HIGH VISIBILITY YARNS AND FABRICS AND METHODS RELATING THERETO
Described herein are high visibility yarns and fabrics along with methods and making and using the same.
The present invention relates to high visibility yarns and fabrics along with methods of making and using the same.
BACKGROUNDHigh visibility fabrics are used in a number of settings for safety. Fabrics providing high visibility and desirable properties for wear, laundering, and safety are desired.
SUMMARYA first aspect of the present invention is directed to a yarn comprising: a blend of fibers, the blend of fibers comprising: about 90% to about 99% fiber dyed modacrylic fibers by weight of the yarn; about 0% to about 10% para-aramid fibers by weight of the yarn; and about 0% to about 2% anti-static fibers by weight of the yarn, wherein at least one of para-aramid fibers and anti-static fibers is present in the yarn.
A further aspect of the present invention is directed to a fabric comprising a yarn as described herein.
Another aspect of the present invention is directed to a fabric comprising: a plurality of yarns, wherein each yarn of the plurality of yarns comprises fiber dyed modacrylic fibers blended with para-aramid fibers and/or anti-static fibers, wherein the fabric comprises: about 90% to about 99% fiber dyed modacrylic fibers by weight of the fabric; about 0% to about 10% para-aramid fibers by weight of the fabric; and about 0% to about 2% anti-static fibers by weight of the fabric.
Another aspect of the present invention is directed to use of a yarn as described herein in forming a fabric and/or garment (e.g., a shirt, pant, vest, jacket, etc.).
Another aspect of the present invention is directed to use of a fabric as described herein in forming a garment (e.g., a shirt, pant, vest, jacket, etc.).
It is noted that aspects of the invention described with respect to one embodiment, may be incorporated in a different embodiment although not specifically described relative thereto. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination. Applicant reserves the right to change any originally filed claim and/or file any new claim accordingly, including the right to be able to amend any originally filed claim to depend from and/or incorporate any feature of any other claim or claims although not originally claimed in that manner. These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below. Further features, advantages and details of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments that follow, such description being merely illustrative of the present invention.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTSThe present invention is now described more fully hereinafter in which embodiments of the invention are described. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art.
The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the present application and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. In case of a conflict in terminology, the present specification is controlling.
Also as used herein, “and/or” refers to and encompasses any and all possible combinations of one or more of the associated listed items, as well as the lack of combinations when interpreted in the alternative (“or”).
Unless the context indicates otherwise, it is specifically intended that the various features of the invention described herein can be used in any combination. Moreover, the present invention also contemplates that in some embodiments of the invention, any feature or combination of features set forth herein can be excluded or omitted. To illustrate, if the specification states that a complex comprises components A, B and C, it is specifically intended that any of A, B or C, or a combination thereof, can be omitted and disclaimed.
As used herein, the transitional phrase “consisting essentially of” (and grammatical variants) is to be interpreted as encompassing the recited materials or steps “and those that do not materially affect the basic and novel characteristic(s)” of the claimed invention. See, In re Herz, 537 F.2d 549, 551-52, 190 U.S.P.Q. 461, 463 (CCPA 1976) (emphasis in the original); see also MPEP § 2111.03. Thus, the term “consisting essentially of” as used herein should not be interpreted as equivalent to “comprising.”
The term “about,” as used herein when referring to a measurable value such as an amount or concentration and the like, is meant to encompass variations of ±10%, ±5%, ±1%, ±0.5%, or even ±0.1% of the specified value as well as the specified value. For example, “about X” where X is the measurable value, is meant to include X as well as variations of ±10%, ±5%, ±1%, ±0.5%, or even ±0.1% of X. A range provided herein for a measurable value may include any other range and/or individual value therein.
As used herein, the terms “increase,” “increases,” “increased,” “increasing,” and similar terms indicate an elevation in the specified parameter or value of at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 150%, 200%, 300%, 400%, 500% or more such as compared to another measurable property or quantity (e.g., a control value).
As used herein, the terms “reduce,” “reduces,” “reduced,” “reduction,” “inhibit,” and similar terms refer to a decrease in the specified parameter or value of at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 97%, or 100% such as compared to another measurable property or quantity (e.g., a control value).
Provided according to embodiments of the present invention are yarns and fabrics that can provide and/or are configured to provided high visibility. A yarn and/or fabric of the present invention may meet the requirements of ANSI/ISEA 107-2020 entitled “American National Standard for High-Visibility Safety Apparel.” A yarn of the present invention may comprise a blend of fibers, the blend of fibers comprising: about 90% or more fiber dyed modacrylic fibers by weight of the yarn; about 0% to about 10% para-aramid fibers by weight of the yarn; and about 0% to about 2% anti-static fibers by weight of the yarn. At least one of para-aramid fibers and anti-static fibers may be present in the yarn. “Fiber dyed” as used herein refers to a fiber that includes a coloring agent that was present during formation of the fiber itself. “Coloring agent” as used herein refers to a dye (e.g., an insoluble dye), a pigment (e.g., insoluble pigment) and/or additive that modifies the color and/or shade of a fiber to which the coloring agent is contacted and/or present in and/or on compared to the color and/or shade of the fiber in the absence of the coloring agent. A coloring agent may be included in a composition including a fiber forming polymer that is used to form a fiber to thereby provide a fiber dyed fiber. Thus, a fiber dyed fiber is a fiber that is dyed prior to and/or during the formation of the fiber itself. A fiber dyed fiber is also dyed prior to preparing a yarn or fabric using the fiber and is distinguished from fibers that are dyed when already in the form of a fiber (such as stock dyed fibers), yarn or fabric. As another example, a fiber dyed anti-static fiber may refer to an anti-static fiber that includes during the anti-static fiber forming process a coloring agent that modifies the natural black, gray, or white color of the anti-static fiber to another color and/or shade. Exemplary fiber dyed fibers are solution dyed fibers and/or gel dyed fibers. Solution-dyed fibers are dyed/pigmented during the spinning process of the fibers such as by introducing a coloring agent (e.g., a pigment and/or dye (e.g., insoluble dye or pigment)) into the polymer solution or dope prior to extrusion. Gel dyed fibers are fibers that have been contacted with a coloring agent in the gel state (e.g., a coloring agent is contacted to a wet-spun fiber prior to quenching/drawing and drying of the fiber). In some embodiments, a gel dyed fiber may be prepared by contacting a wet-spun fiber with a composition (e.g., a bath such as an aqueous solution) comprising a coloring agent such as by passing the wet-spun fiber through a bath comprising a coloring agent. In contrast to fiber dyed fibers, stock dyed fibers are dyed/pigmented after extrusion of the fibers.
In some embodiments, a yarn and/or fabric of the present invention comprises para-aramid fibers and fiber dyed modacrylic fibers, optionally wherein the para-aramid fibers are fiber dyed para-aramid fibers. In some embodiments, a yarn and/or fabric of the present invention comprises fiber dyed modacrylic fibers and anti-static fibers, which may be fiber dyed anti-static fibers. In some embodiments, a yarn and/or fabric of the present invention comprises fiber dyed modacrylic fibers, para-aramid fibers, and anti-static fibers, optionally wherein the anti-static fibers and/or para-aramid fibers are fiber dyed. In some embodiments, a yarn and/or fabric of the present invention comprises para-aramid fibers that are not fiber dyed para-aramid fibers. In some embodiments, a yarn and/or fabric of the present invention comprises para-aramid fibers that are not dyed and/or that are devoid of a dye. A “natural fiber” as used herein refers to a fiber (e.g., a modacrylic fiber, para-aramid fiber, or anti-static fiber) that is devoid of a coloring agent and/or is a fiber that is not dyed. In some embodiments, a natural fiber may be ecru. As one of skill in the art will understand, a “natural anti-static fiber” includes a fiber forming polymer and a conductive additive and the conductive additive may provide the fiber with a color of white, gray, or black. Thus, a natural anti-static fiber may be white, gray, or black, but is devoid of a coloring agent other than the conductive additive that modifies its color and/or shade. In some embodiments, a natural anti-static fiber may be prepared by including the conductive additive in the composition used to form the anti-static fiber and thus the conductive additive may be present during the anti-static fiber forming process, thereby the natural anti-static fiber may be a solution-dyed anti-static fiber even in its natural state. A solution-dyed anti-static fiber may also be a natural anti-static fiber (i.e., a natural, solution-dyed anti-static fiber) if the conductive additive was present during the anti-static fiber forming process (e.g., present in the polymer solution or dope prior to extrusion of the fiber) and the anti-static fiber is white, gray, or black and is devoid a coloring agent other than the conductive additive. A yarn and/or fabric of the present invention may comprise fiber dyed fibers that consist of fiber dyed modacrylic fibers and/or fiber dyed anti-static fibers. In some embodiments, a yarn and/or fabric of the present invention consists of fiber dyed modacrylic fibers and para-aramid fibers and/or anti-static fibers, optionally wherein the anti-static fibers are fiber dyed anti-static fibers. A yarn and/or fabric of the present invention may be devoid of cellulosic fibers (e.g., cotton, rayon, acetate, triacetate, and/or lyocell fibers).
