LIGHTWEIGHT, ARC-RATED, DYEABLE FABRICS

Lightweight, dyeable fabrics with a balance of high thermal properties, especially arc resistance, on the one hand, and durability and comfort properties, on the other hand, are disclosed. Articles, such as garments and linen, made from the lightweight dyeable fabrics are also disclosed. The fabrics are particularly useful in garments for utility workers, industrial workers, military personnel, and firefighters, especially for use in environments requiring high visibility.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Application No. 62/043,442 filed Aug. 29, 2014, the entire disclosure of which is incorporated by reference.

FIELD OF THE INVENTION

The present invention generally relates to performance fabrics. More particularly, the invention relates to lightweight, arc-rated, dyeable and dyed fabrics with a balance of thermal, durability, and comfort properties and to the garments and article made from the fabrics.

BACKGROUND OF THE INVENTION

Flame-resistant fabrics (also variously referred to as “FR”, “fire-resistant,” “flame-retardant,” and “fire-retardant” fabrics) are fabrics that, once ignited, tend not to sustain a flame, when the ignition source 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 ignition source 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. A significant portion of severe and fatal burn injuries are due to the individual's clothing igniting and continuing to burn, not due to the initial exposure itself. Abrasion resistance of protective fabrics is also important, as garments that 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 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 launderings with hypochlorite bleach. Hypochlorite bleach attacks the finish and reduces the flame-resistant properties of the fabric. 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 to areas of the body covered by the garment. The level of protection typically rests in the fabric weight, construction, and composition. After the ignition source is removed, a flame resistant garment will self-extinguish, limiting the body burn percentage.

Flame-resistant fabrics may contain a low percentage of natural fibers and have limited comfort properties, such as water absorption and breathability. Flame-resistant fabrics are most often worn in work environments, where comfort, including absorption 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 aramid fibers, are hydrophobic and do not provide high comfort performance. Adding a high concentration of hydrophilic fibers, however, may negatively impact moisture management properties and/or fire resistance properties. In addition, garments made from fabrics having high percentage content of hydrophilic fibers may become oversaturated with moisture, such as from sweat, and cause additional burns, when expose to a high temperature.

In addition, fabrics made with a high percentage of aramid fibers, including meta-aramid and/or para-aramid, fibers are typically stiff, have poor softness or drape properties, and are generally uncomfortable to wear. The softness of fabrics made with a high percentage of aramid fibers may be improved by repeated washings but tend to become more hydrophobic. Therefore, many industrial workers, pilots, and emergency responders repeatedly wash garments made with high percentages of aramid fibers to increase comfort, even washing new garments many times prior to the initial use. Unfortunately, many of these garments are made with hydrophobic and/or hydrophilic coatings that can lose effectiveness with repeated washings. Therefore, washed treated garments may have improved softness but decreased moisture management properties.

Various types of inherently 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 based 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. DuPont de Nemours and Company of Wilmington, Del.), FR rayon fibers (sold under the Lenzing FR name, from Lenzing Group, Austria), 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 addition to char formation, and having high Oxygen Limiting Index (LOI), many FR fibers are poor conductors of heat. In the case of non-filled FR fibers, the high percentage of FR fibers form char, or exhibit other characteristics that 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 and home 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 a 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.

One of the hazards to which workers are exposed is arc flash, which is an explosive release of energy caused by an electrical arc. An arc flash results from either a phase to ground or a phase to phase fault caused by, for example, accidental contact with electrical systems, accumulation of conductive dust, corrosion, dropped tools, and improper work procedures. During an arc flash, the temperature can reach 35,000° F., and exposure to an arc flash can result in serious burn injury and death.

Arc rating is the value of energy necessary to pass through any given fabric to cause with 50% probability a second or third degree burn. This value is measured in calories/cm2. The necessary arc rating for an article of clothing is determined by a Hazard/Risk Assessment and the resulting Hazard Risk Category, and is typically measured in terms of arc thermal performance value (ATPV) or energy break open threshold (EBT). For a fabric to be considered useful in most job situations, an arc rating of at least 8 calories/cm2 is required, which is a Hazard Risk Category II (HRC II). Arc rating determines the protective characteristics of the fabric and the higher the arc rating value the greater the protection.

The primary purpose of FR fabric is to resist ignition (as tested by ASTM D-6413, also known as Vertical Flame Test). If fabric is ignited by an arc flash, flash fire, molten metal, and like, the hazard to the wearer instantaneously escalates, because the fire will last much longer than the initial hazard, will typically burn the victim over a much larger body surface area and more deeply, and is more likely to result in airway and lung damage. By not continuing to burn after the initial hazard is over, FR fabric limits burn injury to, at most, only the body surface area directly impacted by the hazard. Limiting the total body surface area greatly improves survival for the victim. The second goal of FR fabric is to insulate the wearer from the thermal hazard, thus reducing or eliminating any second or third degree burn through the fabric, even in areas directly impacted by the hazard. Arc rating measures the protective value of the fabric to this hazard.

To improve arc rating, garment manufacturers adjust the fabric weight, composition, and construction. For example, increasing the weight of the fabric typically improves the arc rating. Unfortunately, increased fabric weight can make garments uncomfortable, bulky, and stiff and may lead to non-compliance by the wearer. Also, for lighter weight fabrics, such as those used in undergarments, it may not be possible to achieve the arc rating, required by workers in high hazard fields, such as utility workers, transportation workers, industrial workers, fire fighters, and military personnel.

High visibility is critical to the personal protection of workers in certain environments. The American National Standards Institute (ANSI), in conjunction with the Safety Equipment Association (ISEA), has developed a standard (ANSI 107 (2010)) and guidelines for high-visibility luminescent safety apparel based on classes of apparel. The standard defines three classes of successively more-visible garments to protect workers exposed to successively higher levels of risk from motor vehicles and heavy equipment. ANSI 107 (2010) sets certain standards for chromaticity and minimum total luminance for three high-visibility colors (fluorescent yellow-green, fluorescent orange-red, and fluorescent red). Fabrics formed from modacrylic fiber blends are known that have an arc rating of HRC II, which also can meet the ANSI 107 standard. However, these fabrics are generally not lightweight.

Thus, there exists a need for lightweight, arc-rated, dyeable fabrics that are capable of meeting the chromaticity and luminance required for high visibility set forth in ANSI 107 (2010). The dyeable and dyed fabrics, garments, and articles of the present invention are directed toward these, as well as other, important ends.

