FIBER BLENDS FOR DUAL HAZARD AND COMFORT PROPERTIES

Info

Publication number: 20140187113
Type: Application
Filed: Mar 15, 2013
Publication Date: Jul 3, 2014
Inventors: Robert Winfred Hines, Jr. (Columbus, GA), James Jonathan Bailey (Forston, GA)
Application Number: 14/238,294

Abstract

Fiber blends useful for garments with a balance of high thermal and comfort properties are disclosed. The fiber blends comprise a FR fiber component, a comfort fiber component, a structural fiber component, and an optional antistatic fiber. Yarns, fabrics, and garments comprising the fiber blends are also disclosed. Such garments are particularly useful for occupations requiring high thermal properties, such as oil and gas workers, fire fighters, utility workers, and military personnel, without compromising comfort of the wearers by maintaining breathability and moisture management properties of the fabric.

Description

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser. No. 61/620,417, filed Apr. 4, 2012 and titled “Fiber Blends for Dual Hazard and Comfort Properties,” the entirety of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to fiber blends. More particularly, the invention relates to fiber blends used for a balance of high thermal and comfort properties and to the yarns, fabrics, and garments made from the fiber blends.

BACKGROUND

Flame-resistant fabrics (also variously referred to as “fire-resistant,” “flame-retardant,” and “fire-retardant” fabrics) are fabrics that, once ignited, tend not to sustain a flame when the source of ignition is removed. Considerable research has been directed toward the development and improvement of flame-resistant fabrics for use in various products, including clothing and bedding. Flame-resistant clothing is often worn by workers involved in activities such as industrial manufacturing and processing (such as oil, gas, and steel industries), fire-fighting, electrical utility work, military work, and other endeavors that entail a significant risk of being exposed to open flame, flash fire, momentary electrical arcs, and/or molten metal splash. Non-flame resistant work clothes can ignite and will continue to burn even after the source of ignition has been removed. Untreated natural fabrics will continue to burn until the fabric is totally consumed and non-flame resistant synthetic fabrics will burn with melting and dripping causing severe contact burns to the skin. The majority of severe and fatal burn injuries are due to the individual's clothing igniting and continuing to burn, not by the exposure itself. Abrasion resistance of protective fabrics is also important, as garments which have developed failures such as holes and rips can compromise the protective properties of the fabric.

Flame-resistant fabrics include both fabrics that are treated to be flame-resistant as well as flame-resistant fabrics made from inherently flame-resistant fibers. The former types of fabrics are not themselves flame-resistant, but are made flame-resistant by applying to the fabric a chemical composition that renders the fabric resistant to flame. These types of fabrics are susceptible to losing their flame-resistance with repeated laundering because the flame-resistant composition tends to wash out. In contrast, inherently flame-resistant fabrics do not suffer from this drawback because they are made from fibers that are themselves flame-resistant. The use of flame resistant clothing provides thermal protection at the exposure area. The level of protection typically rests in the fabric weight and composition. After the source of the ignition is removed, flame resistant garments will self-extinguish, limiting the body burn percentage.

Flame-resistant fabrics often contain a low percentage of natural fibers and have limited comfort properties such as adsorption of water. Flame-resistant fabrics are most often worn in work environments and comfort, including adsorption of sweat from the skin, is an important performance factor, especially in extreme conditions such as firefighting. Combining some percentage of natural hydrophilic fibers with FR fibers may provide some improvement in comfort and moisture wicking, however this typically comes at a loss of FR performance properties. Most FR fibers, including modacrylic fibers, are hydrophobic and do not provide high comfort performance.

Various types of inherently flame-resistant (FR) fibers have been developed, including modacrylic fibers (e.g., modacrylic fibers sold under the PROTEX name from Kaneka Corporation of Osaka, Japan, and Tairylan sold by Formosa Plastics of Taiwan). Acrylic FR fibers sold under the name PyroTex, (Hamburg, Germany), aramid fibers (e.g., meta-aramid fibers sold under the NOMEX name and para-aramid fibers sold under the KEVLAR name, both from E. I. Du Pont de Nemours and Company of Wilmington, Del.), FR rayon fibers, oxidized polyacrylonitrile fibers, and others. It is common to blend one or more types of FR staple fibers with one or more other types of non-FR staple fibers to produce a fiber blend from which yarn is spun, the yarn then being knitted or woven into fabrics for various applications. In such a fiber blend, the FR fibers render the blend flame-resistant even though some fibers in the blend may themselves be non-FR fibers, because in the case of antimony and halogen filled fibers when the FR fibers are exposed to heat and flame they release non-combustible gases that tend to displace oxygen and thereby extinguish any flame. In the case of non-filled FR fibers the high percentage of FR fibers form char, or exhibit other characteristics which provide wearer protection.

In addition to the above-noted performance specifications of fabrics, other properties are also important if a fabric is to be practical and commercially viable, particularly for clothing. For instance, the fabric should be durable under repeated industrial launderings and should have good abrasion-resistance. Furthermore, the fabric should be comfortable to wear. Unfortunately, many of the FR blends are not comfortable under typical environmental conditions. In such cases, wearers tend to be less likely to be compliant and thereby decreasing the probability that the wearer will continue to use the garment as intended. Thus, it is beneficial if an FR fabric exhibits good moisture management properties, i.e., ability to wick away sweat and dry quickly so that the wearer does not become overheated or chilled, and/or the fabric does not irritate the wearer's skin.

Selection of a fiber blends to meet a plurality of the requirements as described, while being affordable is a constant challenge. Some fiber, such as (FR) fiber and especially inherently (FR) fibers that are thermally shrink resistant, as defined herein, are relatively expensive, and incorporating a high percentage of these fibers into a yarn and fabric may be cost prohibitive for many applications.

Woven FR fabrics are well suited for many of the FR test protocols, including NFPA 2112 and especially the thermal shrinkage tests. Woven fabrics are relatively tight, having little void volume, between yarns, therein reducing the propensity to thermally shrink. Other types of fabric structures, such as knits, may be more comfortable to wear, as they typically have higher porosities, however they typically may not meet the thermal shrinkage requirements. The yarns in a knit fabric are looped and therefore not as restrained as yarns in a conventional woven fabric and therefore can shrink more.

There exists a need for a fiber blend and fabric made therefrom that is not only electric arc protective and flame-resistant but that is also thermally shrink resistant, meeting the thermal shrinkage resistance requirements of NFPA 2112, while also providing superior moisture management properties and strength properties to ensure wearer compliance. The fiber blends, fabrics, and garments of the present invention are directed toward these, as well as other, important ends.

SUMMARY OF THE INVENTION

The invention relates generally to fiber blends and to fabrics and garments comprising the fiber blends that achieve a balance of high thermal properties, including flame resistance and thermal shrinkage resistance, as well as moisture management properties to provide both protection and comfort to the wearer. In one embodiment the fiber and fabrics made therefrom are dual hazard materials, meeting both NFPA 2112 requirements and having an arc rating of at least 8 cal/cm²min as described herein. In yet another embodiment, the fabric made from a fiber blend described herein, is a dual hazard fabric and also has an initial weight gain of at least 40% and/or a WRR of at least 0.35%/min after 10 wash cycles, as described herein. An exemplary fiber blend described herein comprises some weight percent of comfort fiber that provides for improved moisture management, such as wicking sweat away from a wearer's skin. In addition, the comfort fiber described herein may comprise a natural fiber that is soft and increases comfort when worn directly against the skin.

