Fabrics and articles having fire resistance, cut resistance, and elastic recovery properties, and methods for manufacturing the same.

Abstract

A fire and cut resistant fabric, and a glove or other article comprising the fabric, the fabric comprising: (a) at least one first yarn comprising at least 50% by weight heat resistant polymeric fibers, wherein at least 30% by weight of the polymeric fibers present in the at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15; and (b) at least one second yarn having a sheath / core construction having a sheath of halogenated self-extinguishing staple fibers and a core comprising at least one continuous elastomeric filament; Including, 60-95% by weight of at least one second yarn is halogenated self-extinguishing fiber, the halogenated self-extinguishing fiber being in contact with at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers; A fire-resistant, cut-resistant fabric, and a glove or other article comprising the fabric, wherein the fabric has a maximum afterflame time of 2 seconds or less and experiences a weight loss of 5% or less by weight when tested in accordance with NFPA-2112-2018.

Description

Technical Field

[0001] The present invention relates to threads and fabrics suitable for use in articles of protective clothing having fire resistance, shape conformity, and also cut resistance.

Background Art

[0002] Description of related art. Twisted yarns and fabrics having cut resistance and elastic recovery, methods for their production, and their use in articles of protective clothing are disclosed in U.S. Patent No. 6,952,915.

[0003] Threads containing modacrylic fibers, p-aramid fibers, and m-aramid fibers useful for producing fabrics having properties of protecting from arc and flame are disclosed, for example, in U.S. Patent Nos. 7,065,950 and 7,348,059. These threads may further contain, as optional components, wear-resistant fibers such as nylon in an amount of 2 to 15% by weight and / or an antistatic component in an amount of 1 to 5% by weight.

[0004] Threads and fabrics having a combination of fire resistance and elastic recovery are described, for example, in U.S. Patent Nos. 5,069,957, 5,527,597; and 5,694,981. These existing solutions utilize threads produced by coating an elastic core yarn with an outer covering of substantially protective fibers made from fire-resistant fibers. In other words, these references describe protecting the elastic core by structurally shielding it from the flame using another fiber within the same thread.

[0005] As used herein, the terms “structural shielding” and “structural barrier” mean that when the covering fibers are exposed to flame, they simply carbonize and remain within the threads covering the elastic filaments in the core, thereby providing a structural barrier between the flame and the elastic core. As taught in these patents, these threads are provided with an outer covering of substantial protective fibers made from fire-resistant fibers that physically protect the elastic core threads from degradation or melting when exposed to extreme temperatures or flames.

[0006] Unfortunately, in many cases, fibers with an outer fiber covering that provides adequate structural shielding tend to be stiff, and therefore fabrics made from such yarns may not be as comfortable as desired. This ultimately leads to protective clothing that may not be as comfortable as desired, and it is well known that when it is not comfortable enough, workers tend to not wear protective gear and put themselves at risk.

[0007] In addition, all solutions for protecting the elastic core must meet current protective clothing standards. Specifically, the recent NFPA 2112-2018 "Standard on Flame-Resistant Clothing for Protection of Industrial Personnel Against Short-Duration Thermal Exposures from Fire" specifies minimum design, performance, testing, and certification requirements and test methods for fire-resistant clothing, shrouds, hoods, balaclavas, and gloves for use in areas at risk of short-term thermal exposure from fire. This standard requires that the afterflame time of the fabric used in the clothing be 2 seconds or less. Afterflame time is the time (measured in seconds, in 0.2-second increments) that the test specimen continues to burn after the burner is removed from the flame.

[0008] This standard imposes an even stricter requirement for fire-resistant gloves: the amount of material consumed during a fire resistance test must not exceed 5.0 percent of the original weight of the test specimen. In other words, after exposing the test specimen to flame for a specified 12 seconds according to the standard procedure, the weight loss of the fabric must be 5.0 percent or less. [Overview of the project] [Problems that the invention aims to solve]

[0009] Therefore, there is a need for yarns and / or fabrics that combine cut resistance with fire resistance and elastic recovery, utilizing fibers that have a fabric-like feel, particularly incorporating elastic core yarns, conforming to the NFPA 2112-2018 standard, and potentially providing more comfortable protective clothing. [Means for solving the problem]

[0010] This invention relates to a fire-resistant and cut-resistant fabric, and gloves or other articles containing this fabric, wherein the fabric is (a) at least one first yarn containing at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first yarn, wherein at least 30% by weight of the polymer fibers present in the at least one first yarn are cut-resistant heat-resistant polymer fibers having a cut resistance of 500 grams by weight or more according to ASTM F2992-15; and (b) At least one second thread having a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fiber and a core containing at least one continuous elastomer filament; Includes, Based on the total weight of the second yarn, at least 60-95% by weight of one second yarn consists of halogenated self-extinguishing fibers, the halogenated self-extinguishing fibers are in contact with at least one continuous elastomer filament, and the second yarn contains or substantially no inorganic fibers; When tested according to NFPA-2112-2018, the maximum afterburn time of the fabric is 2 seconds or less, and the weight loss is 5% by weight or less. [Modes for carrying out the invention]

[0011] This invention relates to yarns and fabrics suitable for use in protective clothing articles, possessing both fire resistance and shape conformability, and also providing protection from cuts. This unique combination is achieved by combining elastic materials, self-extinguishing fibers, and strong heat-resistant polymer fibers in a manner that provides high fire resistance to the yarns and fabrics while minimizing fabric wear during combustion.

[0012] Specifically, the present invention is (a) at least one first yarn containing at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first yarn, wherein at least 30% by weight of the polymer fibers present in the at least one first yarn are cut-resistant heat-resistant polymer fibers having a cut resistance of 500 grams by weight or more according to ASTM F2992-15; and (b) At least one second thread having a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fiber and a core containing at least one continuous elastomer filament; A fire-resistant and cut-resistant fabric containing, Based on the total weight of the second yarn, at least 60-95% by weight of one second yarn consists of halogenated self-extinguishing fibers, the halogenated self-extinguishing fibers are in contact with at least one continuous elastomer filament, and the second yarn contains or substantially no inorganic fibers; This invention relates to a fire-resistant and cut-resistant fabric in which, when tested according to NFPA-2112-2018, the maximum afterflame time of the fabric is 2 seconds or less and the weight loss is 5% by weight or less.

[0013] "Fire-resistant and cut-resistant fabric" means a knitted or woven fabric that possesses both "fire resistance" and "cut resistance." The description of "fire resistance" in relation to a fabric means that, when tested according to ASTM 6143-15, the carbonization length of the fabric is 4 inches (100 mm) or less. "Cut-resistant fabric" means that the fabric has at least a minimum level of cut resistance; generally, a cut-resistant fabric has a cut resistance of at least 200 grams by weight according to ASTM F 2992-15. In some preferred embodiments, the fibers and yarns described herein can provide a fire-resistant and cut-resistant fabric having a cut resistance of at least 500 grams by weight according to ASTM F 2992-15. However, in some other embodiments, it is understood that other fibers or yarns may be incorporated into the fabric that do not necessarily provide cut resistance but can provide other desirable qualities to the fabric, as long as the fire resistance requirements described herein are met in order to be considered a “fire-resistant” fabric and the fabric maintains a minimum cut resistance of at least 200 grams by weight according to ASTM F2992-15.

[0014] Fire-resistant fabrics provide thermal protection from heat events, while cut-resistant fabrics provide mechanical protection from knives and other sharp objects. In addition to fire resistance, these fabrics exhibit an afterflame time of 2 seconds or less and a weight loss of 5% or less when tested according to NFPA-2112-2018.