SUMMARY OF THE INVENTION

The invention relates generally to lightweight, dyeable fabrics with a balance of high thermal properties, especially arc resistance, on the one hand, and durability and comfort properties, on the other hand. The fabric, when dyed, can achieve high visibility. The invention also relates to articles, such as garments and linen, made from the lightweight, dyeable or dyed fabrics. The fabrics are particularly useful in garments for utility workers, industrial workers, military personnel, and firefighters, especially for use in environments requiring high visibility.

Accordingly, one embodiment the invention is directed to dyeable fabrics comprising fiber blends. In certain embodiments, the fiber blends comprise:

about 30% by weight to about 70% by weight, based on the total weight of said fiber blend, of a plurality of hydrophobic fibers comprising at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (FBI), and copolymers thereof, and combinations thereof;

about 15% by weight to about 45% by weight, based on the total weight of said fiber blend, of a plurality of fire-resistant hydrophilic fibers comprising at least one polymer selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof; and

about 5% by weight to about 30% by weight, based on the total weight of the fiber blend, of a plurality of structural fibers comprising at least one polymer selected from the group consisting of aramid, melamine, nylon, elastomeric filament, and combinations thereof;

wherein said aramid is present at a level of greater than about 0% by weight to less than about 10%, by weight, based on the total weight of said fiber blend;

wherein said dyeable fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm2;

wherein said dyeable fabric is capable of meeting the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and

wherein said dyeable fabric has a basis weight of less than about 8.0 oz/yd2.

Another embodiment the invention is directed to dyed fabrics, comprising:

the dyeable fabrics described herein; and

at least one dye;

    • wherein said at least one dye imparts to said dyeable fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.

In other embodiments, the invention is directed to dyed fabrics, wherein said at least one dye comprises:

at least one basic dye for said plurality of hydrophobic fibers;

at least one reactive dye for said plurality of hydrophilic fibers; and

at least one acid dye for said plurality of structural fibers;

wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the weight of said plurality of hydrophilic fibers in said fabric;

wherein said dyed fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010).

In other embodiments, the dyeable or dyed fabric is incorporated into articles, including garments and linens, especially those used in environments requiring both arc rating and high visibility.

In yet other embodiments, the invention is directed to dyed woven fabrics, comprising:

a fiber blend, comprising:

    • about 50% by weight, based on the total weight of said fiber blend, of modacrylic fibers;
    • about 35% by weight, based on the total weight of said fiber blend, of cotton fibers;
    • about 10% by weight, based on the total weight of said fiber blend, of a plurality of fibers selected from the group consisting of nylon fibers, polyurethane-polyurea fibers, and combinations thereof; and about 5% by weight, based on the total weight of said fiber blend, of p-aramid fibers;

at least one dye;

wherein said at least one dye imparts to said woven fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.

wherein said dyed woven fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm2;

wherein said dyed woven fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and

wherein said dyed woven fabric has a basis weight of less than about 8.0 oz/yd2.

In other embodiments, the invention is directed to methods of preparing a high-visibility fabric, comprising:

preparing a yarn from a fiber blend;

wherein said fiber blend comprises:

    • about 30% by weight to about 70% by weight, based on the total weight of said fiber blend, of a plurality of hydrophobic fibers comprising at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (FBI), and copolymers thereof, and combinations thereof;
    • about 15% by weight to about 45% by weight, based on the total weight of said fiber blend, of a plurality of fire-resistant hydrophilic fibers comprising at least one polymer selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof; and
    • about 5% by weight to about 30% by weight, based on the total weight of the fiber blend, of a plurality of structural fibers comprising at least one polymer selected from the group consisting of aramid, melamine, nylon, elastomeric filament, and combinations thereof;
    • wherein said aramid is present at a level of greater than about 0% by weight to less than about 10% by weight, based on the total weight of said fiber blend;

converting said yarn into a fabric substrate;

wherein said fabric substrate is woven, knitted, nonwoven, or a combination thereof; and

dyeing said fabric substrate to prepare said high-visibility fabric;

wherein said high-visibility fabric is colored fluorescent yellow-green, fluorescent orange-red, fluorescent red, or a combination thereof.

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.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

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 are open-ended and 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” is 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 by the context.

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). Aramid fiber is a strong, heat-resistant fiber formed of polymers with repeating aromatic groups branching from a carbon backbone, used in materials for bulletproof vests and radial tires. Examples of para-aramids include, but are not limited to, (poly(p-phenylene terephthalamide), e.g., KEVLAR® (E.I. duPont 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). Unlike Kevlar, Nomex cannot align during filament formation and is typically not as strong as para-aramid or KEVLAR. Meta-aramid, however, has excellent thermal, chemical, and radiation resistance. Aramid fibers feature excellent thermal stability and are highly 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 Limiting Oxygen Index (LOI) value is preferably in the range of between about 28 and about 30. The LOI represents the minimum O2 concentration of an O2/N2 mix required to sustain combustion of a material. The LOI is determined by the ASTM Test D 2862-77. Meta-aramids and para-aramids are inherently hydrophobic but in some cases may be treated to render them hydrophilic, at least temporarily.

As used herein, the term “modacrylic fiber” refers to an 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, 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. FR 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 Pyro-Tex, (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. Modacrylics have a high so-called LOI value as compared with other fibers.

As used herein, the term “nylon fiber” refers to a fiber consisting essentially of a polyamide synthetic polymer. Polyamide is a thermoplastic having high abrasion resistance and toughness. Addition of nylon fiber to the fiber blend may increase abrasion resistance of a dyeable fabric.

As used herein, the term “cellulosic fiber” refers to a fiber that comprises a substantial concentration of cellulosic and/or cellulosic derivative material. A cellulosic fiber may comprise any suitable type or combination of cotton, fire-resistant cotton, rayon, fire-resistant rayon, viscose, Lyocell, acetate, bast fibers (such as linen, jute, hemp, and raime), bamboo, soy, and combinations thereof. A cellulosic derivative fiber may comprise a treatment to render it flame resistant. In most cases, a cellulosic derivative fiber is inherently hydrophilic. However, a cellulosic derivative fiber may comprise treatments to render the fiber hydrophobic, hydrophilic, or oleophobic.