Accordingly, in one embodiment, the invention is directed to fiber blends and fabrics made therefrom, comprising a blend of FR fibers, comprising a first FR modacrylic fiber that is hydrophobic and a second acrylic FR fiber that is thermally shrink resistant and may be hydrophilic. A fiber blend may comprise any suitable percent by weight of the blend of FR fibers including, but not limited to, more than about 30%, more than about 40%, more than about 50%, more than about 60%, more than about 70%, no more than about 80%, or any range between and including the weight percentages provided. In one embodiment the acrylic FR fiber is hydrophilic, providing improved moisture wicking performance and may also be dye accepting. The thermally shrink resistant acrylic FR fiber component of the FR fiber blend is relatively expensive compared to the FR modacrylic fiber component, and therefore, optimizing and or minimizing the concentration of the acrylic FR fiber to while maintaining a surprising combination of properties including meeting the dual hazard requirement and/or meeting the thermal shrink resistance requirement. It has been found that a FR fiber blend and fabric made therefrom can meet the dual hazard requirements as well as the thermal shrinkage requirements with as little as 10% of the acrylic FR fiber. Any suitable weight percentage, based on the total fiber blend weight, of the acrylic FR fiber may be incorporated into the fiber blend including, but not limited to, more than about 10%, more than about 15% more than about 20%, more than about 25%, more than about 30%, and any range between and including the provided weight percentages. The acrylic FR fiber component is expensive and it is therefore preferred to incorporate by total fiber weight, no more than about 30%, or no more than about 25%.

A fiber blend described herein may incorporate the FR fiber blend, as well as other fiber components, such as 10-35%, by weight, based on the total weight of the fiber blend, of a comfort fiber component comprising at least one material selected from the group consisting of cotton, cellulose, cellulose derivatives, wool, and combinations thereof; and 5-25%, by weight, based on the total weight of the fiber blend, of at least one structural fiber component comprising at least one material selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers and combinations thereof. The fiber blend described herein my further comprise 0.1 to 3% by weight, or more preferably 1% to 3%, based on the total weight of the fiber blend, of at least one antistatic fiber. In addition, the fiber blend, yarns, and fabrics described herein may further comprise an antimicrobial component, such as an antimicrobial fiber or coating.

In another embodiment, the invention is directed to fiber blends comprising: 30-80%, by weight, of a FR fiber component comprising a first FR fiber component, comprising at least one fiber selected from the group consisting of modacrylic, FR acrylic, acrylic derivatives, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof that is hydropobic, and a second thermally shrink resistant FR fiber that is at a concentration of at least 10% by weight of the total fiber blend; 10-35%, by weight, based on the total weight of the fiber blend, of a comfort fiber component comprising at least one material selected from the group consisting of cotton, cellulose, lyocell, cellulose derivatives, wool, and combinations thereof and 5-25%, by weight, based on the total weight of the fiber blend, of at least one structural fiber component comprising at least one material selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers (PAN) and combinations thereof. The fiber blend described herein my further comprise 0.1 to 3% by weight, based on the total weight of the fiber blend, of at least one antistatic fiber.

In some embodiments, the FR fiber component comprises, or consists essentially of inherently FR fiber. In one embodiment at least about 20% by weight of the FR fiber component comprises or consists essentially of hydrophobic FR fiber. In yet another embodiment at least about 10% of the FR fiber component is hydrophilic FR fiber. In some embodiments, the thermally shrink resistant FR fiber comprises or consists essentially of inherently FR fiber. In yet other embodiments, the thermally shrink resistant FR fiber component comprises or consists essentially of hydrophilic fiber. In some embodiments the thermally shrink resistant FR fiber is a dye accepting fiber. In some embodiments the thermally shrink resistant FR fiber is a high LOI fiber having a LOI value of at least 38 as described herein.

In some embodiments the FR fiber comprises at least 10% by weight, thermally shrink resistant FR fiber. In another embodiments the FR fiber comprises at least 20% by weight, thermally shrink resistant FR fiber.

In some embodiments, the fiber blend as described herein, is a dual hazard fiber blend, whereby fabric made therefrom meets NFPA 2112 requirement and has an arc rating of at least 8 cal/cm2. Furthermore, the dual hazard fabric may have an initial water weight gain of at least 40% and/or a WRR of at least 35%/min after 10 wash cycles.

In some embodiments, the invention is directed to yarns comprising the fiber blends described herein. In other embodiments, the invention is directed to fabrics comprising the fiber blends described herein. In yet other embodiments, the invention is directed to garments, especially outerwear, comprising the fabric formed from the fiber blends described herein.

The summary of the invention is provided as a general introduction to some of the embodiments of the invention, and is not intended to be limiting. Additional example embodiments including variations and alternative configurations of the invention are provided herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain principles of the invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

FIG. 1 is a graph showing the fiber blend concentrations of Fiber Blend 1, an exemplary embodiment described herein.

FIG. 2 is a graph showing the fiber blend concentrations of Fiber Blend 2, an exemplary embodiment described herein.

FIG. 3 is a graph showing the fiber blend concentrations of Fiber Blend 3, an exemplary embodiment described herein.

FIG. 4 is a graph showing the fiber blend concentrations of Fiber Blend 4, an exemplary embodiment described herein.

FIG. 5 is a graph showing the fiber blend concentrations of a comparative example.

FIG. 6 is a top view of woven fabric in a 2×1 twill weave.

FIG. 7 is a top down view of a knit having looped yarns.

The figures represent an illustration of some of the embodiments of the present invention and are not to be construed as limiting the scope of the invention in any manner. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

As employed above and throughout the disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Also, use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

As used herein with reference to fiber, yarn or fabric compositions, the term “consisting essentially of” means that the fiber, yarn or fabric is made primarily of a described component, such as a polymer, material or fiber type and may include small amounts, less than 5% by weight of additional treatments, coating or finishes.

As used herein with reference to fabric, the term “formed substantially of” means that the fabric includes at least 50% by weight, based on the total weight of the fabric, preferably at least 75% by weight, based on the total weight of the fabric, and more preferably at least 95% by weight, based on the total weight of the fabric of a specific fiber blend or yarn composition.

As used herein, the term “modacrylic fiber” refers to a acrylic synthetic fiber made from a polymer comprising primarily residues of acrylonitrile, especially polymers that have between 35 to 85% acrylonitrile units, and which may be modified by other monomers. Modacrylic fibers are spun from an extensive range of copolymers of acrylonitrile. The modacrylic fiber may contain the residues of other monomers, including vinyl monomer, especially halogen-containing vinyl monomers, such as but not limited to vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, and the like. The types of modacrylic fibers that can be produced within this broad category are capable of wide variation in properties, depending on their composition. Acrylic derivative fibers, as used herein includes modacrylic fibers as described herein and any fiber comprising acrylic monomer units, including acrylic FR fibers sold under the name PyroTex, (Hamburg, Germany). Some examples of commonly available modacrylics are PROTEX™, KANEKALON™, KANECARON™ by Kaneka Corporation. Modacrylic fibers have excellent fire retardancy performance combined with non-melt, non-drip and self-extinguishing properties. These are critically important attributes in many working environments. If sufficiently high temperatures are reached on exposure to fire or explosion, a garment made with the inventive fiber blends of the invention will carbonize by forming a protective charred barrier. This prevents propagation of flames, thereby protecting the wearer from severe burn injuries. Modacrylics have a high so-called LOI value as compared with other fibers. The LOI represents the minimum oxygen concentration of an O₂/N₂mix required to sustain combustion of a material. The LOI is determined by the ASTM Test D 2862-77. Modacrylics have an LOI value preferably between about 28 and 33 while conventional polyesters have a much lower value of about 20 to 22. A high LOI fiber or material, as defined herein, has an LOI of more than 38. For example, acrylic FR fiber, available from Pyrotex has an LOI greater than 40.

Some FR fiber are more environmentally friendly and do not contain antimony or halogen compounds. In addition, most FR fibers have a limiting oxygen index LOI, greater than 25, and some FR fibers may be characterized as being high LOI FR fibers, having an LOI of greater than 38. A high LOI is preferred as it improves FR performance, including the performance of fiber blends. Finally, some FR fibers are hydrophilic including Acrylic FR fiber sold under the name PyroTex. Hydrophilic fibers, including hydrophilic FR fibers are typically dye accepting fibers.

As used herein, acrylic FR fiber, refers to a FR fiber that is thermally shrink resistant, hydrophilic and in some embodiments has and LOI greater than 38. In some embodiments an acrylic FR fiber is antimony and halogen free, such as acrylic FR fiber available from Pyrotex.

As used herein, the term “fluoropolymer” refers to a fluorocarbon-based polymer with at least one, but preferably multiple, strong carbon-fluorine bonds, including, but not limited to, polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), or fluorinated ethylene-propylene (FEP).