In some embodiments, a yarn of the present invention comprises fiber dyed modacrylic fibers in an amount of about 95% by weight of yarn and the para-aramid fibers (e.g., natural para-aramid fibers) are present in an amount of about 5% by weight of the yarn. In some embodiments, a yarn of the present invention comprises fiber dyed modacrylic fibers in an amount of greater than 95% by weight of yarn and the para-aramid fibers are present in an amount of less than 5% by weight of the yarn.
A yarn and/or fabric of the present invention may comprise one or more (e.g., 1, 2, 3, 4, 5, or more) different types of fibers that are fiber dyed fibers. In some embodiments, the yarn and/or fabric comprises fiber dyed modacrylic fibers and fiber dyed anti-static fibers. In some embodiments, the yarn and/or fabric comprises fiber dyed modacrylic fibers and natural para-aramid fibers and/or natural anti-static fibers. A yarn of the present invention may comprise fiber dyed fibers in an amount of about 90%, 91%, 92%, 93%, 94%, or 95% to about 96%, 97%, 98%, 99%, or 100% by weight of the yarn such as in an amount of about 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100%. In some embodiments, a yarn of the present invention comprises fiber dyed fibers in an amount of greater than 95% by weight of the yarn. Once formed, a yarn of the present invention may not be treated and/or contacted with a coloring agent (e.g., dye) and/or the yarn is devoid of a post-formation dye. A “post-formation dye” as used herein refers to a coloring agent (e.g., a dye) that is contacted to a yarn or fabric itself (i.e., contacted to a yarn or fabric after it is formed). In some embodiments, a fabric of the present invention is not piece dyed and/or the fabric is devoid of a coloring agent (e.g., a dye) added by piece dyeing. A fabric of the present invention may be devoid of a post-formation dye.
A fabric of the present invention may comprise fiber dyed fibers in an amount of about 90%, 91%, 92%, 93%, 94%, or 95% to about 96%, 97%, 98%, 99%, or 100% by weight of the fabric such as in an amount of about 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100%. In some embodiments, a fabric of the present invention comprises fiber dyed fibers in an amount of greater than 95% by weight of the fabric. Once formed, a fabric of the present invention may not be treated and/or contacted with a coloring agent (e.g., a dye) and/or the fabric is devoid of a post-formation dye.
It was unexpectedly discovered by the inventors of the present invention that a yarn and/or fabric of the present invention including fiber dyed modacrylic fibers can provide sufficient color and/or properties without needing to be piece dyed and/or dyed after formation of the yarn and/or fabric. For example, a yarn and/or fabric of the present invention (e.g., comprising fiber dyed modacrylic fibers and natural para-aramid fibers and/or natural anti-static fibers) that is devoid of a post-formation dye (e.g., has not been piece dyed) can meet the requirements of ANSI/ISEA 107-2020. In some embodiments, the natural anti-static fibers are black fibers, gray fibers, and/or white fibers. Additionally, a yarn and/or fabric of the present invention may have improved color, laundering and/or performance compared to a yarn and/or fabric not in accordance with the present invention (e.g., a yarn and/or fabric devoid of fiber dyed modacrylic fibers and/or a yarn and/or fabric including a post-formation dye). For example, a fabric of the present invention (e.g., comprising fiber dyed modacrylic fibers and natural para-aramid fibers and/or natural anti-static fibers) that is devoid of a post-formation dye (e.g., has not been piece dyed) can meet the requirements of ANSI/ISEA 107-2020 after an exposure test performed in accordance with AATCC 16.3-2014 and/or after laundering performed in accordance with AATCC 61-2013 at a temperature of about 105° F. to about 140° F., optionally at a temperature of about 120° F. to about 140° F.
Modacrylic fibers (e.g., fiber dyed modacrylic fibers) may be present in a yarn and/or fabric of the present invention in an amount of about 90% or more by weight of the yarn and/or fabric, respectively. In some embodiments, modacrylic fibers are present in the yarn in an amount that is greater than 90% by weight of the yarn and/or modacrylic fibers are present in the fabric in an amount that is greater than 90% by weight of the fabric. In some embodiments, fiber dyed modacrylic fibers are present in the yarn and/or fabric in an amount of about 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% by weight of the yarn and/or fabric, respectively. In some embodiments, the yarn and/or fabric comprises 90% to about 100% fiber dyed modacrylic fibers by weight of the yarn and/or fabric such as about 92% to about 100%, about 92% to about 98%, about 93% to about 100%, about 93% to about 98%, about 93% to about 97%, about 94% to about 100%, about 94% to about 98%, about 94% to about 97%, about 94% to about 96%, about 94% to about 95%, about 95% to about 100%, about 95% to about 98%, about 95% to about 97%, about 95% to about 96%, about 96% to about 100%, about 96% to about 98%, about 97% to about 100%, about 97% to about 99%, about 98% to about 99%, or about 98% to about 100% by weight of the yarn and/or fabric, respectively. In some embodiments, the modacrylic fibers are fiber dyed modacrylic fibers. In some embodiments, the modacrylic fibers are solution-dyed modacrylic fibers. In some embodiments, the modacrylic fibers are gel dyed modacrylic fibers.
Fiber dyed modacrylic fibers of the present invention may be inherently flame retardant. “Inherently flame retardant” as used herein in reference to a fiber means that the fiber has flame resistance built into its chemical structure and the fiber itself is not flammable. In some embodiments, a fiber dyed modacrylic fiber is self-extinguishing and does not melt or drip when exposed to a flame, optionally when exposed to a flame as performed and/or measured in accordance with ASTM F1506. In some embodiments, a fiber dyed modacrylic fiber does not melt or drip, has an after-flame of less than 2 seconds, and has a char length of less than 6 inches when exposed to a flame as performed and/or measured in accordance with ASTM F1506. In some embodiments, a fiber dyed modacrylic fiber has a limiting oxygen index (LOI) of about 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, or more. In some embodiments, a fiber dyed modacrylic fiber has a LOI of about 32% or more. In some embodiments, a fiber dyed modacrylic fiber has a LOI of about 34% or more.
Fiber dyed modacrylic fibers of the present invention comprise a polymer that includes 35% to 85% acrylonitrile monomer units by weight of the polymer. In some embodiments, a fiber dyed modacrylic fiber comprises 35% to 85% acrylonitrile monomer units by weight of the polymer, such as about 35% to about 60%, about 40% to about 80%, about 40% to about 70%, about 40% to about 60%, about 40% to about 50%, about 50% to about 85%, about 50% to about 80%, about 50% to about 70%, about 50% to about 60%, about 60% to about 80%, about 60% to about 70%, or about 70% to about 80% acrylonitrile monomer units by weight of the polymer. The polymer of a fiber dyed modacrylic fiber comprises one or more (e.g., 1, 2, 3, 4, 5, or more) comonomer unit(s) (e.g., a neutral and/or acid comonomer unit). A comonomer may be present in the polymer of a modacrylic fiber in an amount of about 0.1% to about 65% by weight of the polymer such as about 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60% or 65% by weight of the polymer. Example comonomer units include, but are not limited to, vinyl chloride, vinylidene chloride, dichloromethane, and/or vinyl bromide. In some embodiments, a fiber dyed modacrylic fiber comprises acrylonitrile units and vinylidene chloride units. As those skilled in the art will understand, a polymer of a fiber dyed modacrylic fiber may be obtained by polymerizing an acrylonitrile monomer, optionally in the presence of one or more comonomers.