As used herein, the term “elastomeric filament” refers to an elastomeric polymer formed into a filament, wherein the elastomeric polymer is formed from polyurethane-polyurea copolymer (spandex or elastane), silicone, fluoroelastomer, polyurethane, fire-resistant (FR)-modified elastic, rubber and the like.

As used herein, the term “polyurethane-polyurea copolymer” refers to synthetic polymers sold as “spandex” or “elastane” under the brand names of LYCRA (Invista), ELASPAN (Invista), ACEPORA (Taekwang), CREORA (Hyosung), INVIYA (Indorama Corporation), ROICA and DORLASTAN (Asahi Kasei), LINEL (Fillattice), and ESPA (Toyobo).

As used herein, the term “hydrophilic fiber” means a fiber that when a fabric made exclusively therefrom has a horizontal wicking time of less than about ten seconds, and more preferably, less than five seconds based upon the AATCC 79 Test Method for horizontal wicking.

As used herein, the term “hydrophobic fiber” means a fiber that is relatively non-water absorptive and moisture insensitive. For the purpose of this invention, hydrophobic fibers are those fibers that will absorb from 0% to 10% of their weight in water. For the purpose of this invention, the amount of water that fibers will absorb may be measured by weighing the dried fibers, exposing the fibers to conditions of 100% relative humidity and room temperature, for a period of twelve hours, and weighing the fibers to determine the weight % of water absorbed.

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 underwear (such as t-shirts and thermal underwear), socks, outer wear (such as coats, shirts, pants, coveralls, overalls, firefighter turnout coats, combat and flight, and the like), footwear (such as shoes, boots, socks, and the like), headwear (such as hood, hats, balaclavas, headbands, and the like), sleepwear, swimwear, belts, gloves, wristbands, and liners thereof.

As used herein, the term “linen” (when not in relation to the hydrophilic fiber) refers to any article used to cover: (a) a user (human or animal); (2) any article to cover a seating or used by a user (human or animal); (3) an article to cover an architectural features (such as a door or window). Non-limiting representative examples include, but are not limited to sheets, blankets, draperies, upholstery covering, vehicle upholstery covering, and mattress covering.

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

The invention relates generally to lightweight, dyeable and dyed fabrics with a balance of high thermal properties, especially arc resistance, on the one hand, and durability and comfort properties, on the other hand. The fabrics, when dyed, can achieve high visibility. The invention also relates to articles, such as garments and linen, made from the lightweight, dyeable or dyed fabrics. The fabrics are particularly useful in garments for utility workers, industrial workers, military personnel, and firefighters, especially for use in environments requiring high visibility.

Accordingly, one embodiment the invention is directed to dyeable fabrics comprising fiber blends. In certain embodiments, the fiber blends comprise:

about 30% by weight to about 70% by weight, based on the total weight of said fiber blend, of a plurality of hydrophobic fibers comprising at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof;

about 15% by weight to about 45% by weight, based on the total weight of said fiber blend, of a plurality of fire-resistant hydrophilic fibers comprising at least one polymer selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof; and

about 5% by weight to about 30% by weight, based on the total weight of the fiber blend, of a plurality of structural fibers comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, polyurethane-polyurea copolymer fiber, and combinations thereof;

wherein said aramid fiber is present at a level of greater than about 0% by weight to less than about 10% by weight, based on the total weight of said fiber blend;

wherein said dyeable fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm2;

wherein said dyeable fabric is capable of meeting the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and

wherein said dyeable fabric has a basis weight of less than about 8.0 oz/yd2.

In yet other embodiments, the invention is directed to dyed woven fabrics, comprising:

a fiber blend, comprising:

about 50% by weight, based on the total weight of said fiber blend, of modacrylic fibers;

about 35% by weight, based on the total weight of said fiber blend, of cotton fibers;

about 10% by weight, based on the total weight of said fiber blend, of a plurality of fibers selected from the group consisting of nylon fibers, polyurethane-polyurea fibers, and combinations thereof; and

about 5% by weight, based on the total weight of said fiber blend, of p-aramid fibers;

at least one dye;

wherein said at least one dye imparts to said woven fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.

wherein said dyed woven fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm2;

wherein said dyed woven fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and

wherein said dyed woven fabric has a basis weight of less than about 8.0 oz/yd2.

In certain embodiments, the hydrophobic fibers comprise at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof. In other embodiments, the hydrophobic fibers are modacrylic or a copolymer thereof. In yet other embodiments, the hydrophobic fibers are fluoropolymer or a copolymer thereof. In another embodiment, the hydrophobic fibers are polybenzimidazole (FBI) or a copolymer thereof. In yet further embodiments, the hydrophobic fibers are any combination of modacrylic, fluoropolymer, polybenzimidazole (FBI), and copolymers thereof.

In certain embodiments, the fire-resistant hydrophilic fibers are selected from the group consisting of cellulose, wool, silk, and combinations thereof. In other embodiments, the fire-resistant hydrophilic fibers are cellulose, including, but not limited to, cotton, fire-resistant cotton, rayon, fire-resistant rayon, viscose, Lyocell, acetate, bast fibers (such as linen, jute, hemp, and raime), bamboo, soy, and combinations thereof, with fire-resistant rayon, cotton, or fire-resistant cotton preferred. In yet other embodiments, the fire-resistant hydrophilic fibers are wool. In another embodiment, the fire-resistant hydrophilic fibers are silk. In yet further embodiments, the hydrophobic fibers are any combination of cellulose, wool, and silk. In certain embodiments, the fire-resistant hydrophilic fiber(s) is (are) inherently fire resistant. In other embodiments, the fire-resistant hydrophilic fibers are treated to make them fire resistant. Combination of inherently fire resistant and treated fibers may be used in the fiber blends.

In certain embodiments, the structural fibers comprise at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, elastomeric filament, and combinations thereof. In other embodiments, the structural fibers comprise aramid fibers; nylon fibers; and optionally, elastomeric filaments. In yet other embodiments, the structural fibers comprise p-aramid fibers; nylon fibers; and optionally, elastomeric filaments.

In certain embodiments, the plurality of hydrophobic fibers are present at a level of about 30% by weight to about 70% by weight, preferably at a level of about 40% by weight to 60% by weight, based on the total weight of said fiber blend.

In certain embodiments, the fire-resistant hydrophilic fibers are present at a level of about 15% by weight to about 45% by weight, preferably about 25% by weight to 45% by weight, based on the total weight of said fiber blend.