[0015] In addition, it is often important, or desirable, that articles such as protective gloves made from such fabrics be comfortable and have a good fit and conformability. “Good fit and conformability” means, for example, that the gloves conform well to the shape of the wearer's hand, allowing them to grasp and handle small objects while wearing them. The fire-resistant and cut-resistant fabrics described herein provide articles that are both highly fire-resistant and cut-resistant, while also being soft, flexible, and conforming to shape. Protective clothing made from such fabrics is very comfortable and effective against multiple threats.

[0016] The fire-resistant and cut-resistant fabric is manufactured from at least a first yarn providing heat-resistant polymer fibers and at least a second yarn providing at least one continuous elastomer filament covered with halogenated self-extinguishing fibers in contact with at least one continuous elastomer filament. The at least first yarn and the at least second yarn are then used to manufacture the fabric.

[0017] In some embodiments, at least a first yarn and at least a second yarn are twisted together to form a plied yarn. In some embodiments, the plied yarn consists of only one first yarn and only one second yarn. In another embodiment, the plied yarn consists of only one first yarn and multiple second yarns; in yet another embodiment, the plied yarn consists of multiple first yarns and only one second yarn. Similarly, in some embodiments, the plied yarn consists of multiple first yarns and multiple second yarns. Finally, in some embodiments, the plied yarn includes at least one first yarn and at least one second yarn. Any number of other yarns made from fibers can be included in the plied yarn, as long as the final fabric meets the performance criteria described herein.

[0018] In some other embodiments, at least a first yarn and at least a second yarn are used in a weft-inserted interlocking structure. "Weft insertion" means a knitted fabric in which at least a second yarn is inserted into a knitted fabric structure containing at least a first yarn, as is done when making the elastomer cuffs of knitted gloves.

[0019] In some other embodiments, at least a first yarn and at least a second yarn can be used in a parallel relationship with each other in the fabric. As used herein, the term “parallel” means that the individual yarns are normally adjacent to each other in the fabric, the yarns are independent and separate from each other, and they are not twisted or tangled. In knitted fabrics, this type of parallel arrangement in the fabric is also known as a type of interwoven fabric. In one interwoven manufacturing process, interwoven fabric is formed by joining the warp threads of two separate yarns, i.e., knitting both together on a single knitting machine. This structure and process keeps the two different yarns in close proximity in the fabric and maintains their parallel relationship. It is advantageous for this process to include a step of joining the two warp threads of the yarn while knitting, so that one warp thread is mainly positioned on the first surface of the garment and the other warp thread is mainly positioned on the second surface of the garment. This typically allows the more comfortable warp thread to be mainly positioned on the inside of the garment and the other warp thread to be mainly positioned on the outside.

[0020] The present invention also relates to gloves or other articles comprising a fire-resistant and cut-resistant fabric, including all embodiments described herein, wherein the fire-resistant and cut-resistant fabric is (a) at least one first yarn containing at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first yarn, wherein at least 30% by weight of the polymer fibers present in the at least one first yarn are cut-resistant heat-resistant polymer fibers having a cut resistance of 500 grams by weight or more according to ASTM F2992-15; and (b) At least one second thread having a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fiber and a core containing at least one continuous elastomer filament; A fire-resistant and cut-resistant fabric containing, Based on the total weight of the second yarn, at least 60-95% by weight of one second yarn consists of halogenated self-extinguishing fibers, the halogenated self-extinguishing fibers are in contact with at least one continuous elastomer filament, and the second yarn contains or substantially no inorganic fibers; When tested in accordance with NFPA-2112-2018, the maximum afterglow time of the fabric is 2 seconds or less, and the weight loss is 5% by weight or less.

[0021] At least the first thread contains at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first thread, and at least 30% by weight of the polymer fibers present in at least one first thread are cut-resistant heat-resistant polymer fibers having a cut resistance of 500 grams or more according to ASTM F2992-15.

[0022] "Heat-resistant polymer fiber" means a fiber made from a synthetic organic polymer that retains 9o% of its original fiber weight when heated to 500 °C at a rate of 20 °C per minute in air. Preferred heat-resistant polymer fibers have a yarn strength of at least 3 grams / denier (2.7 grams / dtex). Heat-resistant polymer fibers include para-aramid fibers, aramid copolymer fibers, polybenzazole fibers, polybenzimidazole fibers, polyimide fibers, and mixtures thereof. Preferred heat-resistant polymer fibers are para-aramid fibers, and preferred para-aramid fibers are poly(p-phenylene terephthalamide fibers).

[0023] At least one first thread contains at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first thread. In some embodiments, at least one first thread contains at least 60% by weight of heat-resistant polymer fibers based on the total weight of the first thread. In some embodiments, at least one first thread contains 60-85% by weight of heat-resistant polymer fibers based on the total weight of the first thread, and in some other embodiments, at least one first thread contains 60-80% by weight of heat-resistant polymer fibers based on the total weight of the first thread. In some embodiments, at least one first thread contains 100% by weight of heat-resistant polymer fibers based on the total weight of the first thread.

[0024] At least 30% by weight of the polymer fibers present in at least one first yarn are cut-resistant and heat-resistant polymer fibers having a cut resistance of 500 grams by weight or more according to ASTM F2992-15. The cutting performance of the fibers is determined by measuring the cutting performance of a 345 grams / square meter (10 ounces / square yard) fabric woven or knitted from 100% of the fibers to be tested, and then measuring the cut resistance (grams by weight) according to ASTM F2992-15.

[0025] Examples of cut-resistant and heat-resistant polymer fibers having cut resistance of 500 grams by weight or more according to ASTM F2992-15 include para-aramid fibers, aramid copolymer fibers, polybenzazole fibers, polybenzimidazole fibers, and mixtures thereof. Preferred cut-resistant and heat-resistant polymer fibers are para-aramid fibers, and preferred para-aramid fibers are poly(paraphenylene terephthalamide) fibers. The cut-resistant and heat-resistant polymer fibers in at least one first thread may be the same as or different from the heat-resistant polymer fibers in at least one first thread, provided that the heat-resistant polymer fibers have sufficient cut resistance.

[0026] Therefore, cut-resistant and heat-resistant polymer fibers are understood to be both the heat-resistant polymer fibers and the cut-resistant fibers as defined above. Furthermore, at least one first yarn may be a 100% cut-resistant and heat-resistant polymer fiber. That is, such a yarn having 100% cut-resistant and heat-resistant polymer fibers is understood to consequently have at least 50% by weight of heat-resistant polymer fibers and at least 30% by weight of cut-resistant and heat-resistant polymer fibers. It is also understood that at least one first yarn may include a fiber that is a heat-resistant polymer fiber as defined herein but not a cut-resistant fiber as defined herein. Table 1 provides guidance giving selected exemplary compositions regarding the possible percentage ratios of non-cut-resistant and heat-resistant (non-CR HR) polymer fibers and cut-resistant and heat-resistant (CH-HR) polymer fibers.

[0027] [Table 1]

[0028] Therefore, it is understood that at least 30% by weight of the polymer fibers present in at least one first yarn are both cut-resistant and heat-resistant polymer fibers as defined herein. In some embodiments, the cut-resistant and heat-resistant polymer fibers are present in at least one first yarn in an amount of 50% to 100% by weight based on the total amount of polymer fibers in at least one first yarn. In some other embodiments, the cut-resistant and heat-resistant polymer fibers are present in at least one first yarn in an amount of 80% to 100% by weight based on the total amount of polymer fibers in at least one first yarn. In another embodiment, the cut-resistant and heat-resistant polymer fibers are present in at least one first yarn in an amount of 80% to 95% by weight based on the total amount of polymer fibers in at least one first yarn.