A fiber dyed modacrylic fiber may have a halogen (e.g., chlorine and/or bromine) content in an amount of about 10% to about 50% by weight of the fiber dyed modacrylic fiber, such as about 10%, 15%, or 20% to about 25%, 30%, 35%, 40%, 45%, or 50% by weight of the fiber dyed modacrylic fiber. A fiber dyed modacrylic fiber may comprise a synergist. Exemplary synergists that may be present in a fiber dyed modacrylic fiber include, but are not limited to, antimony oxides such as antimony trioxide and/or antimony pentoxide. In some embodiments, a fiber dyed modacrylic fiber comprises an antimony oxide, optionally wherein the fiber dyed modacrylic fiber comprises antimony pentoxide. A synergist may be present in an amount of about 5% or 10% to about 50% by weight of the fiber dyed modacrylic fiber, such as about 5%, 10%, 15%, or 20% to about 25%, 30%, 35%, 40%, 45%, or 50% by weight of the fiber. In some embodiments, fiber dyed modacrylic fibers present in a yarn and/or fabric of the present invention are annealed modacrylic fibers, which may have reduced or no irregularities (e.g., internal fissures, fractures, pitting, etc.), deformities and/or internal stresses compared to modacrylic fibers that are not annealed such as quenched modacrylic fibers. Annealed modacrylic fibers may be achieved by a process that comprises gradually cooling the extruded modacrylic fibers optionally through a series of convective ovens/rollers. In contrast, quenched modacrylic fibers can be prepared by a process in which filaments are rapidly cooled from their melt temperature to a temperature below their glass transition phase by way of air blasts, water/chemical baths, and/or the like. The quenching process is often done in the shortest time frame and corresponding distance possible to eliminate die swell and other changes in filament size, shape and orientation. A fiber dyed modacrylic fiber of the present invention may be Prop 65 compliant.
A fiber dyed modacrylic fiber may have a degree of crystallinity of at least 35%. In some embodiments, a fiber dyed modacrylic fiber has a degree of crystallinity of about 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, or 50% or more. In some embodiments, a fiber dyed modacrylic fiber has a degree of crystallinity of about 36% to about 50%, about 36% to about 45%, about 36% to about 42%, about 36% to about 40%, about 38% to about 45%, about 38% to about 42%, about 38% to about 41%, about 38% to about 48%, about 39% to about 45%, about 39% to about 43%, or about 39% to about 41%. In some embodiments, a fiber dyed modacrylic fiber has a degree of crystallinity of at least 38% to about 45% or at least 38% to about 40%.
Anti-static fibers may be present in a yarn and/or fabric of the present invention in an amount of about 0.01% or 0.1% to about 2% by weight of the yarn and/or fabric, respectively, such as about 0.01% to about 2%, about 0.1% to about 2%, about 0.1% to about 1.5%, about 0.1% to about 1%, about 0.1% to about 0.5%, about 0.5% to about 2%, about 0.5% to about 1.5%, about 0.5% to about 1%, about 0.5% to about 0.75%, about 1% to about 2%, about 1% to about 1.5%, or about 1.5% to 2% by weight of the yarn and/or fabric, respectively. In some embodiments, anti-static fibers are present in the yarn and/or fabric in an amount of about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, or 2% by weight of the yarn and/or fabric, respectively. In some embodiments, the anti-static fibers are fiber dyed anti-static fibers. In some embodiments, the anti-static fibers are solution-dyed anti-static fibers. In some embodiments, the anti-static fibers are stock dyed anti-static fibers. In some embodiments, the anti-static fibers are gel dyed anti-static fibers. In some embodiments, the anti-static fibers are natural anti-static fibers. In some embodiments, the anti-static fibers are natural, solution-dyed anti-static fibers, optionally white, natural, solution-dyed anti-static fibers. In some embodiments, the natural anti-static fibers are black fibers, gray fibers, white fibers, or a combination of two or more thereof. A yarn and/or fabric of the present invention may comprise solution-dyed anti-static fibers, stock dyed anti-static fibers, gel dyed anti-static, and/or natural anti-static fibers. In some embodiments, a yarn and/or fabric of the present invention is devoid of anti-static fibers (i.e., there are 0% anti-static fibers by weight of the yarn and/or fabric, respectively).
Para-aramid fibers may be present in the yarn and/or fabric in an amount of about 0.01% or 0.1% to about 10% by weight of the yarn and/or fabric such as about 0.5% to about 9%, about 0.5% to about 8%, about 0.5% to about 7%, about 0.5% to about 6%, about 0.5% to about 5%, about 0.5% to about 4%, about 0.5% to about 3%, about 0.5% to about 2%, about 0.5% to about 1%, about 1% to about 10%, about 1% to about 9%, about 1% to about 8%, about 1% to about 7%, about 1% to about 6%, about 1% to about 5%, about 1% to about 4%, about 1% to about 3%, about 1% to about 2%, about 2% to about 10%, about 2% to about 9%, about 2% to about 8%, about 2% to about 7%, about 2% to about 6%, about 2% to about 5%, about 2% to about 4%, about 2% to about 3%, about 4% to about 10%, about 5% to about 10%, or about 6% to about 10% by weight of the yarn and/or fabric, respectively. In some embodiments, para-aramid fibers are present in the yarn and/or fabric in an amount of about 0%, 0.01%, 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5%, 5.5%, 6%, 6.5%, 7%, 7.5%, 8%, 8.5%, 9%, 9.5%, or 10% by weight of the yarn and/or fabric, respectively. In some embodiments, para-aramid fibers are not present in the yarn and/or fabric (i.e., there are 0% para-aramid fibers by weight of the yarn and/or fabric, respectively). In some embodiments, the para-aramid fibers are fiber dyed para-aramid fibers. In some embodiments, the para-aramid fibers are solution-dyed para-aramid fibers. In some embodiments, the para-aramid fibers are stock dyed para-aramid fibers. In some embodiments, the para-aramid fibers are gel dyed para-aramid fibers. In some embodiments, the para-aramid fibers are devoid of a coloring agent (i.e., natural para-aramid fibers). A yarn and/or fabric of the present invention may comprise stock dyed para-aramid fibers, solution-dyed para-aramid fibers, gel dyed para-aramid fibers, and/or natural para-aramid fibers.
A yarn and/or fabric of the present invention may have a color that is fluorescent yellow-green, fluorescent orange-red, or fluorescent red, as defined by ANSI/ISEA 107-2020. In some embodiments, color may be measured in accordance with ASTM E1164-17 and/or using a spectrophotometer at a wavelength in a range of 400 nm to 700 nm and at intervals of 10 nm as well as illumination D65 and 45/0 or 0/45 geometry with 2° standard observer and a black underlay with a reflectance of less than 0.04. In some embodiments, a yarn and/or fabric of the present invention may have a color, prior to an exposure test (e.g., prior to a xenon exposure test), having chromaticity coordinates that fall within the chromaticity coordinates as defined by ANSI/ISEA 107-2020 for fluorescent yellow-green, fluorescent orange-red, or fluorescent red. Exemplary exposure tests include, but are not limited to, xenon exposure tests such as those carried out in accordance with AATCC 16.3-2014 entitled “Colorfastness to Light Xenon Arc.” A xenon exposure test may expose a fabric to 40 AATCC fading units (170 kJ/m2@420 nm). Color may be measured (optionally in accordance with AATCC 16.3-2014 and/or with chromaticity coordinates as defined by ANSI/ISEA 107-2020) before and after an exposure test. In some embodiments, a yarn and/or fabric has a color, after an exposure test (e.g., after a xenon exposure test), having chromaticity coordinates as defined by ANSI/ISEA 107-2020 that fall within the chromaticity coordinates for fluorescent yellow-green, fluorescent orange-red, or fluorescent red, optionally as measured in accordance with AATCC 16.3-2014. In some embodiments, a yarn and/or fabric of the present invention has a color, before and after an exposure test (e.g., as carried out in accordance with AATCC 16.3-2014), that is fluorescent yellow-green, fluorescent orange-red, or fluorescent red (e.g., has chromaticity coordinates as defined by ANSI/ISEA 107-2020 for fluorescent yellow-green, fluorescent orange-red, or fluorescent red). In some embodiments, a yarn and/or fabric of the present invention may have a color, chromaticity coordinates, and/or luminance factor as shown in Table 1.