In certain embodiments, the structural fibers are present at a level of about 5% by weight to about 30% by weight, preferably about 5% by weight to 20% by weight, more preferably, about 10% by weight to 15% by weight, based on the total weight of said fiber blend.

In certain embodiments, the aramid fiber is present at a level of greater than about 0% by weight to less than about 10% by weight, preferably about 5% by weight to less than about 10%, based on the total weight of said fiber blend.

In certain embodiments, the dyeable fabric is a woven fabric. Wovens include, for example, twill weaves, rip-stop, plain weaves, and denim weaves.

In certain embodiments, the dyeable fabric is a knit fabric. Knits may be single or double knits, as well as weft-knit or warp-knit. Examples of knits include jersey, Swiss pique, interlock, and the like.

In certain embodiments, the dyeable fabric is a non-woven fabric. Nonwoven include, for example, hydroentangled, felts, thermal or point bonded, needle-punched, and wet-laid fabrics.

In certain embodiments, the dyeable or dyed fabric has a basis weight of less than about 8.0 oz/yd2, preferably, less than about 7.5 oz/yd2, and more preferably, less than about 7.0 oz/yd2. In certain embodiments, the dyeable or dyed fabric has a basis weight of greater than about 5.0 oz/yd2, preferably, greater than about 5.5 oz/yd2, more preferably, greater than about 6.0 oz/yd2, and even more preferably, greater than about 6.5 oz/yd2.

In certain embodiments, the fiber blend is intimately blended. For example, the fibers that form the fiber blend are combined before they are spun into a yarn to produce a yarn with a substantially even distribution of the blended fibers.

Another embodiment the invention is directed to dyed fabrics, comprising:

said dyeable fabric described herein; and

at least one dye.

In certain embodiments, the dye imparts to the dyeable fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.

In other embodiments, the invention is directed to dyed fabrics, wherein said at least one dye comprises:

at least one basic dye for said plurality of hydrophobic fibers;

at least one reactive dye for said plurality of hydrophilic fibers; and

at least one acid dye for said plurality of structural fibers.

In certain embodiments, the at least one reactive dye is present at a level of greater than about 1% by weight, preferably, greater than about 2% by weight, more preferably, greater than about 3% by weight, even more preferably, greater than about 4% by weight, based on the total weight of said fabric. In certain embodiments, the at least one reactive dye is present at a level of less than about 10% by weight, preferably, less than about 9% by weight, more preferably, less than about 8% by weight, even more preferably, less than about 7% by weight, yet even more preferably, less than about 6% by weight, and yet further more preferably, less than about 5% by weight, based on the total weight of said fabric. In certain embodiments, the at least one reactive dye is present at a level of greater than about 1% by weight to about 5% by weight, based on the total weight of said fabric. In certain embodiments, the dyed fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010).

In other embodiments, the dyeable fabric is incorporated into articles, including garments (especially shirts, pants, and coveralls) and linens, especially those used in environments requiring both arc rating and high visibility.

In other embodiments, the invention is directed to methods of preparing a high-visibility fabric, comprising:

preparing a yarn from a fiber blend described herein;

converting said yarn into a fabric substrate;

wherein said fabric substrate is woven, knitted, nonwoven, or a combination thereof; and

dyeing said fabric substrate to prepare said high-visibility fabric;

wherein said high-visibility fabric is colored fluorescent yellow-green, fluorescent orange-red, fluorescent red, or a combination thereof.

In certain embodiments, the dyeing, comprises:

(a) contacting said hydrophobic fibers with at least one basic dye;
(b) contacting said hydrophilic fibers with at least one reactive dye;

    • wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric substrate; and
      (c) contacting said structural fibers with a composition comprising:
    • (i) at least one acid dye; and
    • (ii) optionally, at least one dye assist.
      In certain embodiments, the at least one reactive dye is present at a level of greater than about 1% by weight, preferably, greater than about 2% by weight, more preferably, greater than about 3% by weight, even more preferably, greater than about 4% by weight, based on the total weight of the fabric. In certain embodiments, the at least one reactive dye is present at a level of less than about 10% by weight, preferably, less than about 9% by weight, more preferably, less than about 8% by weight, even more preferably, less than about 7% by weight, yet even more preferably, less than about 6% by weight, and yet further more preferably, less than about 5% by weight, based on the total weight of the fabric. In certain embodiments, the at least one reactive dye is present at a level of greater than about 1% by weight to about 5% by weight, based on the total weight of the fabric. In certain embodiments, step (b) and step (c) are carried out substantially simultaneously, i.e., there is at least some overlap in the two contacting steps, such as adding the different dyes in close sequence without rinsing in between dye contacting steps. In certain embodiments, the at least one dye assist is present.

In certain embodiments, the dyeing, comprises:

(a1)) contacting said hydrophobic fibers with at least one basic dye;
(a2) optionally, reduction cleaning said hydrophobic fibers after said step (a1);
(b1) contacting said hydrophilic fibers with at least one reactive dye;

    • wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric substrate;
      (b2) optionally, contacting said hydrophilic fibers with an after treatment after said step (b1);
    • wherein said after treatment comprises a process selected from the group consisting of: soaping, fixing, and combinations thereof; and
      (c) contacting said structural fibers with at least one acid dye.
      In certain embodiments, the at least one reactive dye is present at a level of greater than about 1% by weight, preferably, greater than about 2% by weight, more preferably, greater than about 3% by weight, even more preferably, greater than about 4% by weight, based on the total weight of said fabric substrate. In certain embodiments, the at least one reactive dye is present at a level of less than about 10% by weight, preferably, less than about 9% by weight, more preferably, less than about 8% by weight, even more preferably, less than about 7% by weight, yet even more preferably, less than about 6% by weight, and yet further more preferably, less than about 5% by weight, based on the total weight of said fabric substrate. In certain embodiments, the at least one reactive dye is present at a level of greater than about 1% by weight to about 5% by weight, based on the total weight of said fabric substrate.

In certain embodiments, the methods of the invention further comprise:

pre-treating said fabric substrate, prior to said dyeing;

wherein said pre-treating comprises at least one process selected from the group consisting of desizing, scouring, bleaching, and combinations thereof.

In certain embodiments, the methods of the invention further comprise:

post-treating said high-visibility fabric;

wherein said post-treating comprises at least one process selected from the group consisting of resin finishing, controlled compressive shrinkage processing (also known in the trade as “Sanforized”; used of woven fabrics), overfeed shrinkage control during drying, shrinkage control processing via open width compactor (typically used for knit fabrics), and combinations thereof.