As used herein, the term “aramid fiber” refers to a manufactured fiber in which the fiber-forming substance is a long-chain synthetic polyamide in which at least 85% of the amide linkages, (—CO—NH—), are attached directly to two aromatic rings, including, but not limited to, para-aramid (p-aramid) and meta-aramid (m-aramid). Examples of para-aramids include, but are not limited to, (poly(p-phenylene terephthalamide), e.g., KEVLAR® (E.I. du Pont de Nemours and Company), TWARON® (Teijin Twaron BV), and TECHNORA by Teijin Company. KEVLAR is a para-aramid fiber having a very high tenacity of between 28 and 32 grams/denier and outstanding heat resistance. Examples of meta-aramids include, but are not limited to, (poly(m-phenylene isophthalamide), such as NOMEX® (E.I. du Pont de Nemours and Company) and CONEX® (Teijin Twaron BV). Preferably, the structural fiber is p-aramid, microdenier p-aramid. Such structural fibers feature excellent thermal stability and are virtually non-flammable. These fibers have a very high resistance to heat and are resistant to melting, dripping and burning at a temperature of at least 700° F. Moreover, their LOI value is preferably in the range of between about 28 and about 30.

As used herein, the term “melamine fiber” is a manufactured fiber in which the fiber-forming substance is a synthetic polymer composed of at least 50% by weight of a crosslinked non-thermoplastic melamine polymer of melamine units joined by methylene and dimethylene ether linkages. In the polymerization reaction, methylol derivatives of melamine react with each other to form a three-dimensional structure. This structure is the basis for the fiber's heat stability, solvent resistance, and flame resistance.

As used herein, the term “antistatic fiber” or conductive refers to a fiber that, when incorporated into a fabric or other material, eliminates or reduces static electricity. Suitable fibers include, but are not limited to, metal fibers (steel, copper or other metal), metal-plated polymeric fibers, and polymeric fibers incorporating carbon black on the surface and/or in the interior of the fiber, such as those described in U.S. Pat. No. 3,803,453, U.S. Pat. No. 4,035,441, U.S. Pat. No. 4,107,129, and the like. Antistatic carbon fiber is a preferred antistatic fiber. One example of such conductive fiber is NEGASTAT® produced by E.I. du Pont de Nemours and Company, a carbon fiber comprising a carbon core of conductive carbon surrounded by non-conductive polymer cover, either nylon or polyester. Another example is RESISTAT® made Shakespeare Conductive Fibers LLC, a fiber where the fine carbon particles are embossed on the surface of a nylon filament. The yarns of both such fibers are available in a denier of at least 40. By way of example, a steel wire is available under the names BEKINOX and BEKITEX from Bekaert S.A. in a diameter as small as 0.035 millimeter. Another antistatic fiber is the product X-static made by Noble Fiber Technologies, a nylon fiber coated with a metal (silver) layer. The X-static fibers may be blended with other fibers, such as modacrylics, in the process of yarn spinning.

As used herein, the term “structural carbon fiber” refers to fibers of about 0.005-0.010 mm in diameter and formed primarily of carbon atoms. The carbon atoms are bonded together in microscopic crystals that are more or less aligned parallel to the long axis of the fiber. Each carbon filament is produced from a precursor polymer. Common precursor polymers include commonly rayon, polyacrylonitrile (PAN), and petroleum pitch. For synthetic polymers such as rayon or PAN, the precursor is first spun into filaments, using chemical and mechanical processes to initially align the polymer atoms in a way to enhance the final physical properties of the completed carbon fiber. After drawing or spinning, the polymer fibers are then heated to drive off non-carbon atoms (carbonization), producing the final carbon fiber. Suitable structural fibers are available from Zoltek, SGL Carbon, Fortafil, Sumitomo, and Kureha Corporation.

As used herein, with reference to fibers, yarns and fabric made therefrom, the term “thermally shrink resistant”, means that the said fabrics meet the thermal shrinkage resistance requirements of NFPA 2112-0.7 Ed, Section 8.4, and has less than 10% shrinkage according to the test described herein.

Some specialty fibers are thermally shrink resistant, and when incorporated into a fiber blend may provide enough thermal shrink resistance to allow the yarn or fabric made therewith to meet thermal shrinkage requirements. For example, acrylic FR fiber available from Pyrotex has low thermal shrinkage properties, and when incorporated into the fiber blend in a concentration of more than 10%, as shown herein, a fabric made with the fiber blend meets the thermal shrinkage requirements of NFPA 2112-0.7 Ed, Section 8.4.

Suitable thermally shrink resistant fibers include, but are not limited to, acrylic FR fibers (e.g., PyroTex, Hamburg, Germany), polyacrylonitrile (PAN), aramid fibers (e.g., meta-aramid fibers sold under the NOMEX name and para-aramid fibers sold under the KEVLAR name, both from E. I. Du Pont de Nemours and Company of Wilmington, Del.), and the like FR Rayon, FR Cotton, Basofill etc. In some embodiments, a thermally shrink resistant fiber may be hydrophilic and/or dye accepting, as used herein to mean that the fiber may accept a die to substantially and durably impart a color to the fiber. Durably impart a color to the fiber means that the fiber will substantially retain the color after three or more wash cycles.

Many of the thermally shrink resistant fibers are hydrophobic and are not dye accepting, such as polyacrylonitrile (PAN), and aramid fibers. Certain acrylic derivative fibers, such as acrylic FR fibers available from PyroTex, are both thermally shrink resistant and can accept a dye. These fibers provide, when incorporated into the fiber blends described herein, a unique combination of properties heretofore unachieved. In particular, yarns, fabric and garments incorporating thermally shrink resistant fibers as described herein, may be constructed to meet “dual hazard” requirements and also thermal shrinkage resistance requirements.

As used herein, with reference to fibers, yarns and fabrics, the term “dual hazard” means the fiber, yarn, fabric or garment made therefrom meets the requirements of NFPA 2112 and has an arc rating of at least 8 cal/cm²

As used herein, the term “basis weight” refers to a measure of the weight of a fabric per unit area. Typical units include ounces per square yard and grams per square centimeter.

As used herein, the term “garment” refers to any article of clothing or clothing accessory worn by a person, including, but not limited to shirt, pants, underwear, outer wear, footwear, headwear, swimwear, belts, gloves, headbands, and wristbands.

As used herein, the term “linen” (when not in relation to the hydrophilic fiber) refers to any article used to cover a worker or seating equipment used by workers, including, but not limited to sheets, blankets, upholstery covering, vehicle upholstery covering, and mattress covering.

As used herein, the term “intimate blend,” when used in conjunction with a yarn, refers to a statistically random mixture of the staple fiber components in the yarn.

Accordingly, in one embodiment, the invention is directed to fiber blends and fabrics made therefrom, comprising: 30-80%, by weight, of a FR fiber component comprising a first FR fiber component, comprising at least one fiber selected from the group consisting of modacrylic, acrylic derivative, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof that is hydrophobic, and a second thermally shrink resistant FR fiber that is at a concentration of at least 10% by weight of the total fiber blend; 10-35%, by weight, based on the total weight of the fiber blend, of a comfort fiber component comprising at least one fiber selected from the group consisting of cellulose, cellulose derivatives, wool, and combinations thereof; and 5-25%, by weight, based on the total weight of the fiber blend, of at least one structural fiber component comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers, and combinations thereof. The fiber blend described herein my further comprise 0.1 to 3% by weight, based on the total weight of the fiber blend, of at least one antistatic fiber.

In certain embodiments, when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric provides protection against second and third degree burns on less than about 35% of the wearer, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM F 1930-2000. In preferred embodiments, fabric provides protection against second and third degree burns on less than about 25% of the wearer, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM F 1930-2000. In more preferred embodiments, fabric provides protection against second and third degree burns on less than about 15% of the wearer, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM F 1930-2000, as provided in Table 11.

In certain embodiments, when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric has a char length less than about 5 inches, preferably less than about 4 inches, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM 6413, as provided in Table 9.

In certain embodiments, when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric may have a heat and a thermal protective performance value of at least about 5 cal/cm²min, preferably at least about 5.7 cal/cm²min initially, and at least about 6.7 cal/cm²min after 3 washing cycles, when tested in accordance with the National Fire Prevention Association NFPA 1971 (without spacer), as provided in Table 12.