In some embodiments, a yarn and/or fabric of the present invention has a luminance factor, prior to an exposure test (e.g., prior to a xenon exposure test optionally in accordance with AATCC 16.3-2014), of at least 70%, 75%, 80%, 85%, 90%, or 95%, optionally wherein the luminance factor is measured in accordance with ASTM E1164-17. After an exposure test (e.g., after a xenon exposure test optionally in accordance with AATCC 16.3-2014), a yarn and/or fabric of the present invention may have a luminance factor of at least 70%, 75%, 80%, 85%, 90%, or 95%, optionally wherein the luminance factor is measured in accordance with ASTM E1164-17. In some embodiments, before and/or after an exposure test (e.g., a xenon exposure test optionally in accordance with AATCC 16.3-2014), a yarn and/or fabric of the present invention may have a luminance factor of at least 70% such as about 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100%, wherein the luminance factor may be measured in accordance with ASTM E1164-17.
A yarn of the present invention may be a single-ply yarn or a plied yarn (e.g., a multi-ply yarn). The yarn may be a single-ply yarn having a size of about 12/1 to about 40/1. The yarn may be plied yarn having a size of about 12/2 to about 40/2. In some embodiments the yarn is a 12/1, 15/1, 17/1, 18/1, 20/1, 24/1, 30/1, or 40/1 yarn. In some embodiments, the yarn is a 30/2 or 40/2 yarn.
A yarn of the present invention may comprise one or more (e.g., 1, 2, 3 or more) fibers in different forms. For example, a fiber present in the yarn may be a staple, tow, filament, or monofilament fiber. The yarn may comprise staple fibers. In some embodiments, one or more different types of fibers in the yarn are staple fibers. In some embodiments, all fibers present in the yarn are staple fibers. Typically, a staple fiber has a length in a range from about 0.75 inches to about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18 inches, and a filament fiber has any suitable length (e.g., greater than 18 inches to about 2, 4, 6, 8, 10, 100, 200, 1,000, 10,000, or 20,000, 30,000 yards or more). In some embodiments, a yarn of the present invention comprises staple fibers having a length of about 10 mm to about 100 mm, about 20 mm to about 80 mm, about 30 mm to about 60 mm, about 40 mm to about 70 mm, about 40 mm to about 60 mm, or about 25 mm to about 60 mm. In some embodiments, the yarn comprises staple fibers having a length of about 50 mm to about 55 mm.
A yarn of the present invention may comprise fibers (e.g., staple fibers) having a linear density (dtex) of about 1 dtex or more such as about 1 to about 3, about 1.5 to about 2, about 1 to about 2, about 1.5 to about 2.5, or about 2 to about 3 dtex. In some embodiments, the yarn comprises fibers having a linear density of about 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4 dtex or more. In some embodiments, the yarn comprises fibers (e.g., staple fibers such as those having a length of about 50 mm to about 55 mm) having a linear density of about 1.5 to about 2 dtex.
A yarn of the present invention may comprise one or more (e.g., 1, 2, 3, 4, or more) different fibers having a LOI of 20% or more, optionally as measured in accordance with ASTM D2863, ISO 4589-2, and/or NES 714. In some embodiments, the yarn comprises fibers having a LOI of about 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, or more. In some embodiments, the yarn comprises one or more fibers having a LOI of 22% or more. In some embodiments, the yarn comprises one or more fibers having a LOI of 25% or more. In some embodiments, the yarn comprises one or more fibers having a LOI of 28% or more. In some embodiments, the yarn comprises at least 1 or 2 different types of fibers that have a LOI of 28% or more. In some embodiments, the yarn comprises fiber dyed modacrylic fibers that have a LOI of 28% or more.
A yarn comprising a blend of fibers as described herein may be prepared using methods known to those of skill in the art. A “blend of fibers” as used herein refers to a plurality of two or more different types of fibers. In some embodiments, one or more different types of fibers are provided in a given weight percentage, blended, combed, and/or formed into a yarn of the present invention. Methods of forming a yarn are known to those of skill in the art and include, but are not limited to, drawing, drafting, spinning, and/or twisting fibers into a sliver and/or yarn. A yarn of the present invention may be spun using methods known to those of skill in the art such as, but not limited to, ring spinning, vortex spinning, core spinning, air jet spinning and/or texturizing. In some embodiments, a yarn of the present invention may be ring spun or vortex spun. Fibers present in a yarn of the present invention (e.g., modacrylic fibers, anti-static fibers, and/or para-aramid fibers) may be uniformly entangled and/or respective fibers present in the yarn may be arranged parallel to one or more different fibers in the yarn along the Z and or X axis/helix of the yarn. In some embodiments, a yarn of the present invention may be plied or twisted, which may increase the strength of the yarn compared to the strength of the yarn prior to plying or twisting.
A yarn of the present invention may have a denier of about 200 or more such as about 200, 250, 300, 350, 400, 450, 500 or more. The yarn may have a Z twist of about 20 to about 26 and/or a S twist of about 13 to about 19, each optionally as measured in accordance with ASTM D1423. In some embodiments, a yarn has a Z twist of about 20, 21, 22, 23, 24, 25, or 26 and/or a S twist of about 13, 14, 15, 16, 17, 18, or 19, each optionally as measured in accordance with ASTM D1423. A yarn of the present invention may have a break strength of about 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3 lbs/breaking force, optionally on average, and/or an elongation of about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, or 30%, optionally on average, each optionally as measured in accordance with ASTM D2256. In some embodiments, the yarn has a break strength of about 1, 1.2, 1.4, or 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3 lbs/breaking force, optionally on average, and/or an elongation of about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, or 30%, optionally on average, each optionally as measured in accordance with ASTM D2256. A yarn of the present invention may have a shrinkage of about 2% or less, such as about 1.9%, 1.8%, 1.7%, 1.6%, 1.5%, 1.4%, 1.3%, 1.2%, 1.1%, 1%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, 0.1% or less, optionally as measured in accordance with ASTM D2259.
One or more yarn(s) of the present invention may be used to form a fabric of the present invention. In some embodiments, a yarn of the present invention is woven or knit to form a fabric and/or a garment (e.g., a shirt, pant, vest, jacket, etc.). A fabric of the present invention may be a woven fabric. Woven fabrics are known to those of skill in the art and include, but are not limited to, a plain weave, twill weave (e.g., right hand twill), broken twill weave, ripstop weave, satin weave, or basketweave fabric. In some embodiments, the fabric is woven with a plain weave. In some embodiments, a fabric of the present invention may be a knit. Knit fabrics are known to those of skill in the art and include, but are not limited to, interlock, single jersey, double jersey, warp, rib, and/or modified welt knits. In some embodiments, a fabric of the present invention is a mesh. In some embodiments, the fabric is a warp knit mesh. A fabric and/or garment of the present invention may be a single layer (e.g., a single knit or woven layer) or may comprise multiple (e.g., 2 or more) layers. In some embodiments, the yarn and/or fabric is used in safety apparel and/or the garment is safety apparel. In some embodiments, the garment is a shirt (e.g., a T-shirt), vest (e.g., safety vest), and/or rainwear. A fabric and/or garment may meet the conspicuity requirements set forth in ANSI/ISEA 107-2020 and may be a Class 2 or Class 3 as defined by ANSI/ISEA 107-2020.