In certain embodiments, the dyes that impart fluorescent yellow-green, fluorescent orange-red, or fluorescent red color to the dyed fabrics comprises at least one dye selected from the group consisting of Disperse Yellow 82 (CAS No. 27425-55-4), Disperse Yellow 184 (CAS No. 34564-13-1), Disperse Yellow 184:1, Disperse Yellow 186 (CAS No. 28754-28-1), Disperse Yellow 199 (CAS No. 35254-10-5), Disperse Yellow 232 (CAS No. 35773-43-4), Disperse Red 277, Basic Red 14, Basic Red 15, Basic Red 49 Sub, Basic Red 104s, Basic Red Specialty, Basic Yellow 40, International Yellow comprising basic Flavine Yellow (available from Dundee Color of Shelby, N.C. as color number 10GFF), International Orange formed from Blue and Red cationic dyestuffs (available from Yorkshire America in Rock Hill, S.C., as color numbers Sevron Blue 5GMF and Sevron Brilliant Red4 G), dye formulations disclosed in U.S. Pat. No. 6,946,412 B2, which are incorporated herein by reference, and combinations thereof. The dyes that impart fluorescent yellow-green, fluorescent orange-red, or fluorescent red color to the dyed fabrics may be combined with fluorescing dyes of colors other than yellow, orange, and red to provide a range of colors. Alternatively, or in addition, the dyes, dyes that impart fluorescent yellow-green, fluorescent orange-red, or fluorescent red color to the dyed fabrics may be combined with non-fluorescing colors to provide a range of colors. It should be understood that for applications where high-visibility in the safety context is not needed or desired, it is possible to use fluorescing dyes other than those described herein.

In certain embodiments, the basic dye imparts fluorescent yellow-green, fluorescent orange-red, or fluorescent red color to the dyed fabrics, particularly to at least a portion of the hydrophobic fibers. Suitable basic dyes include, but are not limited, to:

a xanthene dye including fluorescein disodium, 2′,7′-bis-(2-carboxy ethyl)carboxyfluorescein, 2′,7′-difluorofluorescein, 5-(N-hexadecanoyl)amino fluorescin, 6-carboxyrhodamine 6G, calcium green 1, carboxynaphthofluorescein, oregon green 488, rhodamine (such as C. I. Basic Red 1), rhodamine 110, rose bengal, tetramethylrhodamine ethyl ester perchlorate, or yakima yellow phosphoramidite; and

a cyclic polyene including Thermoplast Brilliant Yellow 10G; and

combinations thereof.

In certain embodiments, the reactive dye imparts fluorescent yellow-green, fluorescent orange-red, or fluorescent red color to the dyed fabrics, particularly to at least a portion of the hydrophilic fibers. Suitable reactive dyes include, but are not limited, to:

a bifunctional dye;

a vinylsulphone dye;

a chlorotriazinyl dye including monochlorotriazine dye (MCT) and dichlorotriazine dye, such as C. I. Reactive Orange 4; Reactive Red 238 (Red Cibacron CR), and Reactive Yellow 17;

Remazol Luminous Yellow FL (Dystar); and

combinations thereof.

In certain embodiments, the acid dye imparts fluorescent yellow-green, fluorescent orange-red, or fluorescent red color to the dyed fabrics, particularly to at least a portion of the structural fibers. Suitable acid dyes include, but are not limited, to:

a dye with a water soluble anionic group including sulphonic acid such as monosulfonic acid dye (for example C. I. Acid Blue 25) and disulfonic acid dyes; a premetalized dye;

anthraquinone type (blue shades), azo types (reds), and triphenyl methane (yellow and green); and

a mordant dye such as Alizarin Red S; and

combinations thereof.

In certain embodiments, the dyeable or dyed fabric is printable.

In certain embodiments, the fiber blend may include an anti-static fiber, although it is not preferred for purposes of achieving high visibility. In certain embodiments, the anti-static fiber comprises a conductive fiber. In certain embodiments, the anti-static fiber comprises a carbon fiber with a nylon sheath.

In certain embodiments, the dyeable fabric is a two-way stretch dyeable fabric. In certain embodiments, the dyeable fabric is a four-way stretch dyeable fabric.

In certain embodiments, the fiber yarn is formed into a spun yarn. In certain embodiments, the spun yarn is configured into a plied yarn having counts of about 20/2 and about 40/2 or an effective 10 to 20 Ne. In certain embodiments, the spun yarn is configured into a plied yarn having counts of about 40/2, about 36/2, about 33/2, about 30/2, about 28/2, and about 24/2 or about 20/1, about 18/1, about 16.5/1, about 15/1, and about 14/1, and ranges of any combination of end points thereof.

In certain embodiments, the yarn is plied whereby two yarns are plied providing improved softness, and hand, as well as increased durability and strength over a single ply yarn of the same weight. Any suitable number of yarns may be plied together including, but not limited to, two, three, four, five, more than five, and the like. In certain embodiments, the yarn is not plied (single yarn).

In certain embodiments, an elastomeric filament may be incorporated into a plied yarn, whereby the elastomeric filament is essentially covered, or wrapped by one or more spun yarns around the elastomeric filament. Alternatively, or in addition, the elastomeric filament may be incorporated into the knit structure (in knit fabrics) through on of the yarns feeding the knitting machine. An elastomeric filament may comprise any suitable type of elastomeric material, including, for example, polyurethane-polyurea copolymer (spandex or elastane), silicone, fluoroelastomer, polyurethane, FR-modified elastic, rubber, and combinations thereof. A yarn having an elastomer filament may provide two-way or four-way stretch to a dyeable or dyed fabric made therefrom.

The dyeable and dyed fabrics made from the fiber blends described herein may have an initial softness that makes it comfortable to wear as received, and may not require repeated washing to reduce stiffness.

The dyeable and dyed fabrics made from the fiber blends described herein have moisture management properties, or combinations of moisture management properties that demonstrate comfort to a wearer. In addition, the dyeable and dyed fabrics made from the fiber blends described herein may have durable moisture management properties, or performance properties that are not substantially affected by washing.