[0029] In addition to the various exemplary proportions of cut-resistant and heat-resistant polymer fibers and non-cut-resistant and heat-resistant polymer fibers shown in Table 1, in some embodiments, at least one first yarn further comprises other synthetic or organic fibers or filaments that are not heat-resistant polymer fibers, i.e., do not meet the definition of heat-resistant polymer fibers as defined herein. Essentially any type of fiber can be included, as long as the final fabric meets the composition and performance criteria described herein. That is, the composition of at least one first yarn comprises at least 50% by weight of heat-resistant polymer fibers based on the total weight of polymer fibers in the first yarn, and at least 30% by weight of the polymer fibers are cut-resistant and heat-resistant fibers; the final fabric is a fire-resistant fabric having a maximum afterflame time of 2 seconds or less and a weight loss of 5% by weight or less when tested according to NFPA-2112-2018. Preferably, the fibers or filaments that are not heat-resistant polymer fibers are organic fibers, and in some embodiments, polymer-organic fibers. Also in some embodiments, the fibers or filaments that are not heat-resistant polymer fibers are synthetic or organic staple fibers, if present.

[0030] In some preferred embodiments, at least one first yarn may further contain fire-resistant fibers. “Fire-resistant fibers” means that a fabric made solely from the fabric has a carbonization length of 4 inches or less and an afterflame time of 2 seconds or less in a vertical burning test according to ASTM D6143-99, but the fabric does not meet the cut resistance criteria set forth herein for cut-resistant and heat-resistant polymer fibers. Suitable fire-resistant fibers include meta-aramid fibers, with poly(metaphenylene isophthalamide) being a preferred meta-aramid. Other potentially useful fire-resistant fibers include blends of meta-aramids, flame-retardant (FR) cellulose, FR cotton, FR lyocell, or mixtures thereof. In some embodiments, at least one first yarn has 30–70% by weight of fire-resistant fibers based on the total weight of polymer fibers in the first yarn. In some other preferred embodiments, at least one first yarn has 50–70% by weight of fire-resistant fibers based on the total weight of polymer fibers in the first yarn.

[0031] The heat-resistant polymer fiber and the cut-resistant heat-resistant polymer fiber in at least one first thread are both staple fibers, preferably having a length of about 2 to 20 cm, and preferably about 3.5 to 6 cm. The heat-resistant polymer fiber and the cut-resistant heat-resistant polymer fiber in at least one first thread are both staple fibers, preferably having a diameter of 5 to 25 μm and a linear density of 0.5 to 7 dtex. In some embodiments, if any fibers or filaments that are fire-resistant or not heat-resistant polymer fibers are present, they are staple fibers having dimensions similar to those of the heat-resistant polymer fiber and the cut-resistant heat-resistant polymer fiber described above.

[0032] In some embodiments, at least one first yarn contains at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first yarn, and at least 30% by weight of the polymer fibers present in at least one first yarn are cut-resistant heat-resistant polymer fibers having a cut resistance of 500 grams by weight or more according to ASTM F2992-15, and at least one first yarn further has a sheath / core structure having a sheath containing cut-resistant heat-resistant polymer fibers and a core containing inorganic fibers. In applications requiring or needing excellent cut resistance, at least one inorganic fiber is preferably added to the yarn. The reason for using a sheath / core structure is that the staple fibers of the sheath provide a covering and protect the inorganic filaments in the core from direct abrasion contact with the skin, thereby improving the comfort of the fabric containing the sheath / core yarn.

[0033] In some embodiments, when inorganic fibers are present in at least one first yarn, the inorganic fibers are present in an amount of 15–40% by weight of the total weight of the first yarn. Similarly, when inorganic fibers are present, the maximum amount of heat-resistant polymer fibers in the first yarn of these sheath-core is 85% by weight based on the total weight of the first yarn. In some preferred embodiments, the sheath / core yarn has 60–80% by weight of heat-resistant polymer fibers in the sheath and 20–40% by weight of organic fibers in the core. Preferably, the inorganic fibers in the core are steel or tungsten. Preferably, the fibers in the core exist as one or more continuous filaments.

[0034] Sheath fibers can be wound around or spun around an inorganic filament core. Specifically, this can be achieved by known means such as conventional ring spinning, including improvements to conventional processes such as those utilizing COTSON technology; core-spun spinning, such as DREF spinning; air-jet spinning with so-called core insertion by Murata (now Muratec) jet-like spinning; and open-end spinning. Preferably, the staple fibers are packed around the inorganic filament core to a density sufficient to cover the core. The degree of coverage varies depending on the process used for spinning the yarn; for example, core-spun spinning, such as DREF spinning (disclosed in U.S. Patents No. 4,107,909, 4,249,368, and 4,327,545, for example), yields better coverage than ring spinning. Conventional ring spinning only yields partial coverage of the central core, but even partial coverage can provide sufficient sheath / core coverage. The sheath may also contain some fibers from other materials, to the extent that the reduction in cut resistance due to those materials is acceptable.

[0035] The incorporation of at least one inorganic filament as the core in this embodiment of the first yarn can be achieved, for example, in its simplest practical use, by passing a roving, sliver, or aggregate of heat-resistant, cut-resistant fibers and optionally non-heat-resistant fibers through a set of draft rolls to form a drafted fiber mass that will be ring-twisted into a single yarn. The at least one inorganic filament is typically fed from a bobbin through a set of feed rolls and then fed to the staple fibers before a final set of draft rollers. Since the inorganic core filament is not an elastomer, there is no need to apply excessive tension when inserting it into the yarn; only sufficient tension is applied to either the sheath fibers or the core, as is conventionally done.

[0036] The sheath / core yarn consists of at least one first yarn, typically comprising 15-50% by weight of inorganic filaments having a total sheath / core yarn linear density of 100-5000 dtex. The core containing inorganic fibers may be a single filament or a multifilament, preferably a single metal filament or multiple metal filaments, depending on the specific application or the required or desired degree of protection from cuts. Metal filaments refer to filaments or wires made from ductile metals such as stainless steel, copper, aluminum, bronze, tungsten, or metal fiber structures commonly known as "microsteel." Stainless steel is a preferred metal. Metal filaments are generally continuous wires. Useful metal filaments have a diameter of 1-150 μm, preferably 25-75 μm.

[0037] In some embodiments, the inorganic fiber is a glass filament. This may be one or more glass filaments, such as a 110 dtex (100 denier) glass filament. However, glass is less preferable because it has lower cut resistance per unit linear density than metal, and it is far more important that the glass is adequately covered by a staple fiber sheath to minimize skin irritation when the thread is used in areas where the fabric comes into contact with the skin, such as gloves or sleeves. Therefore, in many embodiments, the inorganic fiber is a metal filament.

[0038] To reiterate, for these sheath / core yarns, it is understood that the cut-resistant and heat-resistant polymer fibers are both the heat-resistant polymer fibers and the cut-resistant fibers as defined herein. It is also understood that at least one first yarn may contain fibers that are heat-resistant polymer fibers as defined herein but not cut-resistant fibers as defined herein. Table 2 provides guidance for selected exemplary compositions regarding the possible percentage ratios of the total heat-resistant (CH-HR) polymer fibers and the total inorganic filaments in at least one first yarn, and further shows possible percentage ratios indicating the possible amounts of non-cut-resistant and heat-resistant (non-CR-HR) polymer fibers and cut-resistant and heat-resistant (CH-HR) polymer fibers.

