile product 300, comprising the microfiber structure, with the fire- retarding solution, may result in fire-retarding solution becoming a filler within the microfiber structure. The cotton material forming the microfiber structure may provide more favorable adhesive characteristics with respect to the fire- retarding solution (for example, greater than a polyester material), and may thus be more capable of absorbing and effectively retaining the fire-retarding solution. One skilled in the art, however, will appreciate that the fiber structure may comprise and encompass many different materials and compositions thereof, as long as the fiber structures, either currently known or later developed or discovered, are applicable to the disclosed processes and apparatuses herein within the scope of the present disclosure. In particular instances, the textile product 300, as formed, may comprise, for example, a shirt, pants, coveralls, mittens, an apron, a stovetop blanket, a fire blanket, a car cover, or any other suitable textile product that may be beneficial from the standpoint of exhibiting resistance to or retardation of fire.

Many modifications and other aspects of the disclosures set forth herein will come to mind to one skilled in the art to which these disclosures pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, one skilled in the art that the apparatuses disclosed herein readily lead to associated processes and methods for treating textile products for fire resistance. More particularly, such methods may comprise wetting a textile product with a liquid fire-retarding solution in a washer device, and then drying the wetted textile product in a dryer device after removal thereof from the washer device. In particular method aspects, the liquid fire-retarding solution may ^¬ be an aqueous fire-retarding solution. It may be preferred that the fire-retarding solution be nontoxic and/or have a neutral pH and/or be non-abrasive, hypoallergenic, and/or have any number of otherwise desirable properties. In still further method aspects, the textile product may comprise a fiber structure configured to absorb, retain, and/or entrap the liquid fire- retarding solution therein, wherein, in some instances, at least a portion of the liquid fire- retarding solution may be configured to adhere to a surface of the fiber structure. In any instance, particular advantageous method aspects may involve wetting the textile product until the textile product is fully saturated with the liquid fire-retarding solution. Therefore, it is to be understood that the disclosures are not to be limited to the specific aspects disclosed and that modifications and other aspects are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.