In certain embodiments, a dyeable fabric made from the fiber blend described herein may be formed into an article, such as a garment or linen. In certain embodiments, the dyeable or dyed fabric forms at least one outer portion of the garment or linen because of the protection it provides. A dyeable or dyed fabric made with the fiber blend described herein may be useful in garments such as outerwear, including, but not limited to coats, coveralls, overalls, shirts, vests, and pants, and may be particularly useful in firefighter turnout coats, combat and flight suits. In other embodiments, a dyeable or dyed fabric may be formed into a garment, such as an undershirt, in a single tubular design to reduce the number of seams. In certain embodiments, the garment, such as a vest, comprises the dyed fabric of the invention and reflective material, such as retroreflective tape.

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.

EXAMPLES

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

Moisture Management and Comfort Testing Gravimetric Drying Test Method (WRR, Drying Time and Wet Pick-Up)

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

For a typical test, four 2.5×2.5 inch square samples were used. Two of the samples 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 65% relative humidity for at least 4 hours prior to test. The samples were then weighed using a laboratory balance, accurate to 0.0001 g to establish the conditioned dry weight. Then 10 mL of distilled water was placed into a 25 ml beaker. Samples were submerged, one sample in the beaker for five to ten minutes, making certain that the sample was completely submerged under the water to insure complete wetting. Even samples exhibiting poor or no horizontal wicking, such as 100 seconds or more horizontal wicking time, absorb water if submerged as described. Samples were then removed from the beaker and sandwiched between two pieces of unused AATCC blotter paper and passed through a wringer (LabPro Padder). The samples were then left sandwiched in the wet blotters until removed and affixed to the vertical samples stand. A vertical sample stand comprising a wire loop supported by a foam base, wherein the top of the wire loop was approximately 15 cm above the top of the base and the parallel wire portions extending from the base were approximately 7.5 cm apart, was used for supporting the samples during drying. The vertical sample stand, and clips were placed on the balance and the balance was tared. The blotted wet sample was attached to the top of the wire loop using the clips, such that the sample hung down within the wire loop. The weight of the sample was recorded to establish a wet weight. The balance was coupled to a data acquisition system comprising Lab View software. Weight readings were automatically recorded every 15 seconds by the computer. The test was complete once the sample weight had reached a designated stopping moisture level versus the conditioned dry weight. The stopping moisture level was approximately 2%. The test was ended by stopping data acquisition in Lab View. The data file was saved for that sample.

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:


WRRtotal=100×(WRRtest−WRRcontrol)/WRRcontrol

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 flat dish capable of holding 500 ml of distilled water was filled with 200 ml of water. Samples of dyeable fabric approximately 10 cm in length (warp) and width (weft) direction were cut for evaluation. A paper clip was attached to the bottom of the sample to ensure submerging the lower end of the sample. A top end was attached with a binding clip to a horizontal bar making sure the bottom paper clip will be submerged into the water. The sample was lowered into the dish and timed in minutes until the water traveled up the sample to a height of 2 cm. Also after 3 and 5 minutes, the distance travelled by the water was noted as vertical wicking length. Final wicking length was the average of warp and weft wicking length after 5 minutes.

Horizontal Wicking (AATCC 79-2010)

The fabrics made according to the present invention, as well as comparative fabrics, were tested for horizontal wicking in accordance with AATCC 79-2010.

Moisture Vapor Transmission Rate

The rate of moisture vapor diffusion through the dyeable fabric is determined according to the Simple Dish Method, similar to ASTM E96-80. A sample is placed on a water dish (82 mm in diameter and 19 mm in depth) allowing a 9 mm air space between the water surface and specimen. A vibration free turntable carrying eight dishes rotates uniformly at 5 meters per minute to insure that all dishes are exposed to the same average ambient conditions during the test. The assembled specimen dishes are allowed to stabilize for two hours before taking the initial weight. They are weighed again after a 24-hour interval. Then the rate of moisture vapor loss (MVTR) is calculated in units of g/cm2−24 hours. A higher MVTR value indicates there is a greater passage of moisture vapor through the sample.

Heat Loss Testing (ASTM F1868, Part C)

Heat transfer makes it possible to predict body heat that will flow from the skin surface through a material, such as a fabric, into the surrounding atmosphere. Heat and moisture transfer properties are key properties affecting clothing comfort. Inventive and comparative fabrics were tested in accordance with the procedures of ASTM F 1868, Standard Test Method for Thermal and Evaporative Resistance of Clothing Materials using a Sweating Hot Plate, Part C. The heat and moisture transfer properties of the fabrics were calculated from measurements of thermal transport made with large skin model hot plate instrumentation from Measurement Technology Northwest, Inc., housed in an environmental test chamber set to achieve the required conditions.

Thermal Properties Testing

Arc Rating (ASTM F 1959/F 1959M-06ae1)

ASTM F 1959/F 1959M-06ae1 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). The test method measured the arc rating of materials that meet the following requirements: less than 150 mm (6 inches) char length and less than 2 seconds after flame, when tested in accordance with Test Method D 6413A.

Visibility Testing Chromaticity and Minimum Total Luminance Factor Requirements (ANSI 107 (2010))

ANSI 107 (2010) was used to measure the chromaticity and luminance factors of the fabrics. The fabrics were tested as received (no light exposure) and after 40 hours of exposure to Xenon arc lamp (AATCC 16-2004, Textiles-Colorfastness to Light (Test Option 3)). The results are plotted in a chromaticity diagram. To meet the requirements for chromaticity, the results for both before and after Xenon arc lamp exposure must fall within the parallelograms formed by the chromaticity coordinates shown in the following table (which also show the minimum total luminance factor requirement):

Chromaticity Minimum total coordinates luminance factor Color X y Y (%) Fluorescent 0.387 0.610 70 yellow-green 0.356 0.494 0.398 0.452 0.460 0.540 Fluorescent 0.610 0.390 40 orange-red 0.535 0.375 0.570 0.340 0.655 0.344 Fluorescent 0.655 0.344 25 red 0.570 0.340 0.595 0.315 0.690 0.310

Several fabrics (inventive and comparative) were tested. The compositions and test results are shown in the following table.