[0039] [Table 2]

[0040] At least one second yarn has a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fibers and a core containing at least one continuous elastomer filament, wherein 60–95% by weight of at least one second yarn is halogenated self-extinguishing fiber based on the total weight of the second yarn, the halogenated self-extinguishing fiber is in contact with at least one continuous elastomer filament, and the second yarn contains or substantially no inorganic fibers.

[0041] At least one second thread has a sheath / core structure, where the sheath of the halogenated self-extinguishing staple fiber contacts and coats the core of at least one continuous elastomer filament. The halogenated self-extinguishing staple fiber is thought to provide an active fire-extinguishing coating to the core of at least one continuous elastomer filament. This is different from a cover fiber that provides "structural shielding" of the core, i.e., a cover fiber that simply carbonizes and remains in place when exposed to flame, thereby providing a structural barrier between the flame and the elastic core. Instead, the sheath of the halogenated self-extinguishing staple fiber decomposes in the presence of a high heat flux such as a flame, releasing halogen gases from the thread that replace localized oxygen, thus preventing the combustion of the core of at least one continuous elastomer filament. Therefore, it is thought that the halogenated self-extinguishing staple fiber needs to not only coat the core but also be in direct contact with the core to locally displace oxygen from the surface of the core of at least one continuous elastomer filament.

[0042] The sheath of halogenated self-extinguishing staple fibers can be wound around or spun around at least one continuous elastomer filament. This can be achieved by known means such as conventional ring spinning, including improvements on conventional processes such as those utilizing COTSON technology; core-spun spinning, such as DREF spinning; air-jet spinning with so-called core insertion by Murata (now Muratec) jet-like spinning; and open-end spinning. Preferably, the staple fibers are packed around the core of at least one continuous elastomer filament with sufficient density to cover the core. The degree of coverage varies depending on the process used for spinning the yarn; for example, core-spun spinning, such as DREF spinning (disclosed in U.S. Patents No. 4,107,909, 4,249,368, and 4,327,545, for example), yields better coverage than ring spinning. While conventional ring spinning only yields partial coverage of the central core, partial coverage is considered acceptable in this specification for sheath / core structures.

[0043] The fire-extinguishing effect of halogenated self-extinguishing staple fibers is considered appropriate when at least 60-95% by weight of one second thread, based on the total weight of the second thread, is halogenated self-extinguishing fiber. In some embodiments, it is desirable that at least 80-95% by weight of one second thread, based on the total weight of the second thread, is halogenated self-extinguishing fiber. The sheath may also contain fibers of other materials to a certain extent, up to the point where the reduction in fire-extinguishing effect due to the other materials is acceptable.

[0044] Halogenated self-extinguishing fibers include those manufactured from halogenated polymers. One particularly preferred halogenated self-extinguishing fiber is a fiber manufactured from modacryl polymer. "Modacryl polymer" preferably means a copolymer in which the polymer comprises 30-70% by weight of acrylonitrile and 70-30% by weight of halogen-containing vinyl monomer. The halogen-containing vinyl monomer is at least one monomer selected from, for example, vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, etc.

[0045] In some embodiments, the modacryl copolymer is acrylonitrile combined with vinylidene chloride. In some embodiments, the modacryl copolymer further contains antimony oxide or antimony oxides. In some preferred embodiments, the modacryl copolymer has less than 1.5 wt percent antimony oxide, or the copolymer is completely antimony-free. By limiting or completely eliminating any antimony compounds added to the copolymer during manufacturing, polymers with very low antimony content and antimony-free polymers can be produced. Representative processes for modacryl polymers, including those that can be modified in this way, are disclosed in U.S. Patent No. 3,193,602, which contains 2 wt% antimony trioxide; U.S. Patent No. 3,748,302, which is manufactured using various antimony oxides present in amounts not exceeding 2 wt%, preferably 8 wt%; and U.S. Patents Nos. 5,208,105 and 5,506,042, which contain 8 to 40 wt% antimony compounds. In some embodiments, the modacryl polymer has at least 26 lines of interest (LOIs). In one preferred embodiment, the modacryl polymer has at least 26 LOIs but does not contain antimony.

[0046] The halogenated self-extinguishing staple fiber in at least one second thread is preferably a staple fiber having a length of about 2 to 9 cm, preferably about 3.5 to 6 cm. The halogenated self-extinguishing staple fiber in at least one second thread is preferably a staple fiber having a diameter of 5 to 25 μm and a linear density of 0.5 to 7 dtex.

[0047] The fabric includes at least one second yarn having a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fibers and a core containing at least one continuous elastomer filament. The halogenated self-extinguishing fibers are in contact with at least one continuous elastomer filament, eliminating the need for the entire surface of the elastomer filament to be actually completely covered by the staple fiber sheath.

[0048] In some embodiments, when viewed under a microscope with the thread relaxed, i.e., when no tension is applied to the sheath-core thread, preferably at least 90% of the core is covered by the sheath. The actual coverage of the core may vary depending on the degree of tension applied to the thread. However, as long as modacrylic is in contact with the elastomer core, modacrylic is considered to exert a shielding effect.

[0049] In some embodiments, 5 to 40% by weight of the total weight of at least one second yarn is at least one continuous elastomer filament. In some embodiments, the ring-spun second yarn has a core comprising at least one elastomer filament and a partial coating of halogenated self-extinguishing staple fibers. In some preferred embodiments, the core of elastomer filaments constitutes 5 to 25% by weight of the total sheath / core single-fiber density of 100 to 1500 dtex.

[0050] As used herein, “core comprising at least one continuous elastomer filament” means a core formed from or containing elastomer filaments, which preferably has the ability to quickly return to its original length after being repeatedly stretched to at least twice its original length. Preferred elastomer cores include polyurethane-based yarns such as spandex or elastane, but any fiber generally having elasticity and resilience can be used. Suitable well-known elastomer yarns include products marketed under the trade names Dorlastan® and Lycra®.

[0051] A preferred continuous elastomer filament is a spandex fiber. As used herein, “spandex” has its usual definition, namely, a manufactured fiber in which the fiber-forming material is a long-chain synthetic polymer composed of at least 85% by weight of segmented polyurethane. Examples of spandex-type segmented polyurethanes include those described in U.S. Patent Nos. 2,929,801; 2,929,802; 2,929,803; 2,929,804; 2,953,839; 2,957,852; 2,962,470; 2,999,839; and 3,009,901.

[0052] In some processes for producing spandex elastomer filaments, coalescing jets are used to solidify the spandex filament immediately after extrusion. It is also well known that dry-spun spandex filaments are sticky immediately after extrusion. The combination of joining such sticky filaments together and using coalescing jets produces fused multifilament yarn, which is then typically coated with silicone or other finishing agents before winding to prevent sticking in the package. In reality, such fused filament groupings, which are numerous very small individual filaments that adhere to each other along their length, are superior in many ways to a single filament of spandex of the same linear density.

[0053] The elastomer filaments in the elastomer monofilament are preferably continuous filaments and may exist in the second filament as one or more individual filaments or as one or more fused filament groups. However, in a preferred elastomer monofilament, it is preferable to use only one fused filament group. Regardless of whether they exist as one or more individual filaments or one or more fused filament groups, the overall linear density of the elastomer filaments in a relaxed state is generally 17 to 560 dtex (15 to 500 denier), with a preferred linear density range of 44 to 220 dtex (40 to 200 denier).

