Patent ID: 7819994

Claim:
A process for making a reinforced nonwoven fabric that bulks in heat or flame for fire blocking an article, comprising the steps of: a) forming a mat comprising crimped heat-resistant organic fibers and thermoplastic binder fibers, b) contacting the mat with the first side of an open mesh scrim, said scrim having a first and a second side, to form a fabric assembly, c) applying thermoplastic binder powder to the fabric assembly, d) heating the fabric assembly to activate the thermoplastic binder fibers and thermoplastic binder powder, e) compressing the fabric assembly to a compressed state, and f) cooling the fabric assembly in a compressed state to form a reinforced nonwoven fabric; the reinforced nonwoven fabric comprising the open mesh screen with the first side having the crimped, heat resistant organic fibers compressed thereon, the fibers held in the compressed state by the thermoplastic binder fibers and the thermoplastic binder power, wherein when the fabric is exposed to heat or flame, the fabric increases its thickness by at least three times.