Example Example Example Example Example Example Example Example Fabric 1 Fabric 2 Fabric 3 Fabric 4 Fabric 5 Fabric 6 Fabric 7 Fabric 8 (Inventive) (Inventive) (comparative) (comparative) (comparative) (comparative) (comparative) (comparative) Fiber Content 50% 50% 50% 50% 45% 100% FR 100% FR 100% FR (weight proportion modacrylic modacrylic modacrylic modacrylic modacrylic cotton cotton cotton based on total 35% cotton 35% cotton 35% cotton 35% cotton 35% Lyocell weight of fabric) 10% nylon 10% nylon 10% nylon 10% nylon 20% p-aramid 5% p-aramid 5% p-aramid 5% p-aramid 5% p-aramid Construction Jersey Jersey Jersey Jersey Swiss pique Interlock Jersey Interlock knit knit knit knit knit knit knit knit Basis weight 6.6 7.9 6.3 6.2 6.7 7.2 7.6 6.8 (oz/yd2) Heat loss (Qt) 701 — — — 603 615 705 587 Moisture vapor 781 — — — 744 700 706 748 transmission rate (g/cm2-24 hours) Horizontal wicking 1 — — — 1 3 4 2 (seconds) Vertical wicking 8.6 — — — 6.4 8.1 6.5 6.6 length in 5 minutes (cm) Total dry time 83.3 — — — 91.4 111.4 112.3 127.9 (total-2% moisture) (minutes) WWR 0.53 — — — 0.50 0.44 0.43 0.39 (total-2% moisture) (%/minute) Arc rating 8.6 (meets 11 (meets <8 <8 8.1 9.6 8.9 9.8 (ASTM F 1959/F Level 2) Level 2) (fails to meet (fails to meet 1959M - 06ae1 Level 2)) Level 2)) (2012) (cal/cm2) Meets ANSI 107- Yes — — — No No No No 2010 requirement (chromaticity and minimum total luminance factor)

As can be seen from the data table, the fabrics of the invention provide the lowest dry time, highest water release rate, highest vertical wick length, high heat loss, and highest MVTR.

Meeting the high visibility standard of ANSI 107 and an arc rating of HRC II (>8 cal/cm2) in a lightweight fabric is challenging due to the conflicting nature of the fiber blends. Modacrylic fibers are useful because of their good compatibility with dyes that are useful in meeting the ANSI 107 requirement. Unfortunately, modacrylic fibers are relatively weak and do not resist arc flash well. Lightweight fabrics with a high percentage of modacrylic break open when used alone or with other lower strength fibers like cotton, which are typically included for improved comfort. Further complicating the dilemma, lightweight fabrics provide less insulation and therefore achieving an arc rating of HRC II (>8 cal/cm2) difficult. The addition of structural fibers, such as p-aramids, assist in providing resistance to arc flash energy. However, dyeing these fibers is difficult and often incompatible with modacrylic and cotton fibers. For example, in blends with modacrylic and cotton fibers, the dye process necessary for dyeing the p-aramid fibers damages the modacrylic and cotton fibers. It was not believed possible to leave the p-aramid fibers undyed and still meet the requirements of the ANSI 107 standard.

Applicants have unexpectedly discovered a fiber blend that may be used to prepare a fabric that simultaneously:

  • (1) has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm2 (i.e., arc-rated; meets HRC II);
  • (2) is capable of meeting the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010) (i.e., high-visibility); and
  • (3) has a basis weight of less than about 8.0 oz/yd2 (i.e., lightweight).

Applicants have also discovered a dyeing process that increases the level of dye on the hydrophilic portion which compensates for the lack of chromaticity and luminance in the undyed p-aramid fiber, thereby permitting the dyed fabric to achieve the requirements of ANSI 107 (2010) (i.e., high-visibility).

When ranges are used herein for physical properties, such as molecular weight, or chemical properties, such as chemical formulae, all combinations, and subcombinations of ranges specific embodiments therein are intended to be included.

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 dyeable fabric, comprising:

a fiber blend, comprising: about 30% by weight to about 70% by weight, based on the total weight of said fiber blend, of a plurality of hydrophobic fibers comprising at least one fiber selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (FBI), and copolymers thereof, and combinations thereof; about 15% by weight to about 45% by weight, based on the total weight of said fiber blend, of a plurality of fire-resistant hydrophilic fibers comprising at least one fiber selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof; and about 5% by weight to about 30% by weight, based on the total weight of the fiber blend, of a plurality of structural fibers comprising at least one fiber selected from the group consisting of aramid, melamine, nylon, elastomeric filament, and combinations thereof; wherein said aramid is present at a level of greater than about 0% by weight to less than about 10% by weight, based on the total weight of said fiber blend;
wherein said dyeable fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm2;
wherein said dyeable fabric is capable of meeting the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and
wherein said dyeable fabric has a basis weight of less than about 8.0 oz/yd2.

2. The dyeable fabric of claim 1,

wherein said plurality of hydrophobic fibers are modacrylic.

3. The dyeable fabric of claim 1,

wherein said plurality of fire-resistant hydrophilic fibers are selected from the group consisting of cellulose, wool, silk, and combinations thereof.

4. The dyeable fabric of claim 1,

wherein said cellulose is selected from the group consisting of cotton, fire-resistant cotton, rayon, fire-resistant rayon, viscose, Lyocell, acetate, bast, bamboo, soy, and combinations thereof.

5. The dyeable fabric of claim 1,

wherein said cellulose is fire-resistant rayon, cotton, or fire-resistant cotton.

6. The dyeable fabric of claim 1,

wherein said cellulose is cotton.

7. The dyeable fabric of claim 1,

wherein said plurality of structural fibers comprise:
aramid fibers;
nylon fibers; and
optionally, elastomeric filaments.

8. The dyeable fabric of claim 1,

wherein said plurality of structural fibers comprise:
p-aramid fibers;
nylon fibers; and
optionally, elastomeric filaments.

9. The dyeable fabric of claim 1,

wherein said plurality of hydrophobic fibers are present at a level of about 40% by weight to 60% by weight, based on the total weight of said fiber blend.

10. The dyeable fabric of claim 1,

wherein said plurality of hydrophobic fibers are present at a level of about 45% by weight to 55% by weight, based on the total weight of said fiber blend.

11. The dyeable fabric of claim 1,

wherein said plurality of fire-resistant hydrophilic fibers are present at a level of about 25% by weight to 45% by weight, based on the total weight of said fiber blend.

12. The dyeable fabric of claim 1,

wherein said plurality of structural fibers are present at a level of about 5% by weight to 20% by weight, based on the total weight of said fiber blend.

13. The dyeable fabric of claim 1,

wherein said plurality of structural fibers are present at a level of about 10% by weight to 15% by weight, based on the total weight of said fiber blend.