[0054] It is preferable to incorporate at least one continuous elastomer filament into the second yarn under tension by stretching or elongating at least one continuous elastomer filament before combining it with the staple fibers by using a transport speed slower than the final second yarn speed. This stretching can be described as the elongation ratio of the continuous elastomer filament, which is the final second yarn speed divided by the transport speed of the continuous elastomer filament.

[0055] A typical stretch ratio is between 1.5 and 5.0, with 1.5 to 3.50 being preferable. A low stretch ratio results in poor elastic recovery, while a very high stretch ratio makes processing the single yarn difficult and results in a fabric that is too tight and uncomfortable. The optimal stretch ratio also depends on the weight percentage content of the elastomer core. While tensioning devices can be used to apply tension to and stretch the elastomer fibers, this is not preferred due to the difficulty in reproducing and controlling tension and stretch. Ultimately, the optimal stretch ratio is determined for each fabric based on the desired fit and feel.

[0056] Incorporating at least one continuous elastomer filament into a second yarn of halogenated self-extinguishing staple fiber can be achieved, for example, in its simplest practical application, by passing a roving, sliver, or aggregate of halogenated self-extinguishing staple fiber through a set of draft rolls to form a drafted fiber mass that will be ring-twisted into single yarns. At least one continuous elastomer filament is typically fed from a bobbin through a set of feed rolls and then fed into the staple fiber before a final set of draft rollers. The slowness of the feed roller's surface velocity relative to the draft roller's surface velocity is increased or decreased using conventional techniques to determine the amount of elastic stretch and tension of the final ring-twisted single yarn.

[0057] In some embodiments, the sheath of at least one second thread may further include heat-resistant polymer fibers as described herein. In some other embodiments, the sheath of at least one second thread may further include cut-resistant heat-resistant polymer fibers as described herein.

[0058] In some embodiments, the sheath of at least one second yarn may further contain fire-resistant fibers. “Fire-resistant” means that a fabric made solely from that fiber has a carbonization length of 4 inches or less and an afterburn time of 2 seconds or less in a vertical burning test according to ASTM D6143-99. Suitable fire-resistant fibers include aramid fibers, with meta-aramid fibers being particularly preferred. A preferred meta-aramid is poly(metaphenylene isophthalamide). Potentially useful fire-resistant fibers include meta-aramid, polyamide-imide, flame-retardant (FR) cellulose, FR cotton, FR lyocell, or mixtures thereof. In some embodiments, at least one second yarn has fire-resistant fibers, preferably 5% to 35% by weight based on the total weight of polymer fibers in at least one second yarn. Also in some embodiments, at least one first yarn also has fire-resistant fibers, preferably 5% to 35% by weight based on the total weight of polymer fibers in at least one first yarn.

[0059] Any number of fibers can be included in the second yarn, as long as the second yarn and the final fabric meet the performance standards described herein.

[0060] When used in the second thread, the heat-resistant polymer fiber, cut-resistant heat-resistant polymer fiber, or fire-resistant fiber is preferably a staple fiber having a length of about 2 to 20 cm, preferably about 3.5 to 6 cm. Also, when used in the second thread, the heat-resistant polymer fiber, cut-resistant heat-resistant polymer fiber, and fire-resistant fiber is preferably a staple fiber having a diameter of 5 to 25 μm and a linear density of 0.5 to 7 dtex.

[0061] In some embodiments, the sheath of at least one second yarn may further include fibers known in the art as antistatic fibers, or fibers having the ability to reduce charge accumulation in the yarn or the resulting fabric. In some preferred embodiments, the sheath of at least one second yarn contains at least 1 to 5% by weight of antistatic fibers based on the total weight of at least one second yarn. Preferred antistatic fibers are fibers that function by the presence of carbon within the fiber as a carbon coating or carbon particles; in particular, antistatic fibers are useful for removing charge accumulation but are not considered conductive in a practical sense. In some embodiments, aramid fibers containing carbon particles are preferred.

[0062] In preferred embodiments, the second yarn contains or substantially no inorganic fibers. Since the cut resistance benefits of inorganic fibers are obtained by the first yarn, the need to add inorganic fibers to the second yarn is eliminated for most intended applications.

[0063] In some embodiments, the twisted yarn is formed from at least a first yarn and at least a second yarn. The twisted yarn is produced by twisting together at least two separate single yarns. The phrase "twisting together at least two separate single yarns" means that the two single yarns are twisted together without one yarn completely covering the other. This distinguishes the twisted yarn from a covered or wrapped yarn in which the first single yarn is substantially or completely wrapped around the second single yarn so that, ideally, only the first single yarn is exposed on the surface of the resulting covered yarn.

[0064] In a preferred embodiment, the plied yarn is made from at least two single yarns, the first single yarn being (a) at least one first yarn containing at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first yarn, and at least 30% by weight of the polymer fibers present in the at least one first yarn being ASTM A cut-resistant and heat-resistant polymer fiber having cut resistance of 500 grams by weight or more according to F2992-15, wherein at least one first yarn further has a sheath / core structure, the sheath comprising cut-resistant and heat-resistant polymer fibers and the core comprising inorganic fibers; a second monofilament is at least one second yarn having a sheath / core structure comprising (b) a sheath of halogenated self-extinguishing staple fibers and a core comprising at least one continuous elastomer filament, wherein 60-95% by weight of at least one second yarn, based on the total weight of the second yarn, is halogenated self-extinguishing fiber, the halogenated self-extinguishing fiber is in contact with at least one continuous elastomer filament, and the second yarn does not contain or substantially contains inorganic fibers. Each monofilament may have some twist.

[0065] In some embodiments, a plied yarn made from two single filaments has a total linear density of 200 to 3000 dtex. Each individual staple fiber of either single filament may have a linear density of 0.5 to 7 dtex, with a preferred linear density range of 1.5 to 3 dtex. The plied yarns, and the single filaments constituting them, may contain other materials, provided that the function or performance of the yarn or the fabric made from it is not impaired for the desired application.

[0066] Plyed yarns can be produced from monofilaments by the process disclosed in Prickett's U.S. Patent No. 6,952,915, and plyed yarns can have the wide range of plying disclosed therein.

[0067] Subsequently, the plied yarns can be combined with other identical or different plied yarns to form yarn bundles and create fabric, or the individual plied yarns can be used to create fabric according to the requirements of the desired fabric. For example, two or more of the described plied yarns can be combined to form yarn bundles that can be supplied to a knitting machine with or without twist. Alternatively, the yarn bundles can be manufactured using one or more of the above plied yarns with one or more different single yarns to impart the desired properties to the final fabric. Modern knitting machines can be supplied with multiple plied yarns to knit fabric, so the bundles of plied yarn supplied to the machine do not need to be twisted, but twist can be added to the bundles if necessary.

[0068] In the absence of an inorganic core, the preferred plied yarn is preferably a ring-spun 420 dtex (380 denier, equivalent to cotton count 14) single yarn. This yarn has a poly(paraphenylene terephthalamide) (PPD-T) staple sheath, and the PPD-T has a cut length of 3.8 cm (1.5 inches) and a filament density of 1.7 dtex (1.5 denier per filament).