In some embodiments, a garment of the present invention comprises a first fabric meeting the requirements of ANSI/ISEA 107-2020 and a second fabric that does not meet the requirements of ANSI/ISEA 107-2020 and optionally the second fabric is a light color (e.g., white, ecru, light tan, etc.), wherein the first fabric is immediately adjacent to the second fabric. The second fabric may be an acetate, cotton, nylon, polyester, acrylic, and/or wool. In some embodiments, the first fabric does not bleed onto and/or stain the second fabric, optionally after laundering (e.g., laundering performed in accordance with AATCC 61-2013 at a temperature of about 105° F. to about 140° F.).
Fabrics of the present invention may comprise a yarn of the present invention. In some embodiments, a fabric of the present invention comprises one or more yarn(s) of the present invention in an amount of about 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% by weight of the fabric. In some embodiments, a fabric of the present invention comprises one or more yarn(s) of the present invention in an amount of about 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% of the total amount of yarns present in the fabric. In some embodiments, the fabric comprises a yarn of the present invention in the warp direction and/or fill direction or machine direction and/or cross-machine direction. A plurality of yarns of the present invention may be arranged in a random manner in a fabric of the present invention or a pattern. For example, in some embodiments, a plurality of yarns of the present invention are woven together such as in a plain weave, twill weave, satin weave, or basketweave, or are knit together.
According to some embodiments of the present invention, provided is a fabric comprising a yarn of the present invention. The yarn may comprise a blend of fibers comprising: about 90% to about 99% fiber dyed modacrylic fibers by weight of the yarn; about 0% to about 10% para-aramid fibers by weight of the yarn; and about 0% to about 2% anti-static fibers by weight of the yarn, wherein at least one of para-aramid fibers and anti-static fibers are present in the yarn. In some embodiments, a fabric of the present invention comprises a plurality of yarns, wherein each yarn of the plurality of yarns comprises fiber dyed modacrylic fibers blended with para-aramid fibers and/or anti-static fibers, and the fabric comprises: about 90% to about 99% fiber dyed modacrylic fibers by weight of the fabric; about 0% to about 10% para-aramid fibers by weight of the fabric; and about 0% to about 2% anti-static fibers by weight of the fabric. In some embodiments, the fabric comprises para-aramid fibers, optionally wherein the para-aramid fibers are not fiber dyed para-aramid fibers (e.g., are natural para-aramid fibers). In some embodiments, the para-aramid fibers are not dyed and/or are devoid of a dye. In some embodiments, the fabric comprises anti-static fibers, optionally fiber dyed anti-static fibers. In some embodiments, the fabric comprises para-aramid fibers and anti-static fibers, optionally wherein the anti-static fibers are fiber dyed anti-static fibers. In some embodiments, a yarn comprising anti-static fibers is incorporated about every two centimeters in the warp direction and/or weft direction or machine direction and/or cross-machine direction and may form a grid of overlapping yarns comprising anti-static fibers.
In some embodiments, a fabric of the present invention comprises fiber dyed modacrylic fibers in an amount of about 95% by weight of fabric and the para-aramid fibers (e.g., natural para-aramid fibers) are present in an amount of about 5% by weight of the fabric. In some embodiments, a fabric of the present invention comprises fiber dyed modacrylic fibers in an amount of greater than 95% by weight of fabric and the para-aramid fibers (e.g., natural para-aramid fibers) are present in an amount of less than 5% by weight of the fabric.
A fabric of the present invention may comprise one or more single-ply yarn(s) and/or one or more plied yarn(s) (e.g., one or more multi-ply yarn(s)). The fabric may comprise a single-ply yarn having a size of about 12/1 to about 40/1. The fabric may comprise a plied yarn having a size of about 12/2 to about 40/2. In some embodiments, the fabric comprises a 12/1, 15/1, 17/1, 18/1, 20/1, 24/1, 30/1, and/or 40/1 yarn. In some embodiments, the fabric comprises a 30/2 and/or 40/2 yarn. In some embodiments, the fabric comprises 30/2 yarns in the warp direction and/or fill direction or machine direction and/or cross-machine direction. In some embodiments, the fabric comprises 40/2 yarns in the warp direction and/or fill direction or machine direction and/or cross-machine direction.
In some embodiments, a fabric of the present invention may have a basis weight in a range of about 5 ounces per square yard (osy) to about 7 osy such as about 5 osy to about 6 osy or about 6 to about 7 osy. In some embodiments, the fabric has a basis weight of about 5, 5.5, 6, 6.5, or 7 osy or more.
A fabric of the present invention may have an improved and/or increased protection to weight ratio compared to a fabric not in accordance with the present invention (e.g., a control fabric). For example, in some embodiments, a fabric of the present invention may have a protection to weight ratio of about 1 or more (arc rating (cal/cm2) as measured in accordance with NFPA 70E:weight of the fabric). In some embodiments, a fabric of the present invention may have a protection to weight ratio of about 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, or more (arc rating (cal/cm2) as measured in accordance with NFPA 70E:weight of the fabric). In some embodiments, a fabric of the present invention may have a protection to weight ratio of about 1.5 or more such as about 1.5 to about 1.6, 1.7, 1.8, 1.9, or 2 (arc rating (cal/cm2) as measured in accordance with NFPA 70E:weight of the fabric). It is difficult to provide a light weight fabric having the necessary flame resistance and/or arc resistance. A light weight fabric having a high protection rating can have the advantage of increased user compliance. In some embodiments, a fabric of the present invention has a basis weight of about 5 osy to about 7 osy and is a category 1 fabric (i.e., has an arc rating that satisfies the arc rating requirement for PPE in category 1 (e.g., has an arc rating of at least 4.0 cal/cm2 as measured in accordance with ASTM F1959 and/or ASTM F1506)). In some embodiments, a fabric of the present invention has a basis weight of about 6.6 osy or less and is a category 1 fabric. In some embodiments, a fabric of the present invention has a basis weight of about 5.3 osy to about 6.6 osy and is a category 1 fabric.
In some embodiments, a fabric of the present invention may have a total denier in the warp direction and/or weft direction or machine direction and/or cross-machine direction of about 100 to about 500, about 150 to about 400, or about 300 to about 400. In some embodiments, the fabric has a total denier in the warp direction and/or weft direction or machine direction and/or cross-machine direction of about 100, 150, 200, 250, 300, 350, 400, 450, or 500.
A fabric of the present invention may have about 20 to about 80 picks per inch (PPI) or courses per inch (CPI) such as about 20 to about 50, about 20 to about 40, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 70, about 50 to about 60, about 60 to about 80, about 60 to about 70, about 70 to about 80, about 55 to about 70, or about 55 to about 65 PPI or CPI. In some embodiments, the fabric has a PPI or CPI of about 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80 or more. In some embodiments, the fabric has about 20 to about 40 PPI or CPI. As one of skill in the textile industry would understand, picks per inch, or PPI, is the number of weft yarns or cross-machine direction yarns per inch of the fabric and is measured in the warp direction or machine direction of the fabric. In some embodiments, a knit fabric of the present invention may have about 20 or 25 to about 35 or 40 wales and/or about 30 or 35 to about 40, 45, or 50 courses.
A fabric of the present invention may be heat set with standard textile techniques, optionally with or without a chemical. A fabric of the present invention may comprise a finish on at least one surface of the fabric. A finish may be present on and/or in a fabric of the present invention in an amount of up to 3% of the total weight of the finished fabric. In some embodiments, a yarn and/or fabric of the present invention is devoid of a flame retardant.