In certain embodiments, the yarns comprising the fiber blends described herein are constructed into a fabric that has a thermal shrinkage value of less than about 10%, when tested in accordance with the National Fire Prevention Association NFPA 2112. Section 8.4, as provided in Table 10.

In certain embodiments, when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric may have a water weight gain of at least 40% and/or a WRR after three was cycles of at least 0.35%/min when tested according to AATCC MM TS-05, as provided in Table 7.

In certain embodiments, when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric may have a wet and dry abrasion performance of 1500 and 4000 respectively when tested according to American Society for Testing and Materials Standard Test ASTM D 1424, as provided in Table 8.

The FR fiber component of the fiber blend of the invention is present at a level of about 30-80%, by weight, based on the total weight of the fiber blend, wherein at least 10% of the FR fiber is a thermally shrink resistant fiber, and comprises at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof. The FR fiber may comprise any suitable weight percent of the fiber blend, based on the total weight of the fiber blend including, but not limited to, greater than about 30%, greater than about 40% greater than about 50%, greater than about 60%, greater than about 65%, about 70% and any range between and including the weight percentages provided. The FR fiber component of the fiber blend may comprise any suitable weight percentage of a thermally shrink resistant fiber including, but not limited to, greater than about 5%, greater than about 10% greater than about 15%, greater than about 20%, greater than about 30%, greater than about 40%, greater than about 50%, greater than about 60%, and any range between and including any of the weight percentages provided. The shrink resistant fiber is typically more expensive than conventional FR fiber, such as modacrylic, and therefore it is preferred to optimize the concentration of the shrink resistant fiber component to provide the dual hazard properties while keeping cost of the fiber blend down. In an exemplary embodiment, the fiber blend comprises 75 weight percent, FR component comprising 20 weight percent, based on the total fiber weight, of a thermally shrink resistant fiber. In certain embodiments of the fiber blend, the FR fiber component is modacrylic or copolymer thereof. The FR fiber may be comprised of, or consist of an inherently FR fiber.

In other embodiments, a fluoropolymer fiber comprises a polymer selected from the group consisting of polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), fluorinated ethylene-propylene (FEP), and mixtures thereof.

The comfort fiber component of the fiber blend of the invention is present at a level of about 10% to about 35%, by weight, based on the total weight of the fiber blend, and comprises at least one fiber selected from the group consisting of cellulose, cellulose derivatives (such as cotton, viscose, linen, rayon, fire-resistant rayon, or a combination thereof), wool, and combinations thereof. In one embodiment, the comfort fiber component comprises or consists essentially of hydrophilic fiber. In another embodiment the comfort fiber component comprises or consists essentially of cellulose, or cellulose derivative fibers, as described herein. Any suitable weight percent, based on the total fiber weight, of the comfort fiber component may be incorporated into the fiber including, but not limited to, greater than about 10%, greater that about 15%, greater than about 20%, greater than about 30%, greater than about 35%, and any range between and including the weight percentages provided. In other embodiments, the cellulose derivative is cotton, viscose, linen, rayon, or a combination thereof. A preferred comfort fiber component is cotton or fire-resistant rayon, or a combination thereof.

The structural component of the fiber blend of the invention is present at a level of about 5-25%, by weight, based on the total weight of the fiber blend. The structural fiber component comprises at least one fiber selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers and combinations thereof; wherein said aramid fiber is present at a level of at least about 5%, by weight, based on the total weight of the fiber blend. Any suitable weight percent, based on the total fiber weight, of the structural fiber component may be incorporated into the fiber including, but not limited to, greater than about 5%, greater that about 10%, greater than about 15%, greater than about 20%, about 25% and any range between and including the weight percentages provided. In other embodiments, the structural component is aramid fiber, such as m-aramid polymer fiber or p-aramid polymer fiber. In certain embodiments, the aramid fiber is present at a level of about 5-15%, by weight, based on the total weight of the fiber blend. In other embodiments, the structural component is a combination of nylon fiber and aramid fiber, particularly p-aramid fiber. In certain other embodiments, the structural component is a combination of nylon fiber and aramid fiber, particularly p-aramid fiber, where both components are preferably present at a level of about 10%, by weight, based on the total weight of the fiber blend.

In certain embodiments of the fiber blend, an optional antistatic fiber is present at a level of about 0.1-3%, by weight, based on the total weight of the fiber blend. In certain embodiments, the antistatic fiber is an antistatic carbon fiber.

In certain embodiments of the fiber blend, the FR fiber component is modacrylic or a copolymer thereof; the comfort fiber component is cellulose or a cellulose derivative, or a combinations thereof; and the structural fiber component is aramid fiber, nylon fiber, or a combination thereof.

In certain embodiments of the fiber blend about 70% by weight, based on the total weight of the fiber blend, is acrylic derivative FR fiber copolymers thereof; about 20%, by weight is cotton; about 10%, by weight is para-aramid fiber; and about 2%, by weight is antistatic carbon fiber.

In certain embodiments of the fiber blend about 75%, by weight, based on the total weight of the fiber blend, is acrylic derivative FR fiber and copolymers thereof; about 15%, by weight is cotton; and about 10%, by weight is para-aramid fiber.

In certain embodiments of the fiber blend, about 55% by weight of the fiber, based on the total weight of the fiber, is FR fiber component and comprises modacrylic or a copolymer thereof, and about 20% by weight is thermally shrink resistant fiber; and about 15% by weight is comfort fiber component comprising cellulose or a cellulose derivative, or a combinations thereof; and about 10% by weight is structural fiber component comprising aramid fiber, nylon fiber, or a combination thereof. In an exemplary embodiment, the thermally shrink resistant fiber is acrylic FR fiber.

In certain embodiments of the fiber blend, the FR fiber component is 55% by weight Protec modacrylic fiber, and 20% by weight PyroTex thermally shrink resistant fiber, an acrylic derivative fiber; the comfort fiber component is Tencel G1 fiber; and the structural fiber component is aramid.

In another aspect, the invention is directed to yarns comprising the various fiber blends described herein, wherein said FR fiber component, said comfort fiber component, said structural fiber component, and said optional antistatic fiber are intimately blended. An intimate fiber blend may be formed into any suitable fabric, as described herein. In an exemplary embodiment, an intimate blend of fibers is formed into a woven fabric. In another exemplary embodiment an intimate blend of fibers is formed into a knit fabric.

In another aspect, the invention is directed to fabrics formed from the yarns comprising the various blends described herein. The fabrics may be either woven or knitted. In certain embodiments, the fabric has a basis weight of less than about 8.0 ounces/square yard (OPSY). In certain other embodiments, the fabric has a basis weight of less than about 6.0 ounces/square yard (OPSY).

The fiber blend as described herein may formed into any suitable type of fabric in including, but not limited to, non-wovens, such as hydroentangled, and wet-laid, and wovens including, twill weaves, denim weaves, and knits for example. In one embodiment, the fiber blend described herein may be formed into a knit fabric that meets the dual hazard standards as described herein. As shown in FIG. 7, a fabric having a knit weave typically has more open area than a twill type weave, as shown in FIG. 5. A knit fabric comprises looped yarns that provide a comfortable feel, however, this type of weave may be more susceptible to high thermal shrinkage. Tighter weaves, such as that shown in FIG. 6, however comprise yarns that are more tightly packed and therefore typically perform better in thermal shrinkage tests, than knits. In one embodiment, it is envisioned that the fiber blend described herein may be formed into a knit fabric that meets the standards of dual hazard, as described herein, and is thermally shrink resistant as described herein.

In some embodiments, the fabric may be formed into a garment. In certain embodiments, the fabric forms at least one outer portion of the garment because of the protection it provides. The fabric is useful in garments such as outwear, including, but not limited to coats, coveralls, overalls, shirts, and pants, and is particularly useful in firefighter turnout coats. In other embodiments, the fabric is formed into a garment, such as an undershirt, in a single tubular design to eliminate or reduce the number of seams and failure points.

In other embodiments, linen may be formed from the fabric of the invention.

