FIBERGLASS CORESPUN FABRICS FOR USE IN FLAME RESISTANT DRYWALL INSTALLATIONS

Abstract

Provided is a flame resistant drywall installation, especially those designed to meet ASTM E119. The installations comprise the use of fiberglass corespun flame resistant (FR) woven and fiberglass corespun stitchbonded nonwoven fabrics. The preferred forms of the woven and stitchbonded fabric used in this invention include: WOVEN FABRIC: A 3-8 opsy woven fabric consisting of fiberglass corespun yarns as described below. STITCHBONDED FABRIC: A 4-10 nonwoven batting of 100% cotton, 100% rayon, 100% lyocell, cotton/non-FR fiber blends, rayon/non-FR fiber blends or lyocell/non-FR fiber blends stitched with fiberglass corespun yarns as described below. Fiberglass corespun weaving and stitching yarns, for use in the invention, include those known in the textile industry as Alessandra® yarn (U.S. Pat. Nos. 6,146,759; 6,287,690; 6,410,140; 6,606,846; 6,553,749 by McKinnon Land LLC) and Firegard® yarn (by Springs Industries). The two fabric types mentioned above are used in tandom, between layers of conventional gypsum style drywall paneling to obtain a higher flame rating than would otherwise be able to be obtain in a layered drywall construction which does not include these fabrics. Conventional latex paint or flame resistant coating materials can be used to adhere the fabrics between the drywall paneling.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to the use of fiberglass corespun flame resistant (FR) woven and fiberglass corespun stitchbonded nonwoven fabrics for use in flame resistant drywall installations, especially those designed to meet ASTM E119. The preferred forms of the woven and stitchbonded fabric used in this invention include:

WOVEN FABRIC: A 3-8 opsy woven fabric consisting of fiberglass corespun yarns as described below.

STITCHBONDED FABRIC: A 4-10 nonwoven batting of 100% cotton, 100% rayon, 100% lyocell, cotton/non-FR fiber blends, rayon/non-FR fiber blends or lyocell/non-FR fiber blends stitched with fiberglass corespun yarns as described below.

Fiberglass corespun weaving and stitching yarns, for use in the invention, include those known in the textile industry as Alessandra® yarn (U.S. Pat. Nos. 6,146,759; 6,287,690; 6,410,140; 6,606,846; 6,553,749 by McKinnon Land LLC) and Firegard® yarn (by Springs Industries).

The two fabric types mentioned above are used in tandom, between layers of conventional gypsum style drywall paneling to obtain a higher flame rating than would otherwise be able to be obtain in a layered drywall construction which does not include these fabrics. Conventional latex paint or flame resistant coating materials can be used to adhere the fabrics between the layers of drywall paneling.

2. Description of the Related Art

U.S. Pat. No. 7,043,880 (W. R. Grace & Co.) “In situ molded thermal barriers”) provides methods, systems, and devices for installing thermal barriers in openings or gaps in or between structures such as walls, ceilings, and floors. At least one thermal barrier molding bag is positioned in the hole or gap, and a flowable firestop material that is operative to cure or harden, such as a hydratable cementitious slurry, is introduced into the bag to mold a barrier in the hole or gap.

U.S. Pat. No. 6,562,444 (James Hardie Research Pty Limited) “Fiber-cement/gypsum laminate composite building material” describes a building material in which fiber-cement is laminated to gypsum to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse and impact resistance, but achieves these properties without the excessive weight and thickness of two piece systems. Additionally, because of the reduced thickness, the preferred laminate building material is easier to cut and is quicker and easier to install than two piece systems. Furthermore, forming the fiber-cement and gypsum into a single piece laminate eliminates the need to install two separate pieces of building material, thereby simplifying installation. In one embodiment, a ⅝″ thick laminate composite is provided in which a ½″ thick gypsum panel laminated to a ⅛″ thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119-98.

U.S. Pat. No. 5,974,750 (3M Innovative Properties Company) “Fire barrier protected dynamic joint” describes a fire barrier protected dynamic joint in a structure, and a method for installing the same. The fire barrier protected dynamic joint includes a flexible sheet of a fire barrier material and an adhesive material for bonding the sheet to an attachment area of the joint.

U.S. Pat. No. 5,830,319 (Minnesota Mining and Manufacturing) “Flexible fire barrier felt” describes a flexible fire barrier felt that includes an organic polymeric binder; a phosphorus-containing compound; organic fibers with pendant hydroxyl groups; and a heat absorbing compound.