A fabric of the present invention may have one or more (e.g., 1, 2, 3, 4, or more) improved properties compared to a control fabric. A “control fabric” as used herein refers to a current commercial fabric and/or a fabric in the same form as a fabric of the present invention that it is being compared to, but that is different in a certain manner (e.g., the control fabric is devoid of a yarn of the present invention). An exemplary control fabric may comprise a fabric that is devoid of fiber dyed modacrylic fibers and/or is devoid of a yarn comprising fiber dyed modacrylic fibers. Another exemplary control fabric is one that is devoid of a post-formation dye. In some embodiments, a control fabric is devoid of fiber dyed modacrylic fibers and is devoid of a post-formation dye. In some embodiments, a control fabric comprises a plurality of yarns that each comprise modacrylic fibers that are not fiber dyed modacrylic fibers blended with para-aramid fibers and/or anti-static fibers in the same weight percentages as a yarn present in a fabric of the preset invention that is being compared to. For example, a control fabric may comprise a plurality of yarns that each comprise about 90% to about 99% modacrylic fibers that are not fiber dyed modacrylic fibers by weight of the yarn; about 0% to about 10% para-aramid fibers by weight of the yarn; and about 0% to about 2% anti-static fibers by weight of the yarn, wherein at least one of para-aramid fibers and anti-static fibers are present in the yarn.
A fabric of the present invention may meet or exceed the requirements set forth in ANSI/ISEA 107-2020, ISO 20471:2013, ASTM E1164-17, AATCC 61-2013 (e.g., AATCC 61-2013-2A, AATCC 61-2013-3A, AATCC 61-2013-4A, AATCC 61-2013-5A) optionally as carried out at 105° F. and/or 145° F., AATCC 132-2013, AATCC 133-2013 as carried out at 230° F., 302° F., and/or 392° F., AATCC 8-2016, AATCC 15-2013, ASTM D1424-09 2019, ASTM D3787-07 (2016), ASTM D6797-07 (2015), AATCC 135-2018, AATCC 96-2012, and/or AATCC 107-2013.
A fabric of the present invention may have one or more improvements in regard to laundering compared to a control fabric and/or may have a desired laundering characteristic. In some embodiments, after laundering, a fabric of the present invention has a grade of at least 4-5 or 5 for color change. Laundering may be carried out in accordance with AATCC 61-2013 at a temperature in a range of about 105° F. to about 140° F. such as about 105, 110, 115, 120, 125, 130, 135, or 140° F. For example, a fabric of the present invention, after laundering in accordance with AATCC 61-2013 as carried out at about 105° F., may have a grade of 4-5 or 5 for color change and/or, after laundering in accordance with AATCC 61-2013 as carried out at about 120° F., may have a grade of at least 4-5 or 5 for color change.
In some embodiments, after laundering in accordance with AATCC 61-2013 at a temperature in a range of 105° F. to about 140° F. (e.g., at about 105° F.), a fabric of the present invention has a grade of 4, 4-5, or 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and/or staining of wool. In some embodiments, the fabric has a grade of 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and staining of wool after laundering in accordance with AATCC 61-2013 as carried out at about 105° F. In some embodiments, a fabric of the present invention, after laundering in accordance with AATCC 61-2013 as carried out at about 120° F., has a grade of 4, 4-5, or 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and/or staining of wool. The fabric may have a grade of 4-5 or 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and staining of wool after laundering in accordance with AATCC 61-2013 as carried out at about 120° F.
A fabric of the present invention, after laundering in accordance with AATCC 61-2013 as carried out at about 105° F., may have a grade of 5 for color change and a grade of 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and/or staining of wool. In some embodiments, a fabric of the present invention, after laundering in accordance with AATCC 61-2013 as carried out at about 120° F., has a grade of 5 for color change and a grade of 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and/or staining of wool. The fabric may have a grade of 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and staining of wool, optionally for staining of acetate, staining of cotton, staining of nylon, and staining of acrylic.
In some embodiments, a fabric of the present invention, after laundering in accordance with AATCC 61-2013 (e.g., as carried out at about 105° F.), has an improvement in grade for staining of one or more of acetate, cotton, nylon, polyester, acrylic, and wool compared to a control fabric (e.g., a fabric devoid of a fiber dyed modacrylic fiber). In some embodiments, a fabric of the present invention, after laundering in accordance with AATCC 61-2013 as carried out at about 145° F., has an improvement in grade for color change and/or grade for staining of one or more of acetate, cotton, nylon, polyester, acrylic, and wool compared to a control fabric (e.g., a fabric devoid of a fiber dyed modacrylic fiber).
A fabric of the present invention may have one or more improvements in regard to colorfastness compared to a control fabric and/or may have a desired colorfastness characteristic. In some embodiments, a fabric of the present invention has a colorfastness to crocking, wet and/or dry, having a grade of at least 3.0 or 4.0 by the Gray Scale for Staining when measured in accordance with AATCC 8-2016. In some embodiments, a fabric of the present invention has a colorfastness to crocking, wet and/or dry, having a grade of 3.0, 4.0, or 5.0 by the Gray Scale for Staining when measured in accordance with AATCC 8-2016. The fabric, wet and dry, may have a grade of 4.0 or 5.0 by the Gray Scale for Staining when measured in accordance with AATCC 8-2016.
In some embodiments, a fabric of the present invention may have a colorfastness to perspiration having a grade of at least 4.0 for color change by the Gray Scale for Color Change and/or a grade of at least 3.0 or 4.0 for staining by the Gray Scale for Staining when measured in accordance with AATCC 15-2013. In some embodiments, a fabric of the present invention may have a colorfastness to perspiration having a grade of 4.0 or 5.0 for color change by the Gray Scale for Color Change and/or a grade of 4.0 or 5.0 for staining by the Gray Scale for Staining when measured in accordance with AATCC 15-2013.
A fabric of the present invention may have one or more (e.g., 1, 2, 3, 4, 5, 6, or 7) colorfastness characteristics as defined in Table 2.
A fabric of the present invention, after laundering, may have a dimensional change in the warp direction and/or fill direction or in the length direction and/or width direction (e.g., machine direction and/or cross-machine direction) that is within ±7%, ±6%, ±5%, ±4%, or ±3%, as measured in accordance with AATCC 135-2018 (3) (III) (A) (iii), AATCC 158-2016 and/or AATCC 96-2012 (Mc) (A) and/or (E) carried out at a temperature of about 105° F. to about 140° F. In some embodiments, the laundering is performed in accordance with AATCC 135-2018 (3) (III) (A) (iii), AATCC 158-2016 (dry cleaning) and/or AATCC 96-2012 (commercial laundry) (Mc) (A) and/or (E) at a temperature of about 120° F. to about 140° F. In some embodiments, the dimensional change in the warp direction and fill direction or in the length direction and width direction is within ±7%, optionally within ±6%, ±5%, ±4%, or ±3%, and the laundering may optionally be carried out in accordance with AATCC 135-2018 (3) (III) (A) (iii), AATCC 158-2016 (dry cleaning) and/or AATCC 96-2012 (commercial laundry) (Mc) (A) and/or (E) at a temperature of about 120° F. to about 140° F. In some embodiments, the dimensional change in the warp direction and fill direction for a woven fabric is less than 4% or less than 3%. In some embodiments, the dimensional change in the length direction and width direction for a knit fabric is less than 7%.
In some embodiments, after laundering, a fabric of the present invention has a dimensional change in the warp direction and/or fill direction or machine direction and/or cross-machine direction that is reduced compared to dimensional change in the warp direction and/or fill direction or machine direction and/or cross-machine direction for a control fabric (e.g., a fabric that is devoid of fiber dyed modacrylic fibers) after the same laundering as measured in accordance with AATCC 135-2018 (3) (III) (A) (iii), AATCC 158-2016 and/or AATCC 96-2012 (Mc) (A) and/or (E) carried out at a temperature of about 105° F. or 120° F. to about 140° F.