The present invention is further defined in the following Examples, in which all parts and percentages are by weight, unless otherwise stated. It should be understood that these examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions

Certain exemplary embodiments of the present invention are described herein and illustrated in the accompanying figures. The embodiments described are only for purposes of illustrating the present invention and should not be interpreted as limiting the scope of the invention. Other embodiments of the invention, and certain modifications, combinations and improvements of the described embodiments, will occur to those skilled in the art and all such alternate embodiments, combinations, modifications, improvements are within the scope of the present invention.

It will be apparent to those skilled in the art that various modifications, combination and variations can be made in the present invention without departing from the spirit or scope of the invention. Specific embodiment, features and elements described herein may be modified, and/or combined in any suitable manner. Thus, it is intended that the present invention cover the modifications, combination and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Examples

Initial screening tests on fiber blends were performed to determine how changes in concentration of various fibers effected performance parameters. Samples of each fiber type were weighed out and then blended using a small carding drum, approximately 12 cm wide by approximately 15 cm in diameter. Intimately blended fiber strands, approximately 5 cm long, were made for the flame test. Sample buttons, approximately 6.5 cm in diameter, were made out of the blended fibers for the oven screening tests.

Table 1 below shows the concentration of FR fiber, FR-Thermally Shrink Resistant (TSR) fiber, Comfort Fiber and Structural fiber. Sample A comprised 20%, by weight, FR-TSR fiber, and Sample B contained no FR-TSR fiber.

TABLE 1 Fiber Screening Blend FR FR FR-TSR Comfort Structural Sample Protex-C Protex-M PyroTex Tencel G-100 Kevlar A 50 20 20 10 B 50 35 15

The fiber strands were evaluated in a flame test by igniting the strands with a lab Bunsen burner, and then recording the time the flame remained after removing the ignition source. In addition the time the samples glowed after removal of the ignition source was recorded. Finally, the weight of the sample was measured before and after the flame test and a percent weight loss was calculated.

TABLE 2 Fiber Screening Flame Test Total seconds Flame Flame 2 sec. Afterflame Afterglow Weight Weight % weight Sample flame seconds seconds before after loss A 120 none none 0.5 0.37 26% B 120 none none 0.5 0.33 34%

Sample A with the FT-TSR fiber had a much lower flame % weight loss, at 26%, compared to Sample B.

The button samples were placed in a 500° F. oven for 5 minutes to determine shrinkage and weight loss.

TABLE 3 Fiber Screening Oven Testing 500 degree F. Oven Fiber Oven for 5 min % button Sam- Weight weight weight diameter diameter Shrinkage ple before after loss cm before cm after percent A 0.5 0.32 36% 6.5 5 23% B 0.5 0.3 40% 6.5 5 23%

Sample A with the FT-TSR fiber had a much lower oven weight loss % than Sample B, and the same percent shrinkage as Sample B.

Four different fiber blends, Fiber Blend 1 through 4 as shown in Table 4, were prepared as described herein. Comparative Fiber 1 was prepared to demonstrate the improved properties of the fiber blend described herein. Initial tests suggested that Fiber Blend 4 provided the best combination of properties including thermal properties, shrink resistance properties and comfort, or moisture management properties. FIGS. 1 through 4 graphically show the Fiber Blends 1 through 4, respectively. FIG. 5 graphically shows the fiber blend of Comparative fiber 1. Fiber Blend 1 is comprised of 30% by weight comfort component, Lyocell which is hydrophilic, 20% by weight, thermally shrink resistant fiber component, acrylic FR, which is also hydrophilic, and 5% by weight structural component, para aramid, also hydrophilic. Therefore, Fiber Blend 1 was comprised of 50% by weight hydrophilic fiber component and 50% by weight hydrophobic component. Fiber Blend 2 was comprised of 45% hydrophilic component, and 55% hydrophobic component, as shown in FIG. 2. Fiber Blend 3 was comprised of 40% hydrophilic component, and 60% hydrophobic component, as shown in FIG. 3. Fiber Blend 4 is comprised of 35% hydrophilic component, and 65% hydrophobic component, as shown in FIG. 4. Comparative Fiber 1 however, is comprised of 75% hydrophobic component and only 15% hydrophilic component.

TABLE 4 Fiber Blends: Weight Percent of Fiber Components. Thermally Shrink Resistant FR Fiber (TSR) Comfort Structural Component Component Component Component Fiber Blend 1 45% 20% 30% 5% Fiber Blend 2 50% 15% 30% 5% Fiber Blend 3 55% 20% 15% 10% Fiber Blend 4 55% 20% 20% 5% Comparative 80% 0% 15% 5% Fiber 1

Table 5, below, provides specific details about the types of fibers used in fiber blends 3 and 4.

TABLE 5 Fiber Details, Fiber Blend 3 Generic % Fabric % Fabric Staple Component Manufacturer Type Name Blend 3 Blend 4 Denier Length FR Kanekacaron Protex C Modacrylic 55 55 1.5 2″ TSR Pyrotex 2.5-50 Acrylic-FR 20 20 2.5 2″ Comfort Lenzing Tencel Lyocell 15 15 1.2 2″ G100 o Structural DuPont Kevlar Para 10 5 1.5 2″ Aramid

Fiber blends 3 and 4 were made into woven fabrics as described in Table 6. After blending, the homogenous fiber mix was then processed through carding and drawing. Yarn was formed on Air Jet Spinning equipment to the specified counts preferably in the range from 13/1 to 15/1. Alternative staple fiber spinning technologies that could be used include ring spinning, compact spinning, DREF spinning and Open End spinning Fabric was woven to twill construction constructions in the range of 77 to 82 warp count and 43 to 50 weft counts. Fabric designs include 2×1 right and left hand twills as well as 3×1 left hand twill. Alternative embodiments may be knit and nonwoven fabrics as well as other woven constructions. The fabrics were scoured according to standard industry practices and jet dyed to shade. Mocacrylic and Pyrotex dye procedures are compatible regarding type of dyes and dye process. All fibers are theoretically dye accepting except for Para aramid. For dark shades, a producer dyed black Para aramid would be used. For light shades (khaki) standard Para aramid could be used. Fabric was finished with an antimicrobial after dyeing. Performance finishes may be applied at this point including permanent press or stain resistance.

TABLE 6 Fabric Constructions Fiber Yarn Weight Blend Weave Count Construction oz./yd2 Fabric 1 3 2 × 1R 13 77 × 50 8.2 Fabric 2 3 3 × 1L 14 77 × 48 7.4 Fabric 3 3 2 × 1L 15 82 × 43 6.9 Fabric 4 4 2 × 1R 26/2 77 × 50 8.4

Test Methods

The following test methods were used to evaluate exemplary embodiments, unless otherwise noted.

Water Weight Gain and Water Release Rate (WRR) Test Method

The water release rate (WRR) of materials made according to the present invention as well as comparative materials were measured according to AATCC MM TS-05A.

Gravimetric Drying Test Method.

The drying times of materials made according to the present invention as well as comparative materials were measured according to AATCC MM TS-05A.

For a typical test, four 2.5×2.5 inch square specimens were used. Two of the specimens were the “control” (reference) fabric and two were the “test” fabric of interest. Samples were conditioned in the conditioning room at temperature of 70° F. and 55% relative humidity for at least 4 hours prior to test. The samples were weighed using a laboratory balance, accurate to 0.0001 g. Then 10 mL of distilled water was placed into a 25 ml beaker. Samples were submerge, one specimen in the beaker for 5-10 minutes, making certain that the specimen was completely submerged under the water to insure complete wetting. Samples were removed from the beaker and sandwich between two pieces of unused AATCC blotter paper and passed through a wringer. The samples were left sandwiched in the wet blotters

A vertical specimen stand was placed on a balance and the weight was tarred. The blotted test specimen was hung from the vertical stand. The weight of the test specimen was recorded. The balance was coupled to a data acquisition system comprising LabView software. Weight readings were automatically recorded every 15 seconds by the computer. The test was complete once the specimen weight had reached a designated stopping moisture level vs. the dry conditioned weight. The stopping moisture level was approximately 0.5% to 1%. The test was ended by stopping data acquisition in LabView. The data file was saved for that specimen.