U.S. Pat. No. 5,772,846 (Johns Manville) “Nonwoven glass fiber mat for facing gypsum board and method of making” describes a thermoformable nonwoven fibrous mat having properties particularly suited for a facer on insulating gypsum board and the method of making the mat is disclosed. The mat can also be pleated or thermoformed to produce filter elements and preforms for producing a wide range of fiber reinforced composites and laminates. The mat preferably contains a major portion of glass fibers and a minor portion of polyester fibers bound together with up to 35 wt. percent of a cross linked vinyl chloride acrylate copolymer binder having a glass transition temperature as high as about 113 degrees F., preferably about 97 degrees F. The binder also optionally contains about 3-10 wt. percent stearylated melamine.

U.S. Pat. No. 5,714,421 (Manville Corporation) “Inorganic fiber composition” describes inorganic fibers which have a silicon extraction of greater than about 0.02 wt % Si/day in physiological saline solutions. The fiber contains SiO.sub.2, MgO, CaO, and at least one of Al.sub.2 O.sub.3, ZrO.sub.2, TiO.sub.2, B.sub.2 O.sub.3, iron oxides, or mixtures thereof. Also disclosed are inorganic fibers which have diameters of less than 3.5 microns and which pass the ASTM E-119 two hour fire test when processed into a fiber blanket having a bulk density in the range of about 1.5 to 3 pcf.

U.S. Pat. No. 5,308,692 (Herbert Malarkey Roofing Company) “Fire resistant mat” describes a nonwoven fiber mat for use as a backing material for various components used in the building industry, and having improved fire resistant qualities. The mat comprises a blend of mineral fibers and glass fibers bonded together with a fire resistant binder system. The binder system comprises a mixture of a fire resistant latex and an aqueous aldehyde condensation polymer-based thermosetting resin. The preferred weight ratio of the latex to the aldehyde condensation polymer is at least 1:1 on a non-volatile basis. The binder may optionally further contain an aqueous silica colloid.

U.S. Pat. No. 4,267,089 (Weston Research Corporation) “Adherent, flame-resistant acrylic decorative coating composition for wall board and the like” decribes a coating composition, particularly adapted for providing a flame-resistant, decorative finish coating on walls constructed from wall board, comprising an aqueous dispersion containing nepheline syenite, aluminum hydrate, sodium silicate, wollastonite, titanium dioxide, an acrylic resin, zinc oxide, hydrated magnesium aluminum silicate and water, and optionally an anti-foaming agent and a dispersing agent. The coating composition can be painted onto the wall surface and is capable of “hiding” relatively deep surface indentations with one coat.

U.S. Pat. No. 4,101,475 (Owens-Corning Fiberglas Corporation) “Flame resistant materials and method of making same” describes a scratch resistant, flame resistant material made by producing a sheet molding compound of a melamine-aldehyde precondensate, silica, alumina trihydrate, slightly soluble soap, ammonium hydroxide and acid salt catalyst. The sheet molding compound is applied to the surface of a pelt of glass fibers containing a heat curable binder and the composite is bonded together under heat and pressure to cure both binders simultaneously and bond the sheet molding compound to the fiber layer of the pelt. A need has long existed for a flame proof wallboard for dwellings, hospitals, and other public buildings to take the place of marble, tile, and other hard fire proof surfacing materials which are now too expensive for general use in the building industry. The usual drywall board comprising gypsum between two layers of paper is not sufficiently fire resistant for hospitals and public buildings, nor is the painted fiber board that is presently available. Accordingly, it is an object of the present invention to produce an inexpensive light weight paneling which has a surface which has a very low flame spread rate, that liberates very little smoke when subjected to temperatures of 1,000 degree F. or more, and which contributes practically no fuel to a fire that is contained by the paneling.

Although all of the above cited art describe various forms of FR fabrics and their application in drywall installations, none of them include the idea of using a continuously reinforced fiberglass FR fabric to provide a high level of strength ALONG WITH a nonwoven FR fabric to provide a high degree of insulation against heat. These fabrics are used between the layers of gypsum drywall to obtain a higher flame rated wall while maintaining overall thinner composite wall dimensions. Another innovation of this invention is that conventional latex paint can be used to adhere the fabrics between the layers of drywall, greatly simplifying the bonding process as compared coating materials and procedures described in the prior art. Of course, flame resistant coating materials can also be used to adhere the fabrics between the layers of drywall.