14. The dyeable fabric of claim 1,

said aramid fibers are present at a level of about 5% by weight to less than about 10% by weight, based on the total weight of said fiber blend.

15. The dyeable fabric of claim 1,

wherein said dyeable fabric is a woven fabric.

16. The dyeable fabric of claim 1,

wherein said dyeable fabric is a knit fabric.

17. The dyeable fabric of claim 1,

wherein said dyeable fabric is a non-woven fabric.

18. The dyeable fabric of claim 1,

wherein said dyeable fabric has a basis weight of less than about 7.5 oz/yd2.

19. The dyeable fabric of claim 1,

wherein said dyeable fabric has a basis weight of less than about 7.0 oz/yd2.

20. The dyeable fabric of claim 1,

wherein said fiber blend is intimately blended.

21. A dyed fabric, comprising:

said dyeable fabric of claim 1; and
at least one dye;
wherein said at least one dye imparts to said dyeable fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.

22. The dyed fabric of claim 21,

wherein said at least one dye comprises: at least one basic dye for said plurality of hydrophobic fibers; at least one reactive dye for said plurality of hydrophilic fibers; and at least one acid dye for said plurality of structural fibers; wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric;
wherein said dyed fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010).

23. The dyed fabric of claim 22,

wherein said at least one reactive dye is present at a level of greater than about 4% by weight, based on the total weight of said fabric.

24. An article, comprising:

said dyed fabric of claim 21.

25. The article of claim 24,

wherein said article is a garment or linen.

26. A dyed woven fabric, comprising:

a fiber blend, comprising: about 50% by weight, based on the total weight of said fiber blend, of modacrylic fibers; about 35% by weight, based on the total weight of said fiber blend, of cotton fibers; about 10% by weight, based on the total weight of said fiber blend, of a plurality of fibers selected from the group consisting of nylon fibers, elastomeric filaments, and combinations thereof; and about 5% by weight, based on the total weight of said fiber blend, of p-aramid fibers;
at least one dye;
wherein said at least one dye imparts to said woven fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.
wherein said dyed woven fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm2;
wherein said dyed woven fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and
wherein said dyed woven fabric has a basis weight of less than about 8.0 oz/yd2.

27. The dyed woven fabric of claim 26,

wherein said at least one dye comprises: at least one basic dye for said plurality of hydrophobic fibers; at least one reactive dye for said plurality of hydrophilic fibers; and at least one acid dye for said plurality of structural fibers; wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric.

28. The dyed woven fabric of claim 27,

wherein said at least one reactive dye is present at a level of greater than about 4% by weight, based on the total weight of said fabric.

29. The dyed woven fabric of claim 27,

wherein said dyed woven fabric has a basis weight of less than about 7.5 oz/yd2.

30. The dyed woven fabric of claim 27,

wherein said dyed woven fabric has a basis weight of less than about 7.0 oz/yd2.

31. The dyed woven fabric of claim 27,

wherein said fiber blend is intimately blended.

32. An article, comprising:

the dyed woven fabric of claim 27.

33. The article of claim 32,

wherein the article is a garment or linen.

34. A method of preparing a high-visibility fabric, comprising:

preparing a yarn from a fiber blend; wherein said fiber blend comprises: about 30% by weight to about 70% by weight, based on the total weight of said fiber blend, of a plurality of hydrophobic fibers comprising at least one fiber selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (FBI), and copolymers thereof, and combinations thereof; about 15% by weight to about 45% by weight, based on the total weight of said fiber blend, of a plurality of fire-resistant hydrophilic fibers comprising at least one fiber selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof; and about 5% by weight to about 30% by weight, based on the total weight of said fiber blend, of a plurality of structural fibers comprising at least one fiber selected from the group consisting of aramid, melamine, nylon, elastomeric filaments, and combinations thereof; wherein said aramid is present at a level of greater than about 0% by weight to less than about 10% by weight, based on the total weight of said fiber blend;
converting said yarn into a fabric substrate;
wherein said fabric substrate is woven, knitted, nonwoven, or a combination thereof; and
dyeing said fabric substrate to prepare said high-visibility fabric;
wherein said high-visibility fabric is colored fluorescent yellow-green, fluorescent orange-red, fluorescent red, or a combination thereof.

35. The method of claim 34,

wherein said dyeing, comprises:
(a) contacting said hydrophobic fibers with at least one basic dye;
(b) contacting said hydrophilic fibers with at least one reactive dye; wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric substrate; and
(c) contacting said structural fibers with a composition comprising:
(i) at least one acid dye; and
(ii) optionally, at least one dye assist.

36. The method of claim 35,

wherein said step (b) and step (c) are carried out substantially simultaneously; and
wherein said at least one dye assist is present.

37. The method of claim 34,

wherein said dyeing, comprises:
(a1)) contacting said hydrophobic fibers with at least one basic dye;
(a2) optionally, reduction cleaning said hydrophobic fibers after said step (a1);
(b1) contacting said hydrophilic fibers with at least one reactive dye; wherein said at least one reactive dye is present at a level of greater than about 4% by weight, based on the total weight of said fabric substrate;
(b2) optionally, contacting said hydrophilic fibers with an after treatment after said step (b1); wherein said after treatment comprises a process selected from the group consisting of: soaping, fixing, and combinations thereof; and
(c) contacting said structural fibers with at least one acid dye.

38. The method of claim 34,

wherein said at least one reactive dye is present at a level of greater than about 1% by weight to about 5% by weight, based on the total weight of said fabric substrate.

39. The method of claim 34, further comprising:

pre-treating said fabric substrate, prior to said dyeing;
wherein said pre-treating comprises at least one process selected from the group consisting of desizing, scouring, bleaching, and combinations thereof.

40. The method of claim 34, further comprising:

post-treating said high-visibility fabric;
wherein said post-treating comprises at least one process selected from the group consisting of resin finishing, controlled compressive shrinkage processing, overfeed shrinkage control during drying, shrinkage control processing via open width compactor, and combinations thereof.
Patent History
Publication number: 20160060809
Type: Application
Filed: Aug 25, 2015
Publication Date: Mar 3, 2016
Inventors: Robert Winfred HINES (Columbus, GA), James Jonathan BAILEY (Fortson, GA)
Application Number: 14/834,526
Classifications
International Classification: D06P 3/82 (20060101); D06P 5/02 (20060101); D06P 3/00 (20060101); D02G 3/04 (20060101); D02G 3/44 (20060101);