[0069] The preferred plied yarn uses at least one second yarn, which is a ring-spun 330 dtex (295 denier, equivalent to cotton count 18) monofilament. This yarn has a modacrylic staple sheath that at least partially covers the elastomer core filament, the modacrylic staple having a cut length of 4.8 cm (1.89 inches) and a filament density of 1.7 dtex (1.5 denier per filament). The elastomer core is a 78 dtex (70 denier) spandex fused filament yarn with a stretch ratio of 3.0 times (approximately 200 percent elongation). In some preferred embodiments, approximately 92% by weight of the second yarn consists of modacrylic staple and 8% by weight of the second yarn is the elastomer core.

[0070] The present invention also relates to a cut-resistant woven or knitted fabric made from a yarn or bundle of yarns comprising at least one first yarn and one second yarn. The present invention further relates to a cut-resistant woven or knitted fabric made from a plied yarn or bundle of yarns comprising plied yarns, wherein the plied yarn comprises at least one first yarn and one second yarn as described herein.

[0071] Specifically, the present invention relates to a cut-resistant woven or knitted fabric made from a twisted yarn produced from at least two single yarns, wherein the first single yarn is (a) at least one first yarn containing at least 50% by weight of heat-resistant polymer fibers based on the total weight of the first yarn, and at least 30% by weight of the polymer fibers present in the at least one first yarn is ASTM The fabric is a cut-resistant, heat-resistant polymer fiber having cut resistance of 500 grams by weight or more according to F2992-15; the second single yarn is (b) at least one second yarn having a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fibers and a core containing at least one continuous elastomer filament, wherein 60-95% by weight of at least one second yarn is halogenated self-extinguishing fiber based on the total weight of the second yarn, the halogenated self-extinguishing fiber is in contact with at least one continuous elastomer filament, and the second yarn contains no or substantially no inorganic fibers; the fabric has a maximum afterflame time of 2 seconds or less and a weight loss of 5% by weight or less when tested according to NFPA-2112-2018.

[0072] In some embodiments, the first single yarn further comprises at least one first yarn having a sheath / core structure comprising a sheath containing cut-resistant and heat-resistant polymer fibers and a core containing inorganic fibers.

[0073] At least one first thread and at least one second thread function synergistically in both the thread and the fabric. At least one continuous elastomer filament incorporated into the thread provides improved stretchability and resilience, while heat-resistant staple fibers provide structure in fire, and heat-resistant cut-resistant organic staple fibers and inorganic filaments (if present) provide excellent cut resistance to both the thread and the fabric. Fabrics made from such threads are soft, comfortable, abrasion-resistant, and cut-resistant.

[0074] Twisting the first yarn with the second yarn is preferable because it helps the elastomer monofilament maintain its elongated state without looping when relaxed. However, if the sheath / core elastomer monofilament is supplied simultaneously (without twisting) in bundles with other monofilaments to a knitting or weaving machine with good tension control, an acceptable fabric can be produced. When the bundles consist of twisted yarns, tension control of the yarn during knitting and weaving is not as critical.

[0075] The preferred fabric is a knitted fabric, and any suitable knit pattern is acceptable. Cut resistance and comfort are influenced by the tightness of the knit, which can be adjusted to meet any specific requirements. A very effective combination of cut resistance and comfort in many cut-resistant articles has been found, for example, in single jersey knit patterns and terry knit patterns. The fabric should be approximately 4-30 oz / yd 2 Preferably 6-25 oz / yd 2 Having a basis weight, and when the fabric is at the upper limit of the basis weight range, it provides higher cold protection and protection from cuts.

[0076] Test method Afterflame and weight reduction were determined according to the procedure outlined in NFPA 2112-2018 "Standard on Flame-Resistant Clothing for Protection of Industrial Personnel Against Short-Duration Thermal Exposures from Fire," specifically in section 8.8 of the standard.

[0077] The determination of “heat-resistant polymer fibers” as described herein can be made using ASTM E2105-2016-Standard Practice for General Techniques of Thermogravimetric Analysis (TGA) Coupled With Infrared Analysis (TGA / IR). Analysis to determine whether the synthetic organic polymer retains 90 percent of the original fiber weight is performed by heating the sample in air at a rate of 20°C per minute up to 500°C. [Examples]

[0078] Knitwear made from blended yarn Plyed yarns and knitted products made from them are illustrated in Examples 1, 2, and 3, and Comparative Example A, and summarized in Table 6.

[0079] Example 1 The twisted elastomer yarn was manufactured by twisting a first yarn and a second yarn together. The first yarn was a 14-count cotton sheath-core yarn having a para-aramid fiber sheath and a 50-micron stainless steel wire core, spun on a ring spinning machine. The para-aramid fiber was a 2-inch poly(paraphenylene terephthalamide) staple.

[0080] The second yarn was an 18-count cotton sheath-core yarn produced by core spinning a 2-inch modacrylic staple around a 70-denier spandex core using a ring spinning machine. The spandex core was stretched three times when incorporated (spun) into the sheath-core yarn.

[0081] The resulting twisted elastic yarn, produced by twisting the first and second yarns together, had a total cotton count of 16 / 2, or 675 denier. The relative amounts of the yarn components are shown in Table 3.

[0082] The resulting twisted elastic yarn was knitted into a 13-gauge sleeve using a Shima-Seiki glove knitting machine. The resulting sleeve had excellent feel and shape fit. Fabric samples from the resulting sleeve were subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting elastic fabric was found to have consumed 4.8% of its weight during the test, with 0 seconds of afterflame. This was below the maximum afterflame requirement of 2 seconds and the weight loss limit of 5% permitted by the standard.

[0083] [Table 3]

[0084] Example 2 The twisted elastic yarn of Example 1 was repeated, with the following exceptions.

[0085] The first yarn was a 26-count cotton yarn having a para-aramid fiber sheath and a stainless steel wire core made of 35-micron stainless steel wire. The second yarn was a 32-count cotton yarn having a modacrylic sheath and a 40-denier spandex core that was tripled during spinning.

[0086] Similar to Example 1, the resulting twisted elastic yarn, produced by twisting the first and second yarns together, had a total cotton count of 29 / 2, or 371 denier. The relative amounts of the yarn components are shown in Table 4.

[0087] The resulting twisted elastic yarn was knitted into an 18-gauge sleeve using a Shima-Seiki glove knitting machine. The resulting sleeve exhibited excellent shape-fitting properties. Fabric samples from the resulting sleeves were washed to remove knitting oil and finishing agents, and then subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting elastic fabric was found to have consumed 3.3% of its weight during the test, with a 0-second afterflame. This was below the standard's allowable maximum afterflame requirement of 2 seconds and weight loss limit of 5%.

[0088] [Table 4]

[0089] Example 3 The twisted elastic yarn of Example 1 was repeated, with the following exceptions.

[0090] The first yarn was a 19.5 cotton count yarn having a para-aramid fiber sheath and a stainless steel wire core made from a 45-micron stainless steel wire core that was triple-stretched during spinning. The second yarn was a 32 cotton count sheath-core yarn with a 40-denier spandex core. However, the sheath was a blend of 82 wt% modacrylic staple fibers and 10 wt% meta-aramid staple fiber blend with a cut length of 2 inches. Specifically, the meta-aramid blend contained 93 wt% poly(methaphenylene isophthalamide) staple fibers, 5 wt% poly(paraphenylene terephthalamide) staples, and 2 wt% carbon core nylon antistatic fibers.

[0091] Similar to Example 1, the resulting twisted elastic yarn, produced by twisting the first and second yarns together, had a total cotton count of 24 / 2, or 439 denier. The relative amounts of the yarn components are shown in Table 5.