SUMMARY OF THE INVENTION

To overcome or conspicuously ameliorate the disadvantages of the related art, it is an object of the present invention to provide a flame resistant drywall installation capable of passing open flame tests such as ASTM E119. In the preferred usages of the present invention, a FR corespun woven and a FR stitchbonded fabric are adhered between layers of conventional gypsum drywall panels, with the use of standard latex wall paint, and tested according to standard FR test methods such as: American Standard Testing Method E119. The continuous filament fiberglass corespun FR woven fabric imparts outstanding strength to the drywall, when it is impinged by direct flame, and the continuous filament fiberglass corespun stitched nonwoven batting provides a strong insulation layer to slowdown the transmission of heat through the inorganic drywall paneling, when exposed to direct flame.

The preferred continuous filament fiberglass corespun FR woven fabric consists of 10/1 cotton count Alessandra FR yarns woven into a 44×34 twill construction and weighing about 5.0 ounces per square yard (opsy). Of course, preferred fabric constructions and yarn counts can be modified to produce basis weights between 3.0-8.0 opsy. The preferred filament fiberglass corespun stitched nonwoven fabric consists of a 6 opsy 100% cotton batting stitched with 14/1 cotton count Alessandra FR yarn. Of course, the cotton batting's basis weight can also vary between 4.0-10 opsy, depending on the level of insulative protection desired.

FR spun weaving and stitching yarns can contain any of the following char forming and oxygen depleting fibers, wrapped around the continuous filament fiberglass core. The char and oxygen depleting fibers can, optionally, also be blended with up to 80% of standard non-FR fibers, such as those also listed below:

Char Forming Fibers:

• • melamines (BASOFIL by Basofil Fibers LLC, meta-aramids such as poly(m-phenylene isophthalamide), for example, those sold under the tradenames NOMEX by E. I. Du Pont de Nemours and Co., TEIJINCONEX by Teijin Limited, CHINFMNEX@ ARAMID 1313 by Guangdong Charming Chemical Co. Ltd. and FENYLENE by Russian State Complex; para-aramids such as polyp-phenylene terephthalamide), for example, that sold under the tradename KEVLAR by E. I. Du Pont de Nemours and Co., poly(diphenylether para-aramid), for example, that sold under the tradename TECHNORA by Teijin Limited, and those sold under the tradenames TWARON by Acordis and FENYLENE ST (Russian State Complex); polybenzimidazole such as that sold under the tradename PBI by Hoechst Celanese Acetate LLC, polyimides, for example, those sold under the tradenames P-84 by Inspec Fibers and KAPTON by E. I. Du Pont de Nemours and Co.; polyamideimides, for example, that sold under the tradename KERMEL by Rhone-Poulenc; partially oxidized polyacrylonitriles, for example, those sold under the tradenames FORTAFIL OPF by Toho Tenax America, AVOX by Textron Inc., PYRON by Zoltek Corp., PANOX by SGL Technik, THORNEL by American Fibers and Fabrics and PYROMEX by Toho Rayon Corp.; novoloids, for example, phenol-formaldehyde novolac, for example, that sold under the tradename KYNOL by Gun Ei Chemical Industry Co.; poly (p-phenylene benzobisoxazole) (PBO), for example, that sold under the tradename ZYLON by Toyobo Co.; poly (p-phenylene benzothiazoles) (PBT); polyphenylene sulfide (PPS), for example, those sold under the tradenames RYTON by American Fibers and Fabrics, TORAY PPS by Toray Industries Inc., FORTRON by Kureha Chemical Industry Co. and PROCON by Toyobo Co.; flame retardant viscose rayons, for example, those sold under the tradenames LENZING FR by Lenzing A.G. and VISIL or Sateri Oy Finland; polyetheretherketones (PEEK), for example, that sold under the tradename ZYEX by Zyex Ltd.; polyketones (PEK), for example, that sold under the tradename ULTRAPEK by BASF; polyetherimides (PEI), for example, that sold under the tradename ULTEM by General Electric Co. and fiber combinations thereof;

Oxygen Depleting Fibers:

• • chloropolymeric fibers, such as those containing polyvinyl chloride or polyvinylidene homopolymers and copolymers, for example, those sold under the tradenames THERMOVYL L9S, ZCS & ZCB, FIBRAVYL L9F, RETRACTYL L9R, ISOVYL MPS by Rhovyl S. A; PIVIACID, Thueringische; VICLON by Kureha Chemical Industry Co., TEVIRON by Teijin Ltd., ENVILON by Toyo Chemical Co. and VICRON, made in Korea; SARAN by Pittsfield Weaving, KREHALON by Kureha Chemical Industry Co. and OMNI-SARAN by Fibrasomni, S. A. de C. V.; and modacrylics which are vinyl chloride or vinylidene chloride copolymer variants of acrylonitrile fibers, for example, those sold under the tradenames PROTEX by Kaneka and SEF by Solutia.; fluoropolymeric fibers such as polytetrafluoroethylene (PTFE), for example, those sold under the tradenames TEFLON TFE by E. I. Du Pont de Nemours and Co., LENZING PTFE by Lenzing A. G., RASTEX by W. R. Gore and Associates, GORE-TEX by W. R. Gore and Associates, PROFILEN by Lenzing A. G. and TOYOFLON PTFE by Toray Industries Inc., poly(ethylene-chlorotrifluoroethylene) (E-CTFE), for example, those sold under the tradenames HALAR by Albany International Corp. and TOYOFLON E-TFE by Toray Industries Inc., polyvinylidene fluoride (PVDF), for example, those sold under the tradenames KYNAR by Albany International Corp. and FLORLON (Russian State Complex), polyperfluoroalkoxy (PFA), for example, those sold under the tradenames TEFLON PFA by E. I. Du Pont de Nemours and Co. and TOYOFLON PFA by Toray Industries Inc., polyfluorinated ethylene-propylene (FEP), for example, that sold under the tradename TEFLON FEP by E. I. Du Pont de Nemours and Co., a fiber combinations thereof;
    Suitable Non-FR Fibers for Blending with the Char and Oxygen Depleting Fibers Include:
  • cotton, wool, silk, mohair, cashmere, kenaf, sisal, nylons, polyesters, polyolefins, rayons, lyocells, acrylics, cellulose acetates and polylactides (by Fiber Innovations Technology;

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF INVENTION

The present invention relates to the use of continuous filament fiberglass corespun flame resistant (FR) woven and continuous filament fiberglass corespun stitchbonded nonwoven fabrics for use in flame resistant drywall installations, especially those designed to meet ASTM E119. It is understood by someone skilled in the art that these flame barrier fabrics can be modified by changing their basis weights and/or the composition of the stitching yarns to pass less stringent small open flame tests.

Stitchbonded nonwoven fabrics and processes and machines for making such fabrics are well known. Typically, stitchbonded nonwoven fabrics are made by multi-needle stitching a fibrous material with one or more stitching thread systems. Typically, the material consists of substantially nonbonded fibers, although material consisting of bonded fibers also has been used. The stitching threads form patterns of stitches in the fibrous material. Many different kinds of fibrous materials have been employed to produce stitchbonded fabrics, including carded webs, thin felts, spunlace fabrics, spunbonded nonwoven sheets, paper and the like. These known fibrous layers are made from various natural and synthetic organic staple fibers or continuous filaments.

Known processes for making stitchbonded fabrics typically include the steps of (a) feeding a fibrous material to a stitchbonding machine; (b) threading a multi-needle bar of the stitchbonding machine with stitching threads; (c) inserting the stitching thread into the fibrous material to form a pattern of spaced apart, interconnected rows of stitches, thereby creating the stitchbonded fabric; (d) removing the stitchbonded fabric from the stitchbonding machine; and (e) optionally subjecting the stitchbonded fabric to further finishing operations, such as shrinking, heat setting, molding, coating, impregnating, printing, dyeing and the like.

Among the conventional stitching threads that have been employed in stitchbonding operations are yarns of natural fibers (e.g., cotton, wool); fibers or filaments of fully drawn, crystalline polymers (e.g., nylon, polyester); fibers of partially molecularly oriented synthetic organic polymer; and threads of spandex, or of other elastic or elastomeric materials.

To date, the character and appearance of known stitchbonded fabrics has depended mainly on the particular types of yarns, patterns of stitches formed by the stitching yarns, the amount of shrinkage and other finishing steps used in the manufacture of the fabrics. In general, fabrics and battings that can be pierced by a stitchbonding needle, and that can be fed through a ⅕ inch (5 mm) gap, can be stitchbonded.