Calculation and Interpretation

Total drying time is the time it takes the specimen to reach the stopping weight.

Total water release rate (“WRR”, g/min) was calculated as follows:

Total WRR=(wet specimen weight−ending specimen weight)/(total drying time)

WRR, total (%) is calculated from the respective total WRR values as follows:

WRR_total=100×(WRR_test−WRR_control)/WRR_control

“Comfort Zone” drying time (min) is the time it takes the specimen's moisture content to decrease from 15% to 0.5% (polyester) or 20% to approximately 1%.

“Comfort Zone” WRR (g/min) was calculated as follows:

Active WRR=(wet specimen weight−ending specimen weight)/(“active” drying time)

WRR(Comfort Zone) was calculated in the same manner as for WRR(total) except using test and control WRR(Comfort Zone) values.

Vertical Wicking (AATCC MM TS-06 Vertical Wicking-Modified-Hanes Protocol):

The purpose of this test is to determine the rate at which water will wick vertically up test specimens suspended in water. A 500 ml Erlenmeyer flasks was filled with 200 mL colored water. Samples of fabric six inches by one inch were cut for evaluation. The long direction was cut parallel with the warp direction of the woven fabric samples and parallel with the wale direction of the knitted fabric samples. A straight pin was pierced through one end, approximately 0.25 inch from the top of sample, and the sample was lowered into the flask and supported by the pin across the top of the flask. After one minute, the sample was removed from the flask and the distance the water had wicked up the sample, as indicated by the change in color of the sample, as recorded. The sample was then placed back into the flask and removed after a period of three minutes, five minutes and every additional five minute interval thereafter until the water wicked a distance of six inches or one hour had elapsed. The time it took for the water to wick up the sample six inches or the distance the water level wicked up the sample after one hour was reported.

Dry & Wet Abrasion Resistance (ASTM D 4966):

Test Method followed was Modified ASTM D 4966—Abrasion Resistance of Textile Fabrics (Martindale Abrasion Tester Method) 2. Abradant used was 600 ultrafine grit 3M (9084NA) sandpaper and the fabric was subject to 9 kPa of pressure. For wet abrasion test, fabrics were soaked in water and passed through padding mangle at 0.05 MPa pressure. A, Laboratory Dye Padder available from Lab-Pro, Dorfstrasse 19 Germany, was used for the padding to remove excess water from the samples.

Heat and Thermal Shrinkage Resistance NFPA 2112-0.7 Ed, Section 8.4

This test determines the performance of fabrics when exposed to heat in an oven at 500° F. Observations of ignition, melting, dripping, or separation are recorded and reported for each specimen. The percent change in the width and length direction of the specimen is calculated. Results are recorded and reported as the average of three specimens.

Specimen marking and measurements are conducted in accordance with the procedure specified in AATCC 135 Dimensional Change in Automatic Home Laundering of Fabrics. The specimen is suspended by metal hooks at the top and centered in an oven so that the entire specimen is not less than 50 mm from any oven surface or other specimen, and air is parallel to the plane of the material. The specimen, mounted as specified, was exposed in the test oven for 5 minutes at 500° F.

Flame Resistance of Textiles (Vertical)

This test method determines the response of textiles to a standard ignition source, deriving measurement values for after-flame time, afterglow time, and char length. The vertical flame resistance, as determined by this test method, only relates to a specified flame exposure and application time. This test method maintains the specimen in a static, draft-free, vertical position and does not involve movement except that resulting from the exposure. Test Method D6413 has been adopted from Federal Test Standard No. 191A method 5903.1, which has been used for many years in acceptance testing.

Samples were cut from fabric to be tested and were mounted in a frame that was hung vertically from inside the flame chamber. A controlled flame was exposed to the sample for a specified period of time. After-flame time, the length of time the material continued to burn after removal of the burner, and after-glow time, the length of time the material glowed after the flame was extinguished, were both recorded. Finally, the specimen was torn by use of weights and the char length, the distance from the edge of the fabric that was exposed to the flame to the end of the area affected by the flame, was measured.

Flash Fire Test Results: Manikin Test

ASTM F1930-99 is a full-scale mannequin test designed to test fabrics in completed garment form in a simulated flash fire. A mannequin, with up to 122 heat sensors spaced around its body, is dressed in the test garment, and then exposed to a flash fire for a pre-determined length of time. Tests are usually conducted at heat energies of 1.8-2 cal/cm²sec, and for durations of 2.5 to 5.0 seconds for single layer garments. Results are reported in percentage of body burn. For consistency in data and accuracy of comparison, the test method defines a standard garment size and configuration that must be used on each test.

Arc Rating: ASTM F 1959/F 1959M—06ae1—Standard Test Method for Determining the Arc Rating of Materials for Clothing

This test method was used to measure the arc rating of materials intended for use as flame resistant clothing for workers exposed to electric arcs that would generate heat flux rates from 84 to 120 kW/m2 (2 to 600 cal/cm2 s). This test method will measure the arc rating of materials which meet the following requirements: less than 150 mm [6 in.] char length and less than 2 s after flame when tested in accordance with Test Method D 6413A.

Test Results:

TABLE 7 Vertical Wicking, Water Weight Gain and WRR results Comfort Zone Vertical Wicking Water WRR (20%-3% No. Of Length in 5 Weight Moisture) ITEM Components Launderings minutes (cm) Gain (%) %/min Fabric 2 55% Modacylic 0 Wash 47.9 0.41 20% TSR-FR 5 Wash 52.1 0.28 15% Tencel 10 Wash 53 0.42 10% Para-Aramid Fabric 3 55% Modacylic 0 Wash 45.1 0.44 20% TSR-FR 5 Wash 9.6 48.3 0.3 15% Tencel 10 Wash 49 0.4 10% Para-Aramid Bulwark 65% Modacrylic/ 0 Wash 25.1 0.66 Protera FR (6.5 Oz/Sq Yd) 33% Nomex/ 5 Wash 8.5 27.7 0.62 2% Antistat 10 Wash 28.5 0.75 Carhartt FR 88% Cotton 0 Wash 35.3 0.42 Indura Ultrasoft (7.0 Oz/Sq Yd) 12% Nylon 5 Wash 5.1 37.4 0.37 10 Wash 37.9 0.36 Cool Touch FR 48% Modacrylic 0 Wash 33.7 0.5 Tecasafe Plus (7.0 Oz/Sq Yd) 37% Lyocell 5 Wash 8.2 37.3 0.46 15% Para-Aramid 10 Wash 37.2 0.46

The inventive Fabric 3 showed better vertical wicking performance than the comparative fabrics. The vertical wicking weight of the inventive fabric was almost double that of the Carhart FT comparative sample. Inventive Fabric 2 and 3, as described herein, both had much higher initial, 0 wash, weight gain than comparative FR fabrics, showing that the inventive fabric has a much higher capacity for adsorbing water. In addition, the fabrics made with the fiber blend according to the present invention had relatively high WRR release rates after 10 washes. This relatively high WRR coupled with the high water weight gain provides for increase wicking and removal of sweat.

TABLE 8 Wet and Dry Abrasion Dry Abrasion Wet Abrasion Item/Fabric Components # of Abrasion # of Abrasion Fabric 2 55% Modacylic 4000 1500 20% TSR-FR 15% Tencel 10% Para-Aramid Bulwark 65% Modacrylic/ 2000 1000 Protera FR 33% Nomex/ (6.5 Oz/Dq Yd) 2% Antistat Carhartt FR 88% Cotton 4000 2000 Indura Ultrasoft 12% Nylon (7.0 Oz/Sq Yd) Cool Touch FR 48% Modacrylic 4000 2000 Tecasafe Puls 37% Lyocell (7.0 Oz/Sq Yd) 15% Para-Aramid

Fabric 2 performed better in terms of dry & wet abrasion resistance than BULWARK PROTERA FR, and had relatively equal performance with INDURA ULTRASOFT & TECASAFE PLUS FR fabrics. It was surprising that a composite fabric with only 10% abrasion resistant material, para-aramid, could perform as well as Bulwark's Protera FR, having 33% Nomex, a very abrasion resistant material.

