Flame resistant fabrics and garments made from same

Abstract

Unique blends of fibers that incorporate synthetic cellulosic fibers to render fabrics made with such blends more durable than fabrics made with natural cellulosic fibers such as cotton. While more durable than cotton, the synthetic cellulosic fibers used in the blends are still inexpensive and comfortable to the wearer. Thus, the benefits of cotton (affordability and comfort) are still attained while a drawback of cotton—low durability—is avoided. In one embodiment, the fiber blend includes FR modacrylic fibers and synthetic cellulosic fibers, preferably, but not necessarily non-FR lyocell fibers such as TENCEL™ and TENCEL A100™. Other fibers may be added to the blend, including, but not limited to, additional types of inherently FR fibers, anti-static fibers, anti-microbial fibers, stretch fibers, and / or high tenacity fibers. The fiber blends disclosed herein may be used to form various types of FR fabrics. Desired colors may be imparted in a variety of ways and with a variety of dyes to the fabrics disclosed herein. Fabrics having the fibers blends disclosed herein can be used to construct the entirety of, or various portions of, a variety of protective garments for protecting the wearer against electrical arc flash and flames, including, but not limited to, coveralls, jumpsuits, shirts, jackets, vests, and trousers.

Description

FIELD OF THE INVENTION [0001] The present invention relates to protective fabrics, and more specifically to flame resistant fabrics, having a unique blend of fibers and garments made from such fabrics. BACKGROUND OF THE INVENTION [0002] Many occupations can potentially expose an individual to electrical arc flash and / or flames. To avoid being injured while working in such conditions, these individuals typically wear protective garments constructed of flame resistant materials designed to protect them from electrical arc flash and / or flames. Such protective clothing can include various garments, for example, coveralls, pants, and shirts. Fabrics from which such garments are constructed, and consequently the resulting garments as well, are required to pass a variety of safety and / or performance standards, including ASTM F 1506, NFPA 2112, NFPA 70E, MIL C 43829C. [0003] Many protective garments have been made from fabrics comprising natural cellulosic fibers, such as cotton. Cotton fib...

AI Technical Summary

Benefits of technology

[0009] This invention discloses unique blends of fibers that incorporate synthetic cellulosic fibers to render fabrics made with such blends more durable than fabrics made with natural cellulosic fibers such as cotton. While more durable than cotton, the synthetic cellulosic fibers used in the blends are still inexpensive and comfortable to the wearer. Thus, the benefits of cotton (affordability and comfort) are still attained while a drawback of cotton—low durability—is avoided. The resulting fabrics made with the fiber blends disclosed herein are flame resistant, durable, comfortable, and affordable.

[0014] Fabrics having the fibers blends disclosed herein can be used to construct the entirety of, or various portions of, a variety of protective garments for protecting the wearer against electrical arc flash and flames, including, but not limited to, coveralls, jumpsuits, shirts, jackets, vests, and trousers. In one embodiment, a fabric having blends of fibers disclosed herein is used to form at least a portion of an advanced combat shirt.

Problems solved by technology

Many occupations can potentially expose an individual to electrical arc flash and / or flames.

However, the use of cotton fibers in such fabrics has many disadvantages.

To begin, cotton fibers are not durable.

Thus, fabrics made with them have poor wear life and must be replaced unacceptably often.

Furthermore, cotton fibers pose a health hazard to personnel during the fiber spinning and fabric weaving processes.

When natural cotton fibers are used to make fabrics and garments, the cotton fibers can be inhaled and over time can cause respiratory problems, which can lead to byssinosis or “brown lung” disease.

Work environments where personnel work with natural cotton and are exposed to breathing hazardous cotton fibers are thus subject to governmental and regulatory restrictions for handling and processing of such fibers.

Moreover, cotton fibers are not inherently flame resistant and thus apt to burn.

Treatment of cotton fibers (or the yarns or fabrics made with such fibers) with an FR compound significantly increases the cost of such fibers (or the yarns or fabrics made with such fibers).

However, the FR modacrylic fibers have durability problems similar to those of cotton, and thus fabrics made with blends of these fibers have poor wear life.

Moreover, both natural cotton fibers and FR modacrylic fibers are relatively unstable after thermal exposure, rendering it difficult if not impossible for fabrics made with only these fibers to pass the requisite safety and performance standards for protective garments.

Because of the presence of cotton fibers, the resulting fabrics still exhibit durability problems and unacceptable wear life.