Continuous filament fiberglass corespun yarn stitched nonwoven FR fabrics of the present invention typically consist of 5% to 50% stitching yarn and 50% to 95% of a nonwoven fiber batting. Fabric basis weights range from less than 1 ounces per square yard, to more than 30 ounces per square yard. More preferably, the FR stitching yarn should be between 10% -30% of the total stitchbonded nonwoven batting weight. The preferred filament fiberglass corespun stitched nonwoven fabric consists of a 6 opsy 100% cotton batting stitched with 14/1 cotton count Alessandra FR yarn. Of course, the cotton batting's basis weight can also vary between 4.0-10 opsy, depending on the level of insulative protection desired.

The preferred continuous filament fiberglass corespun FR woven fabric consists of 10/1 cotton count Alessandra FR yarns woven into a 44×34 twill construction and weighing about 5.0 ounces per square yard (opsy). Of course, other fabric constructions and yarn counts can be modified to produce woven fabric basis weights between 3.0-8.0 opsy.

The preferred continuous filament fiberglass corespun weaving and stitching yarns, for use in the invention, include those known in the textile industry as Alessandra® yarn (U.S. Pat. Nos. 6,146,759; 6,287,690; 6,410,140; 6,606,846; 6,553,749 by McKinnon Land LLC) and Firegard® yarn (by Springs Industries).

Conventional latex paint or flame resistant coating materials can be used to adhere the fabrics between the drywall paneling. Typical flame resistant coating materials may include:

Ethylene/vinyl choride copolymers with or without standard acrylic or styrene acrylonitrile polymers; while optionally including materials such as nitrogen phosphorous flame retardant, a phosphate flame retardant, aluminum trihydrate, magnesium hydroxide, calcium hydroxide, calcium carbonate, antimony trioxide, and mixtures thereof.

The following non-limiting examples I and II are set forth to demonstrate the present invention.

Example I

Fiberglass Corespun Fr Fabrics for use in Flame Resistant Drywall Installations

A 6.0 ounce per square yard (osy) batting of 100% cotton is stitchbonded with 14/1 Alessandra corespun yarn such that the final fabric weight is 8.0 osy. The stitchbonded FR fabric has the equivalent of 20% Alessandra corespun yarn and 80% cotton batting.

The Alessandra Corespun Stitching Yarn Consisted of:

• • melamine fiber (Basofil Fiber)—(in sheath)
  • modacrylic fiber—(in sheath)
  • polyester fiber—(in sheath)
  • multifilament fiberglass—(in core)
  • multifilament nylon fiber—(in core)

A 5.0 osy woven 44×34 twill fabric of 10/1 Alessandra corespun yarn, consisting of the fiber blend described above, is painted with standard latex paint and applied to one side of a ⅝″ drywall panel. The stitchbonded nonwoven fabric described above is also painted with latex paint and applied to a second ⅝″ drywall panel.

After the two fabric painted surfaces are allowed to thoroughly dry they are joined together. A propane burner, at full flame, is applied to the outer surface of one side of the drywall composite; while a thermocouple is used to measure the temperature rise at the surface of the other side of the drywall composite. The results below are compared to two ⅝″ drywall panels which have been painted together without any FR fabrics:

	EXAMPLE I	COMPARATIVE (no fabrics)
15 minutes	160 deg F.	180 deg F.
30 minutes	165 deg F.	195 deg F.
45 minutes	168 deg F.	255 deg F.
60 minutes	188 deg F.	350 deg F.

Example II

Fiberglass Corespun Fr Fabrics for use in Flame Resistant Drywall Installations

A 6.0 ounce per square yard (osy) batting of 100% cotton is stitchbonded with 14/1 Alessandra corespun yarn such that the final fabric weight is 8.0 osy. The stitchbonded FR fabric has the equivalent of 20% Alessandra corespun yarn and 80% cotton batting.

The Alessandra Corespun Stitching Yarn Consisted of:

• • melamine fiber (Basofil Fiber)—(in sheath)
  • modacrylic fiber—(in sheath)
  • polyester fiber—(in sheath)
  • multifilament fiberglass—(in core)
  • multifilament nylon fiber—(in core)

A 5.0 osy woven 44×34 twill fabric of 10/1 Alessandra corespun yarn, consisting of the fiber blend described above, is painted with standard latex paint and applied to one side of a ⅝″ drywall panel and the other side has the stitchbonded nonwoven fabric described above painted with latex paint and applied to it. A second ⅝″ drywall panel has the twill fabric painted and applied to one side and a third ⅝″ drywall panel has the stitchbonded fabric painted and applied to it.