TABLE 9 Flame Resistance of Textiles (Vertical Flame Test) Test Description Test Method Requirement Fabric 1 Fabric 2 Fabric 3 Flame Resistance NFPA 2112-07 Ed, Section 8.3 As Received Flammability ASTM D6413 (Warp/Fill) Char Length (in) 4.0 in (max) 3.2 × 2.5 3.7 × 2.7 3.8 × 2.6 After Flame (sec) 2 sec (max) 0 0 0 Melt/Drip NMND No No No Flammability after 100 Washes ASTM D6413 (Warp/Fill) Char Length (in) NFPA 2112-07 Ed, 4.0 in (max) 3.9 × 3.4 4.0 × 4.0 4.0 × 3.9 8.1.3 After Flame (sec) Wash and Dry 2 sec (max) 0 0 0 Procedure Melt/Drip NMND No No No

Fabrics 1 through 3, of the present invention, all meet the flame resistance requirements of NFPA 2112 as shown in Table 9.

TABLE 10 Heat and Thermal Shrinkage Resistance Test Description Test Method Requirement Fabric 1 Fabric 2 Fabric 3 Comparative 1 Thermal Shrinkage NFPA 2112-07 NPFA 1971- Resistance Ed, Section 8.4 07 Sec. 8.6 Modified* Warp Direction (Initial) 10% max 5.2 5.3 3.5 Fail Fill Direction (Initial) 10% max 4.3 7.1 7.1 Fail After 3 wash/dry cycles - NFPA 2112-07 10% max 4.3 6.4 5.5 Warp Direction Ed, 8.1.3, Wash/Dry After 3 wash/dry cycles - NFPA 2112-07 10% max 4.7 6.9 6.2 Fill Direction Ed, 8.1.3, Wash/Dry

Fabrics 1 through 3, of the present invention, all met the thermal shrink resistance requirements of NFPA 2112 as shown in Table 10. Comparative fabric 1, as described herein, a plain weave fabric that was 5.5 oz/yd²failed the shrink test as described in Table 10. The comparative fabric sample shrunk and curled to the point where the dimensions after the test could not be measured. The thermal shrink resistance test shows the surprising value of a blend of FR fiber components, and especially a blend of acrylic derivative FR fiber components, as described herein. The comparative sample, and the Fabrics 1 through 3 all had similar acrylic derivative fiber component, however, only the inventive fabrics, Fabric 1 through 3, passed the thermal shrink resistance test.

TABLE 11 Flash Fire Test Results: Manikin Test Test Description Test Method Requirement Fabric 1 Fabric 2 Fabric 3 Flash Fire Exposure (Manikin NFPA 2112-07 Ed, 3 second Yes Yes Yes Test) Section 8.5 exposure Standard Garment Design ASTM F 1930, Yes Yes Yes 8.3.2 Test Garment after 1 wash cycle ASTM F 1930, 50% max Body 14.75%** 13.93% 15.02% NFPA 2112-07 Ed, Burn 8.1.3 Wash/Dry Cycle Undergarments - 4.5 oz (+/−5%) Yes Yes Yes 100% cotton short sleeved crew neck T-shirt and briefs

Fabrics 1 through 3, of the present invention, all meet the flash fire exposure requirements of NFPA 2112 as shown in Table 11.

TABLE 12 Arc Rating Test Description Test Method Requirement Fabric 1 Fabric 2 Fabric 3 Thermal Protective Performance NFPA 2112-07 Ed (TPP) Initialo Spaced Rating Section 8.2 6.0 cal/cm2 (min) 12.58 13.28 11.62 Initial Contact Rating Section 8.2 3.0 cal/cm2 (min) 8.01 8.07 7.15 After 3 wash/dry cycles Spaced Section 8.2 8.1.3 6.0 cal/cm2 (min) 12.87 13.35 12.95 Rating for wash/dry After 3 wash/dry cycles Contact Section 8.2 8.1.3 3.0 cal/cm2 (min) 8.67 7.57 7.57 Rating for wash/dry

Fabrics 1 through 3, of the present invention, all meet the thermal protective performance requirements of NFPA 2112 as shown in Table 12.

TABLE 13 Other Fabric Properties: Test Description Test Method Requirement Fabric 1 Fabric 2 Fabric 3 Tensile Strength (1506) ASTM D 5034 (Grab 40 × 40 175 × 102 167 × 83 158 × 74 Method) Tear Strength (1506) ASTM D1424 4 × 4 8.9 × 6.5 10.1 × 9.0 8.8 × 6.4 (Elmendorf) Dimensional Stability (% max) AATCC-135, 3, IV, A, 3 6.7 × 2.3*** 6.5 × 4.7*** 4.8 × 5.4 iii (5 cycles) Dimensional Stability (% max) AATCC-135, 1, V, A, 7.7 × 2.6 7.0 × 5.2*** 6.2 × 6.0*** iii (5 cycles) Colorfastness to Laundering AATCC-61 (3 3 3 3 2 to 3 cycles) Colorfastness to Dry Cleaning AATCC 132 3 3 to 4 4 4 Colorfastness to Crocking (dry and AATCC 8 4 to 5 4 to 5 4 to 5 wet) Colorfastness to Light (40 hours) AATCC 16 Opt E 2 to 3 3 to 4 3 Colorfastness to Perspiration AATCC 15 4 4 to 5 3 to 4 pH AATCC 81 8.2 8.2 8.1 Seam Efficiency (%) ASTM D 1683a N/A 45.6 × 77.7 50.4 × 75.6 Seam Slippage, max ASTM D 434 .25″ @ 40 lbf Pass Pass Pass Arc Rating ASTM F 1959 HRC II >8 11 ATPV 10 ATPV 8.2 ATPV

Fabrics 1 through 3, of the present invention, had surprisingly high physical properties, and were durably dyed as shown in Table 13.

The disclosures of each patent, patent application, and publication cited or described in this document are hereby incorporated herein by reference, in their entirety.

Those skilled in the art will appreciate that numerous changes and modifications can be made to the preferred embodiments of the invention and that such changes and modifications can be made without departing from the spirit of the invention. It is, therefore, intended that the appended claims cover all such equivalent variations as fall within the true spirit and scope of the invention.

Claims

1. A fiber blend, comprising:

about 30-80%, by weight, of an acrylic derivative FR fiber component comprising: a first hydrophobic FR modacrylic fiber, and a second hydrophilic thermally shrink resistant acrylic FR fiber that is at a level of at least about 10% by weight, based on the total weight of the fiber blend.

2. The fiber blend of claim 1, further comprising: comfort fiber component comprising at least one material selected from the group consisting of cotton, cellulose, cellulose derivatives, wool, and combinations thereof and

about 10-35%, by weight, based on the total weight of the fiber blend, of a

about 5-25%, by weight, based on the total weight of the fiber blend, of at least one structural fiber component comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers and combinations thereof.

3. The fiber blend of claim 1, further comprising about 0.1 to 3% by weight, based on the total weight of the fiber blend, of at least one antistatic fiber.

4. The fiber blend of claim 1, wherein the acrylic derivative FR fiber component consists essentially of:

the first hydrophobic FR modacrylic fiber; and

the second hydrophilic thermally shrink resistant acrylic FR fiber that is present at a level of at least about 10% by weight, based on the total weight of the fiber blend.

5. The fiber blend of claim 1, wherein the acrylic derivative FR fiber component consists essentially of inherently flame-resistant fibers.

6. The fiber blend of claim 1, wherein the hydrophilic thermally shrink resistant acrylic FR fiber consists essentially of inherently flame-resistant fibers.

7. The fiber blend of claim 1, wherein the hydrophilic thermally shrink resistant FR fiber is a dye accepting fiber.

8. The fiber blend of claim 1, wherein the hydrophilic thermally shrink resistant FR fiber is a high LOI fiber, having an LOI of at least 38.

9. The fiber blend of claim 1, wherein the acrylic derivative FR fiber component comprises up to about 50% by weight, based on the weight of the acrylic FR fiber component, of a thermally shrink resistant acrylic FR fiber component.

10. The fiber blend of claim 1, wherein the acrylic derivative FR fiber component comprises about 20% by weight, based on the total weight of the fiber blend, of a thermally shrink resistant acrylic FR fiber component.