[0092] The resulting twisted elastic yarn was knitted into an 18-gauge sleeve using a Shima-Seiki glove knitting machine. The resulting sleeve exhibited excellent shape-fitting properties.

[0093] The fabric samples of the manufactured sleeves were washed to remove knitting oil and finishing agents, and then subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretchable fabric was found to have consumed 3.9% of its weight during the test, with a 0-second afterflame. This was below the standard's allowable maximum afterflame requirement of 2 seconds and a 5% weight loss limit.

[0094] Another fabric sample of the manufactured sleeve was subjected to a combustion test according to the fire-resistant glove test method detailed in the EN407:2020 standard. The resulting stretchable fabric was found to have zero afterflame and zero dust after 3 and 15 seconds of exposure to flame. This was below the maximum afterflame requirement of 2 seconds and the maximum dust requirement of 5 seconds required to achieve the highest rank specified in the standard.

[0095] [Table 5]

[0096] Comparative example A A comparative twisted elastic yarn similar to that of Example 3 was manufactured. However, the first yarn, which had a para-aramid fiber sheath and a stainless steel wire core, was manufactured using 1.5-inch poly(paraphenylene terephthalamide) staples and a 45-micron stainless steel wire core. Similarly, the second yarn, which was also a 32 cotton count sheath-core yarn, had a sheath consisting only of 1.5-inch cut nylon staples core-spun around a 40-denier spandex core.

[0097] The resulting 24 / 2 count plied yarn was knitted into an 18-gauge sleeve using a Shima-Seiki glove knitting machine. The resulting sleeve exhibited excellent shape-fitting properties.

[0098] However, the manufactured samples were subjected to a combustion test according to the fire-resistant glove test method detailed in the EN407:2020 standard. The resulting stretchable fabric was found to have an afterflame of at least 25 seconds after being exposed to flame for 3 seconds. This was longer than the maximum afterflame requirement of 20 seconds required to achieve the lowest rank specified in the standard.

[0099] Because excessive afterflame was generated with only 3 seconds of flame exposure, subsequent tests for both the 15-second exposure in the EN407 test and the 12-second exposure in the NFPA-2112 test were not performed.

[0100] [Table 6]

[0101] Knitwear is produced by interweaving two parallel warp threads. Examples of knitted products produced by supplying individual warp threads or bundles of individual warp threads to a knitting machine and interweaving the threads are shown in Example 4 and Comparative Example B, and are summarized in Table 4.

[0102] Example 4 The first warp (a two-ply para-aramid ring-spun yarn, each ply manufactured from a 2-inch poly(paraphenylene terephthalamide) staple yarn, with each of the two plies being 16 cotton count) was interwoven with the second warp, which was an 18 cotton count sheath-core yarn from Example 1.

[0103] Next, these two warp threads were interwoven into a sleeve using a 13-gauge knitting machine. The resulting sleeve had excellent feel and shape fit.

[0104] Fabric samples of the manufactured sleeves were washed to remove knitting oil and finishing agents, and then subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretchable fabric was found to have consumed 2.5% of its weight during the test, with a 0-second afterflame. This was below the standard's permitted maximum afterflame requirement of 2 seconds and weight loss limit of 5%.

[0105] Comparative example B The warp threads of 12-count cotton modacrylic ring-spun yarn, manufactured from 2-inch modacrylic staples, were interwoven with the warp threads of 18-count cotton sheath-core yarn from Example 1. These two warp threads were interwoven into a sleeve on a 13-gauge knitting machine. The resulting sleeve had excellent feel and shape fit.

[0106] The manufactured samples were washed to remove knitting oil and finishing materials, and then subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretchable fabric was found to have consumed 5.8% of its weight during the test, with an afterflame duration of 2.3 seconds. This exceeded the standard's allowable maximum afterflame requirement of 2 seconds and a 5% weight loss limit.

[0107] [Table 7]

[0108] Knitwear manufactured by inserting weft threads Examples of knitted fabrics produced by interweaving yarns through weft insertion are shown in Example 3 and Comparative Examples B and C, and are summarized in Table 4.

[0109] Example 5 Fire-resistant yarn was produced by interweaving a first warp (a two-ply para-aramid ring-spun yarn, each ply manufactured from a 2-inch poly(paraphenylene terephthalamide) staple yarn, with each of the two plies being 16 cotton count) with a second warp (a modacrylic sheath-spandex core elastic yarn, manufactured by ring-spinning a 1200 denier core-spun fiber and a 440 denier spandex core, which was stretched three times during the yarn spinning process). The composition of the elastic core yarn was approximately 12% spandex and approximately 88% modacrylic staple fiber.

[0110] Using a weft insertion technique that inserts modacrylic sheath-spandex core elastic yarn every three stitches, the first and second warp threads were interwoven into a 13-gauge knitted cuff on a Shima-Seiki flat knitting machine. The resulting sleeve exhibited excellent shape fit.

[0111] The manufactured samples were washed to remove knitting oil and finishing materials, and then subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretchable fabric was found to have consumed 4% of its weight during the test, with no afterflame for 0 seconds. This was below the maximum afterflame requirement of 2 seconds and the weight loss limit of 5% permitted by the standard.

[0112] Comparative example C In Example 5, the first warp of a two-ply para-aramid ring-spun yarn was combined with a different second warp. This second warp was a rubber elastic cord wrapped and coated with polyester fibers from Supreme Elastic Corporation. The first and second warps were interknitted on a Shima-Seiki flat knitting machine to produce an elastic cuff. The composition of the elastomer cord was estimated to be 75% polyester fiber and 25% rubber. The warps were interknitted using a weft insertion technique in which the rubber elastic cord wrapped and coated with polyester fibers was inserted every three stitches of a 13-gauge knitted cuff. The resulting sleeve exhibited excellent shape fit.

[0113] Fabric samples of the manufactured sleeves were washed to remove knitting oil and finishing agents, and then subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretchable fabric was found to have consumed 9% of its weight during the test, with an afterflame of 43 seconds. This exceeded the limits of a maximum afterflame of 2 seconds and a weight loss of 5% permitted by the standard.

[0114] Comparative example D Four warp threads of ring-spun yarn, each thread being 35 cotton count and manufactured from 2-inch modacrylic staples, were interwoven with a sheath-core elastic yarn having a modacrylic sheath and a spandex core. The sheath-core elastic yarn was manufactured by ring-spinning 1200-denier modacrylic staple yarn with a 440-denier spandex core, and by stretching the spandex three times during spinning, a sheath-core elastic yarn with a composition of approximately 12% spandex and 88% modacrylic staple fiber was produced. The elastic yarn was interwoven using a weft insertion technique every three stitches of a 13-gauge knitted sleeve knitted on a glove knitting machine. The resulting sleeve exhibited excellent shape fit.

[0115] Fabric samples of the manufactured sleeves were washed to remove knitting oil and finishing agents, and then subjected to a combustion test according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretchable fabric was found to have consumed 10% of its weight during the test, with no afterflame. This was below the maximum afterflame requirement of 2 seconds allowed by the standard, but exceeded the limit of 5% weight loss.