A yarn and/or fabric of the present invention may be flame-resistant. “Flame-resistant” as used herein in reference to a yarn or fabric refers to a yarn or fabric that, upon exposure to an external source of ignition (e.g., a flame or electric arc flash), burns slowly or self-extinguishes after removal of the external source of ignition. In some embodiments, a flame-resistant yarn or fabric does not melt or drip, has an after-flame of less than 2 seconds, and has a char length of less than 6 inches when tested in accordance with ASTM F1506 and/or ASTM D6413 and/or does not melt or drip, has an after-flame of less than 2 seconds, and has a char length of less than 6 inches after 25 launderings as tested in accordance with ASTM D6413. In some embodiments, the fabric is flame-resistant and the fabric meets or exceeds the requirements set forth in ASTM D6413. In some embodiments, the fabric is UL compliant and/or the fabric meets or exceeds the requirements set forth in ASTM D6413, NFPA 70E, NFPA 2112, ASTM F1506, NFPA 1975, NFPA 1977, Canadian Standard CGSB 155.20, and/or Canadian Standard CGSB 155.22/22. In some embodiments, the fabric meets or exceeds the requirements set forth in NFPA 1975, NFPA 1977 and Canadian Standard CGSB 155.22.
In some embodiments, a fabric of the present invention has improved flame resistance compared to a control fabric. Flame resistance may be measured in accordance with ASTM D6413, ASTM F1506, ASTM D2261, and/or ASTM D5034. In some embodiments, the fabric, when tested in accordance with ASTM D6413 and/or ASTM F1506, has a char length of less than about 6, 5.5, 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, 1, or 0.5 inches. In some embodiments, the fabric after 10, 25, 50, 75, 100, 125, 150, or more launderings (e.g., industrial launderings and/or wash cycles), when tested in accordance with AATCC 135, Method 3, V, A, iii, ASTM D6413, and/or ASTM F1506, has a char length of less than about 6, 5.5, 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, 1, or 0.5 inches. In some embodiments, the fabric, when tested in accordance with AATCC 135, Method 3, V, A, iii, ASTM D6413, and/or ASTM F1506, has a char length about 0.5, 1, or 1.5 inches to about 2, 2.25, 2.5, or 3 inches, optionally after 25 launderings. In some embodiments, the fabric, when tested in accordance with ASTM D6413 and/or ASTM F1506, has an after-flame and/or self-extinguishes within less than about 2, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 seconds. In some embodiments, the fabric after 10, 25, 50, 75, 100, 125, 150, or more launderings, when tested in accordance with AATCC 135, Method 3, V, A, iii ASTM D6413, and/or ASTM F1506, has an after-flame and/or self-extinguishes within less than about 2, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, 0.5 seconds. In some embodiments, the fabric, when tested in accordance with AATCC 135, Method 3, V, A, iii, ASTM D6413, and/or ASTM F1506, has an after-flame and/or self-extinguishes of about 0 or 0.5 seconds to about 1 or 1.5 seconds, optionally after 25 launderings. The fabric, when tested in accordance with AATCC 135, Method 3, V, A, iii, ASTM D6413, and/or ASTM F1506, may have a char length of less than about 6 inches and may self-extinguish in less than about 2 seconds, optionally after 0, 10, 25, 50, 75, 100, 125, 150, or more launderings.
In some embodiments, a fabric of the present invention has an improved arc rating compared to a control fabric. Arc rating for a fabric may be measured in accordance with ASTM F1959 and/or ASTM F1506. In some embodiments, the fabric has an arc rating of about 4, 8, 10, 15, 20, 25, 30, 35, 40, 45, 50 cal/cm2 or more, optionally as measured in accordance with ASTM F1959 and/or ASTM F1506. In some embodiments, the fabric has an arc rating of at least about 9.5 or 10.1 cal/cm2, optionally as measured in accordance with ASTM F1959 and/or ASTM F1506. In some embodiments, the fabric has an arc rating that satisfies the arc rating requirement for personal protective equipment (PPE) in category 1 (e.g., has an arc rating of at least 4.0 cal/cm2 as measured in accordance with ASTM F1959 and/or ASTM F1506). In some embodiments, the fabric has an arc rating that satisfies the arc rating requirement for PPE in category 2 (e.g., has an arc rating of at least 8.0 cal/cm2 as measured in accordance with ASTM F1959 and/or ASTM F1506). In some embodiments, the fabric has an arc rating that satisfies the arc rating requirement for PPE in category 3 (e.g., has an arc rating of at least 25 cal/cm2 as measured in accordance with ASTM F1959 and/or ASTM F1506). In some embodiments, the fabric has an arc rating that satisfies the arc rating requirement for PPE in category 4 (e.g., has an arc rating of at least 40 cal/cm2 as measured in accordance with ASTM F1959 and/or ASTM F1506). In some embodiments, the fabric is a category 1, 2, 3, or 4 PPE fabric as measured in accordance with ASTM F1959 and/or ASTM F1506.
In some embodiments, color or color fastness of a fabric of the present invention may be measured in accordance with TM AATCC 16E. In some embodiments, the fabric may have a rating of 3, 3.5, 4, 4.5, or 5 as measured in accordance with TM AATCC 16E. A fabric having a dark shade (e.g., navy, black, etc.) may have a rating of at least 3 as measured in accordance with TM AATCC 16E. A fabric having a light shade (e.g., tan, ecru, light gray, etc.) may have a rating of at least 4 as measured in accordance with TM AATCC 16E. The fabric may have a laundering rating of at least 4 as measured in accordance with TM AATCC 61 2A. In some embodiments, the fabric has a laundering rating of about 4, 4.5, or 5 as measured in accordance with TM AATCC 61 2A. In some embodiments, the fabric may have a crocking rating of at least 4 as measured in accordance with TM AATCC 8. In some embodiments, the fabric has a crocking rating of about 4, 4.5, 5, 5.5, or 6, as measured in accordance with TM AATCC 8.
In some embodiments, the fabric may shrink in length and/or width direction after a laundering (e.g., after 1, 10, 25, 50, 75, 100, 150, 160, 200, or more launderings) by less than about 3%, 2.5%, 2%, 1.5%, 1%, or 0.5%, optionally as measured in accordance with TM AATCC 135, method 3, V, A, iii. In some embodiments, the fabric may shrink in length and/or width direction after 10 or 25 launderings (e.g., wash cycles) by less than about 3%, 2.75%, 2.5%, 2.25%, 2%, 1.75%, 1.5%, 1.25%, 1%, 0.7%, or 0.5% as measured in accordance with TM AATCC 135, method 3, V, A, iii. In some embodiments, a fabric of the present invention has improved shrinkage in the length and/or width direction compared to the shrinkage in the length and/or width direction of a control fabric. For example, in some embodiments, the fabric has reduced (e.g., reduced by about 2%, 5%, 10%, 15%, 20%, or more) shrinkage in the length and/or width direction of the fabric compared to the shrinkage of a control fabric in length and/or width direction. In some embodiments, a fabric of the present invention, after exposure to 500° F. for 5 minutes, has a shrinkage in the length and/or width direction of less than 10%, optionally as measured in accordance with Section 8.4 of NFPA 2112-2018 and/or ASTM F2894.
A fabric of the present invention may have tear strength in the warp direction and/or fill direction or machine direction and/or cross-machine direction of about 2.5 lbf or more, optionally as measured in accordance with ASTM D1424. In some embodiments, the fabric may have a tear strength in the warp direction and/or fill direction or machine direction and/or cross-machine direction of about 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, or 20 lbf or more, optionally as measured in accordance with ASTM D1424. In some embodiments, the fabric may have a tear strength in the warp direction and/or fill direction or machine direction and/or cross-machine direction of about 2.5, 3, 3.5, or 4 lbf to about 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, or 20 lbf, optionally as measured in accordance with ASTM D1424. In some embodiments, the fabric has a tear strength in the warp direction and/or fill direction or machine direction and/or cross-machine direction of at least about 4, 5, 6, 7, 8, 9, 10, 11, or 12 as measured in accordance with ASTM D1424.