11. The fiber blend of claim 1, wherein the acrylic FR fiber component comprises no more than about 30% by weight of the total fiber blend, of the hydrophilic thermally shrink resistant acrylic FR fiber component.

12-13. (canceled)

14. The fiber blend of claim 1, wherein said first hydrophobic FR modacrylic fiber consists essentially of antimony containing hydrophobic modacrylic fiber and the second hydrophilic thermally shrink resistant acrylic FR fiber consists essentially of antimony and halogen free acrylic FR fiber.

15. The fiber blend of claim 1, wherein said acrylic derivative FR fiber component is present at a level of about 40-80%, by weight, based on the total weight of the fiber blend.

16. (canceled)

17. The fiber blend of claim 2, wherein the comfort fiber component is hydrophilic.

18. The fiber blend of claim 2, wherein the comfort fiber component consists essentially of cellulose derivatives.

19. The fiber blend of claim 2, wherein said comfort fiber component is cotton.

20. The fiber blend of claim 2, wherein said comfort fiber component is present at a level of about 10-25%, by weight, based on the total weight of the fiber blend.

21. (canceled)

22. The fiber blend of claim 2, wherein said structural fiber component is aramid fiber.

23. (canceled)

24. The fiber blend of claim 2, wherein said structural fiber component is present at a level of about 10-20%, by weight, based on the total weight of the fiber blend.

25. (canceled)

26. The fiber blend of claim 2, wherein said FR fiber component is acrylic derivative fiber or a combinations thereof; wherein said comfort fiber component is cellulose or a cellulose derivative, or a combinations thereof; and wherein said structural fiber component is aramid fiber, carbon or PAN, nylon fiber, or a combination thereof.

27. A fabric comprising a fiber blend, comprising about 30-80% by weight, based on the total weight of the fiber blend, of an acrylic derivative FR fiber component comprising:

a first hydrophobic FR modacrylic fiber; and

a second hydrophilic thermally shrink resistant acrylic FR fiber that is present at a level of at least about 10% by weight, based on the total weight of the fiber blend.

28. The fabric of claim 27, further comprising:

about 10-35%, by weight, based on the total weight of the fiber blend, of a comfort fiber component comprising at least one material selected from the group consisting of cotton, cellulose, cellulose derivatives, wool, and combinations thereof; and

about 5-25%, by weight, based on the total weight of the fiber blend, of at least one structural fiber component comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers and combinations thereof.

29-37. (canceled)

38. A fiber blend, comprising:

about 30-80%, by weight, of a FR fiber component comprising: a first FR fiber component, comprising at least one fiber selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof that is hydrophobic, and

a second thermally shrink resistant FR fiber that is present at a level of at least 10% by weight of the total fiber blend;

about 10-35%, by weight, based on the total weight of the fiber blend, of a comfort fiber component comprising at least one material selected from the group consisting of cellulose, cellulose derivatives, wool, and combinations thereof; and

about 5-25%, by weight, based on the total weight of the fiber blend, of at least one structural fiber component comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers and combinations thereof.

39. The fiber blend of claim 38, wherein the first FR fiber component consists essentially of modacrylic fiber.

40. The fiber blend of claim 38, wherein the second thermally shrink resistant FR fiber consists essentially of acrylic FR fiber.

41. The fiber blend of claim 38, further comprising about 0.1 to 3% by weight, based on the total weight of the fiber blend, of at least one antistatic fiber.

42. The fiber blend of claim 38, wherein the FR fiber component consists essentially of:

a first hydrophobic FR modacrylic fiber; and

a second hydrophilic thermally shrink resistant acrylic FR fiber that is present at a level at least about 10% by weight, based on the total weight of the fiber blend.

43. The fiber blend of claim 38, wherein the FR fiber component consists essentially of inherently flame-resistant fibers.

44. The fiber blend of claim 38, wherein the thermally shrink resistant FR fiber consists essentially of inherently flame-resistant fibers.

45. The fiber blend of claim 38, wherein the thermally shrink resistant FR fiber is a dye accepting fiber.

46. The fiber blend of claim 38, wherein the thermally shrink resistant FR fiber is a high LOI fiber, having an LOI of at least 38.

47. The fiber blend of claim 38, wherein the FR fiber component comprises up to about 50% by weight, based on the weight of the FR fiber component, of a thermally shrink resistant FR fiber component.

48-51. (canceled)

52. The fiber blend of claim 38, wherein said first FR fiber component consists essentially of antimony containing hydrophobic modacrylic fiber and the second FR fiber component consists essentially of antimony and halogen free acrylic FR fiber, that is hydrophilic.

53. The fiber blend of claim 38, wherein said FR fiber component is present at about 40-80%, by weight, based on the total weight of the fiber blend.

54. (canceled)

55. The fiber blend of claim 38, wherein the comfort fiber component is hydrophilic.

56. The fiber blend of claim 38, wherein comfort fiber component consists essentially of cellulose derivatives.

57. The fiber blend of claim 38, wherein said comfort fiber component is cotton.

58. The fiber blend of claim 38, wherein said comfort fiber component is present at about 10-25%, by weight, based on the total weight of the fiber blend.

59. (canceled)

60. The fiber blend of claim 38, wherein said structural fiber component is aramid fiber.

61. (canceled)

62. The fiber blend of claim 38, wherein said structural fiber component is present at about 10-20%, by weight, based on the total weight of the fiber blend.

63. The fiber blend of claim 38, wherein said structural fiber component is present at about 10-15%, by weight, based on the total weight of the fiber blend.

64. (canceled)

65. A fabric comprising:

about 30-80%, by weight, of a FR fiber component comprising: a first FR fiber component, comprising at least one fiber selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof that is hydrophobic, and a second thermally shrink resistant FR fiber that is present at a level of at least 10% by weight of the total fiber blend;

about 10-35%, by weight, based on the total weight of the fiber blend, of a comfort fiber component comprising at least one material selected from the group consisting of cellulose, cellulose derivatives, wool, and combinations thereof; and

about 5-25%, by weight, based on the total weight of the fiber blend, of at least one structural fiber component comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers and combinations thereof.

66-74. (canceled)

75. A fiber blend, comprising:

about 55%, by weight, based on the total weight of the fiber blend, of a FR fiber component that is not thermally shrink resistant;

about 20%, by weight, based on the total weight of the fiber blend, of a thermally shrink resistant FR fiber component;

about 15%, by weight, based on the total weight of the fiber blend, of a comfort fiber; and

about 10%, by weight, of para-aramid fiber structural fiber component.

76. A fiber blend, comprising:

about 55%, by weight, based on the total weight of the fiber blend, of modacrylic and 20% by weight, based on the total weight of the fiber blend, of acrylic FR fiber;

about 15%, by weight, based on the total weight of the fiber blend, of cotton; and

about 10%, by weight, based on the total weight of the fiber blend, of para-aramid fiber.

77. A yarn comprising the fiber blend of claim 2, wherein said FR fiber component, said comfort fiber component, and said structural fiber component are intimately blended.

78. A fabric comprising the yarn of claim 77.

79. A fabric of claim 78, wherein the fabric is a twill weave.

80. A fabric of claim 78, wherein the fabric is a knit.

81-85. (canceled)

86. The fabric of claim 78, wherein said fabric has a basis weight of less than about 8.0 ounces/square yard (OPSY).

87. (canceled)

88. The fabric of claim 78, wherein said fabric is woven.

89. (canceled)

90. A garment comprising the fabric of claim 78.

91. A garment of claim 90, wherein said fabric forms at least one outer portion of said garment.

92. A garment of claim 90, wherein said garment is outerwear.

93. A garment of claim 90, wherein said outerwear is a coat, coverall, overall, shirt, or pants.

94. (canceled)

95. A yarn comprising the fiber blend of claim 38, wherein said FR fiber component, said comfort fiber component and said structural fiber component are intimately blended.

96. A fabric comprising the yarn of claim 95.

97. The fabric of claim 96, wherein the fabric is a twill weave.

98. The fabric of claim 96, wherein the fabric is a knit.

99. The fabric of claim 96, wherein said fabric is woven.

100. A garment comprising the fabric of claim 96.