[0116] [Table 8] This disclosure includes the following embodiments. <Embodiment 1> (a) at least one first yarn containing at least 50% by weight of heat-resistant polymer fibers based on the total weight of polymer fibers in the first yarn, wherein at least 30% by weight of the polymer fibers present in the at least one first yarn are cut-resistant heat-resistant polymer fibers having a cut resistance of 500 grams by weight or more according to ASTM F2992-15; and (b) At least one second thread having a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fiber and a core containing at least one continuous elastomer filament; A fire-resistant and cut-resistant fabric containing, Based on the total weight of the second yarn, 60 to 95% by weight of at least one second yarn is halogenated self-extinguishing fiber, the halogenated self-extinguishing fiber is in contact with at least one continuous elastomer filament, and the second yarn contains or substantially no inorganic fibers; A fire-resistant and cut-resistant fabric, which, when tested according to NFPA-2112-2018, has a maximum afterflame time of 2 seconds or less and a weight loss of 5% by weight or less. <Embodiment 2> The fabric according to Embodiment 1, wherein the at least one first thread has a sheath / core structure comprising a sheath containing the cut-resistant, heat-resistant polymer fiber and a core containing inorganic fibers. <Embodiment 3> The fabric according to Embodiment 1 or 2, wherein the heat-resistant polymer fiber or the cut-resistant heat-resistant polymer fiber is an aramid copolymer, para-aramid, polybenzazole, polybenzimidazole, polyimide, or a mixture thereof. <Embodiment 4> The fabric according to Embodiment 3, wherein the heat-resistant polymer fiber or the cut-resistant heat-resistant polymer fiber is paraaramid. <Embodiment 5> The fabric according to Embodiment 3, wherein the para-aramid fiber is poly(paraphenylene terephthalamide). <Embodiment 6> The fabric according to any one of embodiments 1 to 5, wherein at least one of the first threads further comprises a fire-resistant fiber that is not cut-resistant. <Embodiment 7> The fabric according to Embodiment 6, wherein the fire-resistant fiber is meta-aramid, polyamide-imide, flame-retardant (FR) cellulose, FR cotton, FR lyocell, or a mixture thereof. <Embodiment 8> The fabric according to Embodiment 7, wherein the fire-resistant fiber is meta-aramid. <Embodiment 9> The fabric according to Embodiment 8, wherein the meta-aramid is poly(metaphenylene isophthalamide). <Embodiment 10> The fabric according to any one of embodiments 1 to 9, wherein 80 to 95% by weight of the total weight of at least one second yarn is the halogenated self-extinguishing fiber. <Embodiment 11> The fabric according to any one of Embodiments 1 to 10, wherein the halogenated self-extinguishing fiber is a modacrylic fiber. <Embodiment 12> The fabric according to any one of embodiments 1 to 11, wherein 5 to 40% by weight of the total weight of the at least one second yarn is the at least one continuous elastomer filament. <Embodiment 13> The fabric according to any one of embodiments 1 to 12, wherein the at least one continuous elastomer filament is a spandex filament. <Embodiment 14> The fabric according to any one of embodiments 1 to 13, wherein the inorganic fibers are metal filaments. <Embodiment 15> The fabric according to any one of embodiments 1 to 14, wherein the inorganic fiber is a glass filament. <Embodiment 16> The fabric according to any one of embodiments 1 to 15, wherein the sheath of the at least one second thread further comprises heat-resistant polymer fibers. <Embodiment 17> The fabric according to any one of embodiments 1 to 16, wherein the sheath of at least one second thread further comprises a fire-resistant fiber that is not cut-resistant. <Embodiment 18> The fabric according to Embodiment 17, wherein the fire-resistant fiber is meta-aramid, polyamide-imide, flame-retardant (FR) cellulose, FR cotton, FR lyocell, or a mixture thereof. <Embodiment 19> The fabric according to Embodiment 18, wherein the fire-resistant fiber is meta-aramid. <Embodiment 20> The fabric according to Embodiment 19, wherein the meta-aramid is poly(metaphenylene isophthalamide). <Embodiment 21> The fabric according to any one of embodiments 1 to 20, wherein the sheath of the at least one second thread further comprises an antistatic fiber. <Embodiment 22> The fabric according to any one of embodiments 1 to 21, comprising a twisted yarn of at least one first yarn and at least one second yarn. <Embodiment 23> The fabric according to any one of Embodiments 1 to 22, wherein the aforementioned fabric is a knitted fabric. <Embodiment 24> The fabric according to any one of embodiments 1 to 21, having a cross-knit structure of at least one first yarn and at least one second yarn. <Embodiment 25> The fabric according to embodiment 24, wherein the at least one first yarn and the at least one second yarn are in a parallel relationship with each other in the interwoven structure. <Embodiment 26> The fabric according to embodiment 24, wherein the at least one second yarn is a weft insertion in the interwoven structure. <Embodiment 27> A glove or other article comprising the fabric described in any one of Embodiments 1 to 26.

Claims

1. (a) at least one first yarn containing at least 50% by weight of heat-resistant polymer fibers based on the total weight of polymer fibers in the first yarn, wherein at least 30% by weight of the polymer fibers present in the at least one first yarn are cut-resistant heat-resistant polymer fibers having cut resistance of 500 grams by weight or more according to ASTM F2992-15, and the at least one first yarn has a sheath / core structure comprising a sheath containing the cut-resistant heat-resistant polymer fibers and a core containing inorganic fibers; and (b) At least one second thread having a sheath / core structure comprising a sheath of halogenated self-extinguishing staple fiber and a core containing at least one continuous elastomer filament; A fire-resistant and cut-resistant fabric containing, Based on the total weight of the second yarn, 60 to 95% by weight of at least one second yarn is halogenated self-extinguishing fiber, the halogenated self-extinguishing fiber is in contact with at least one continuous elastomer filament, and the second yarn does not contain or substantially contains inorganic fibers; A fire-resistant and cut-resistant fabric, which, when tested according to NFPA-2112-2018, has a maximum afterflame time of 2 seconds or less and a weight loss of 5% by weight or less.

2. The fabric according to claim 1, wherein the heat-resistant polymer fiber or the cut-resistant heat-resistant polymer fiber is an aramid copolymer, para-aramid, polybenzazole, polybenzimidazole, polyimide, or a mixture thereof.

3. The fabric according to claim 1 or 2, wherein the at least one first thread further comprises a fire-resistant fiber that is not cut-resistant.

4. The fabric according to claim 3, wherein the fire-resistant fiber is meta-aramid, polyamide-imide, flame-retardant (FR) cellulose, FR cotton, FR lyocell, or a mixture thereof.

5. The fabric according to claim 4, wherein the fire-resistant fiber is meta-aramid.

6. The fabric according to any one of claims 1 to 5, wherein 80 to 95% by weight of the total weight of at least one second yarn is the halogenated self-extinguishing fiber.

7. The fabric according to any one of claims 1 to 6, wherein the halogenated self-extinguishing fiber is a modacrylic fiber.

8. The fabric according to any one of claims 1 to 7, wherein the inorganic fiber is a metal filament.

9. The fabric according to any one of claims 1 to 8, wherein the inorganic fiber is a glass filament.

10. The fabric according to any one of claims 1 to 9, wherein the sheath of the at least one second thread further comprises heat-resistant polymer fibers.

11. The fabric according to any one of claims 1 to 10, wherein the sheath of the at least one second thread further comprises a fire-resistant fiber that is not cut-resistant.

12. The fabric according to any one of claims 1 to 11, comprising a twisted yarn of at least one first yarn and at least one second yarn.

13. The fabric according to any one of claims 1 to 12, wherein the aforementioned fabric is a knitted fabric.

14. The fabric according to any one of claims 1 to 11, having a cross-knit structure of at least one first yarn and at least one second yarn.

15. A glove or sleeve comprising the fabric described in any one of claims 1 to 14.

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