In some embodiments, a fabric of the present invention has minimal or no discoloration after about 10, 25, 50, 75, 100, 150, 160, 200, or more launderings compared to the color of the fabric prior to laundering and/or compared to a control fabric. Discoloration may be determined upon visual comparison with the human eye. In some embodiments, a fabric of the present invention after about 10, 25, 50, 75, 100, 150, 160, 200, or more launderings exhibits no visually perceptive color change compared to the color of the fabric prior to laundering.
A fabric of the present invention may have a CIE Delta E of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 at about 3, 6, 9, or 12 months or more (e.g., 3, 6, 9, or 12 months or more of outdoor exposure) and/or after exposure to 880, 1320, or 2200 kJ in accordance with AATCC 169 Option 3.
In some embodiments, a fabric of the present invention has increased and/or improved strength (e.g., tear strength and/or tensile strength), shrinkage, seam slippage, crock, shade consistency, color fastness, arc-flash resistance, and/or laundering properties compared to the strength (e.g., tear strength and/or tensile strength), shrinkage, seam slippage, crock, shade consistency, color fastness, arc-flash resistance, and/or laundering properties for a control fabric.
A fabric and/or yarn of the present invention may be used to form a garment using methods known to those of skill in the art. Exemplary garments include, but are not limited to, shirts, pants, pullovers, jackets, coveralls, vests, gloves, and headwear.
The present invention is explained in greater detail in the following non-limiting examples.
EXAMPLES Example 1Colorfastness to laundering (accelerated) was tested in accordance with AATCC TM61-2013 for a fluorescent yellow woven fabric and a control fabric using a 1993 AATCC Standard Reference Detergent WOB (0.15%), Launder-Ometer Roaches laundering machine, and stainless steel abrasive balls. The fluorescent yellow woven fabric was style number GGSW2532, was not piece dyed, and included, by weight of the fabric, 74% fiber dyed modacrylic fibers, 15% fiber dyed meta-aramid fibers, 10% natural para-aramid fibers and 1% natural (white) anti-static fibers. The control fabric was a fluorescent yellow-green woven fabric that was piece dyed and included, by weight of the fabric, 95% modacrylic fibers (that were not fiber dyed modacrylic fibers) and 5% para-aramid fibers. All results in grade are on gray scale with Grade 5 corresponding to no change in color nor staining and Grade 1 corresponding to severe change in color or staining. The results for the fluorescent yellow woven fabric at four different washing temperatures are provided in Table 3. Including additional fiber dyed modacrylic fibers in the fabric should provide comparable or better results than those provided in Table 3. The results for the control fabric at a washing temperature of 40±2° C. are provided in Table 4.
The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.
Claims
1. A yarn comprising:
- a blend of fibers, the blend of fibers comprising:
- about 90% to about 99% fiber dyed modacrylic fibers by weight of the yarn;
- about 0% to about 10% para-aramid fibers by weight of the yarn; and
- about 0% to about 2% anti-static fibers by weight of the yarn,
- wherein at least one of para-aramid fibers and anti-static fibers are present in the yarn.
2.-17. (canceled)
18. A fabric comprising the yarn of claim 1.
19. A fabric comprising:
- a plurality of yarns, wherein each yarn of the plurality of yarns comprises fiber dyed modacrylic fibers blended with para-aramid fibers and/or anti-static fibers,
- wherein the fabric comprises:
- about 90% to about 99% fiber dyed modacrylic fibers by weight of the fabric;
- about 0% to about 10% para-aramid fibers by weight of the fabric; and
- about 0% to about 2% anti-static fibers by weight of the fabric.
20. The fabric of claim 19, wherein the fabric comprises para-aramid fibers.
21. The fabric of claim 19, wherein the fabric comprises anti-static fibers.
22. The fabric of claim 19, wherein the fabric comprises para-aramid fibers and anti-static fibers.
23. The fabric of claim 20, wherein the para-aramid fibers are not fiber dyed para-aramid fibers.
24. The fabric claim 19, wherein the fiber dyed modacrylic fibers are present in an amount of about 95% by weight of fabric and the para-aramid fibers are present in an amount of about 5% by weight of the fabric.
25. The fabric of claim 19, wherein the fiber dyed modacrylic fibers are present in an amount of greater than 95% by weight of fabric and the para-aramid fibers are present in an amount of less than 5% by weight of the fabric.
26. The fabric of claim 19, wherein the fabric comprises fiber dyed fibers in an amount of about 90% to about 100% by weight of the fabric.
27.-29. (canceled)
30. The fabric of claim 19, wherein the fabric is not treated with a coloring agent and/or wherein each yarn of the plurality of yarns is devoid of a post-formation dye.
31. The fabric of claim 19, wherein the fabric has a weight of about 5 ounces per square yard (osy) to about 7 osy.
32. The fabric of claim 19, wherein the fabric is woven or is a knit.
33-34. (canceled)
35. The fabric of claim 19, wherein the fabric meets or exceeds the requirements set forth in ANSI/ISEA 107-2020, ISO 20471:2013, ASTM E1164-17, AATCC 61-2013 AATCC 132-2013, AATCC 133-2013 as carried out at 230° F., 302° F., and/or 392° F., AATCC 8-2016, AATCC 15-2013, ASTM D1424-09 (2019), ASTM D3787-07 (2016), ASTM D6797-07 (2015), AATCC 135-2018, AATCC 96-2012, and/or AATCC 107-2013.
36. The fabric of claim 19, wherein the fabric, after laundering in accordance with AATCC 61-2013 as carried out at about 105° F. 145° F., has a grade of 4-5 or 5 for color change and/or a grade of 4, 4-5, or 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and/or staining of wool.
37. The fabric of claim 19, wherein the fabric, after laundering in accordance with AATCC 61-2013 as carried out at about 105° F., has a grade of 4, 4-5, or 5 for staining of acetate, staining of cotton, staining of nylon, staining of polyester, staining of acrylic, and/or staining of wool.
38. (canceled)
39. The fabric of claim 19, wherein the fabric, after laundering in accordance with AATCC 61-2013 as carried out at about 145° F., has an improvement in grade for staining of one or more of acetate, cotton, nylon, polyester, acrylic, and wool compared to a control fabric devoid of a fiber dyed modacrylic fiber.
40. The fabric of claim 19, wherein the fabric has a color, prior to and/or after an exposure test, having chromaticity coordinates as defined by ANSI/ISEA 107-2020 that fall within the chromaticity coordinates for fluorescent yellow-green, fluorescent orange-red, or fluorescent red.
41. The fabric of claim 19, wherein the fabric has a luminance factor, prior to an exposure test, of at least 70%, optionally wherein the luminance factor is measured in accordance with ASTM E1164-17.
42.-45. (canceled)
46. The fabric of claim 19, wherein, after laundering, the fabric has a dimensional change in the warp direction and/or fill direction or machine direction and/or cross-machine direction that is within ±7%, as measured in accordance with AATCC 135-2018 (3) (III) (A) (iii), AATCC 158-2016 and/or AATCC 96-2012 (Mc) (A) and/or (E) carried out at a temperature of about 105° F. to about 140° F.
47-53. (canceled)
54. The fabric of claim 19, wherein the fabric is UL compliant and/or the fabric meets or exceeds the requirements set forth in ASTM D6413, NFPA 70E, NFPA 2112, ASTM F1506, NFPA 1975, NFPA 1977, Canadian Standard CGSB 155.20, and/or Canadian Standard CGSB 155.22.
55.-64. (canceled)
65. The fabric of claim 19, wherein the fabric has a protection to weight ratio of about 1 or more (arc rating (cal/cm2) as measured in accordance with NFPA 70E:weight of the fabric).
66. A method of forming a garment, the method comprising:
- providing the fabric of claim 19.
67. (canceled)
Type: Application
Filed: May 6, 2022
Publication Date: Nov 10, 2022
Inventors: Christopher Brent Martin (Winston-Salem, NC), Mia Rauston Alberto (Greensboro, NC), Robert Charles Earhart (Mebane, NC)
Application Number: 17/738,133