After the three fabric painted surfaces are allowed to thoroughly dry they are joined together such that layers are aligned as follows:

(outer surface) drywall/stitchbond/twill/drywall/stitchbond/twill/drywall (inner surface)

A propane burner, at full flame, is applied to the outer surface of the drywall composite; while a thermocouple is used to measure the temperature rise at the inner surface of the drywall composite. The results are compared to three ⅝″ drywall panels which have been painted together without any fabrics:

		COMPARATIVE
	EXAMPLE II	(no fabrics)
15 minutes	105 deg F.	135 deg F.
30 minutes	140 deg F.	150 deg F.
45 minutes	148 deg F.	155 deg F.
60 minutes	148 deg F.	160 deg F.

Claims

1. A flame resistant drywall installation comprising fiberglass corespun flame resistant woven and fiberglass corespun stitchbonded nonwoven fabrics bonded between the drywall panel layers.

2. The installation of claim 1, wherein latex paint is used to bond the fabrics between the drywall panel layers.

3. The installation of claim 1, wherein the fiberglass corespun flame resistant woven fabric is comprised of 10/1 cotton count Alessandra FR yarns.

4. The installation of claim 3, wherein the yarns are woven into a 44×34 twill construction with a basis weight of between 3.0 and 8.0 opsy.

5. The installation of claim 4, wherein the basis weight is about 5.0 opsy.

6. The installation of claim 1, wherein the fiberglass corespun stitchbonded nonwoven fabric is comprised of cotton batting stitched with 14/1 cotton count Alessandra FR yarn.

7. The installation of claim 6, wherein the basis weight of the cotton batting is between 4.0 and 10 opsy.

8. The installation of claim 7, wherein the cotton batting basis weight is about 6 opsy.

9. The installation of claim 3, wherein the yarn contains a char forming and/or oxygen depleting fiber wrapped around a fiberglass core.

10. The installation of claim 9, wherein the char forming fiber is selected from the group consisting of melamines, para-aramides, polybenzimidazoles, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novaloids, poly(p-phenylene benzobisoxazole), poly (p-phenylene benzothiazoles), polyphenylene sulfide, viscose rayons, polyetheretherketones, polyketones and combinations thereof

11. The installation of claim 9, wherein the oxygen depleting fiber is selected from the group consisting of chloropolymeric fibers; modacrylics; fluoropolymeric fibers; poly(ethylene-chlorotrifluoroethylene); polyvinylidene fluoride fibers; polyperfluoroalkoxy, polyfluorinated ethylene-propylene; and combinations thereof.

12. The installation of claim 6, wherein the yarn contains a char forming and/or oxygen depleting fiber wrapped around a fiberglass case.

13. The installation of claim 12, wherein the char forming fiber is selected from the group consisting of melamines, para-aramides, polybenzimidazoles, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novaloids, poly(p-phenylene benzobisoxazole), poly (p-phenylene benzothiazoles), polyphenylene sulfide, viscose rayons, polyetheretherketones, polyketones and combinations thereof.

14. The installation of claim 12, wherein the oxygen depleting fiber is selected from the group consisting of chloropolymeric fibers; modacrylics; fluoropolymeric fibers; poly(ethylene-chlorotrifluoroethylene); polyvinylidene fluoride fibers; polyperfluoroalkoxy, polyfluorinated ethylene-propylene; and combinations thereof.

15. The installation of claim 9, wherein the char forming and/or oxygen depleting fiber is blended with cotton, wool, silk, mohair, cashmere, kenof, sisal, nylons, polyesters, polyolefins, rayons, lyocells, acrylics, cellulose acetates or polyactides.

16. The installation of claim 12, wherein the char forming and/or oxygen depleting fiber is blended with cotton, wool, silk, mohair, cashmere, kenof, sisal, nylons, polyesters, polyolefins, rayons, lyocells, acrylics, cellulose acetates or polyactides.

17. The installation of claim 1, wherein a flame resistant coating is used to bond the fabrics between the drywall panel layers.

18. The installation of claim 17, wherein the flame resistant coating is comprised of ethylene/vinyl chlorides copolymers with or without standard acrylic or styrene acrylonitrile polymers; while optionally including materials such as nitrogen phosphorous flame retardant, a phosphate flame retardant, aluminum trihydrate, magnesium hydroxide, calcium hydroxide, calcium carbonate, antimony trioxide, and mixtures thereof.