WO2024005644A1 - Flame retardant fabric and apparel - Google Patents

Flame retardant fabric and apparel Download PDF

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Publication number
WO2024005644A1
WO2024005644A1 PCT/NO2023/050137 NO2023050137W WO2024005644A1 WO 2024005644 A1 WO2024005644 A1 WO 2024005644A1 NO 2023050137 W NO2023050137 W NO 2023050137W WO 2024005644 A1 WO2024005644 A1 WO 2024005644A1
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WO
WIPO (PCT)
Prior art keywords
fabric
fiber
flame retardant
weight
yarn
Prior art date
Application number
PCT/NO2023/050137
Other languages
French (fr)
Inventor
Yousuf ABDULLAH
Original Assignee
Daletec As
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from NO20220886A external-priority patent/NO20220886A1/en
Application filed by Daletec As filed Critical Daletec As
Publication of WO2024005644A1 publication Critical patent/WO2024005644A1/en

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/443—Heat-resistant, fireproof or flame-retardant yarns or threads
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/20—Cellulose-derived artificial fibres
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/10—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
    • D10B2321/101—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide modacrylic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides

Definitions

  • the present invention relates to an inherently flame retardant fabric and apparel made from such a fabric as well as a method of manufacturing a flame retardant fabric.
  • Fire-retardant and flame-retardant fabrics are two different classes of material. Each class has unique attributes that make them advantageous for intense heat or open flame applications, but they use different mechanisms to do so.
  • Fire-retardant fabrics also known as chemically flame retardant fabrics, are standard fabrics that have been treated with various flame-retardant chemicals. These fabrics will burn, but at a much slower rate than untreated standard fabrics.
  • the chemically treated fabrics have a certain life and wash durability and the fabrics keep on losing their flame and fire-retardant attributes with each wash.
  • Flame-retardant fabrics are typically made up of fibers that resist ignition under prolonged exposure to flame or heat. Because of this construction, they are also referred to as inherently flame-retardant (IFR) fabrics. Instead of burning, these fabrics will eventually begin to melt.
  • IFR fabrics the flame retardant (FR) performance provides continued protection for the wearer, and the fibers retain their FR properties throughout life of the garment.
  • the attributes most important to wearers of flame retardant apparel are protection, comfort and durability.
  • the durability of FR performance and physical performance of these fabrics is crucial.
  • IFR fabrics are usually made from a fiber blend which contains different IFR fibers of an aromatic nature, FR cellulosic and modacrylics. Non-FR fibers may also be incorporated in a small amount to provide other attributes without essentially adversely affecting the FR properties.
  • a flame-retardant fabric and apparel made thereof which have a combination of advantageous properties such as a high strength, stretch, abrasion resistance, comfort and softness; provide a smooth and lustrous feeling, good air permeability and wicking and moisture transport properties, and where the fabric and apparel made thereof are dyeable, printable, industrial launderable and show a controlled shrinkage. It would also be desirable to provide a thicker fabric and/or fabric made of thicker yarn as well as apparel made thereof showing a combination of the advantageous properties mentioned above, in particular high strength, high abrasion resistance, comfort, softness and air permeability. It would also be desirable to provide a method of manufacturing such fabrics and apparel.
  • the present invention provides a flame retardant fabric and apparel made from such fabric exhibiting high or improved strength properties, such as e.g. tensile strength and tear strength, high or improved stretch, abrasion and/or pilling resistance, and where the fabric and apparel are industrially launderable.
  • the present invention makes it possible to provide a comfortable, soft, flame retardant fabric and apparel having a combination and balance of advantages properties such as, for example, high strength, abrasion resistance, stretch, robustness and durability, such that the fabric substantially moves with body movement and thereby provides a comfort level to the wearer.
  • the flame retardant fabric and apparel made thereof according to the invention also exhibit excellent FR and IFR properties and performance.
  • the present invention provides an improved flame retardant fabric and apparel made thereof, in particular in a rugged environment and for demanding and industrial and military applications.
  • the present invention relates to a flame retardant fabric comprising 35-55% by weight of modacrylic fiber, 25-45% by weight of cellulosic fiber, 10- 25% by weight of polyamide fiber, 1-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter.
  • the present invention relates to a flame retardant apparel made from the flame retardant fabric as defined above and herein.
  • the present invention relates to a method of manufacturing a flame retardant fabric comprising making a fabric from 35-55% by weight of modacrylic fiber, 25- 45% by weight of cellulosic fiber, 10-25% by weight of polyamide fiber, 1-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter.
  • the present invention relates to a flame retardant fabric, and apparel made thereof, comprising a fiber and/or filament blend comprising modacrylic fiber, cellulosic fiber, polyamide fiber, elastomeric fiber and antistatic fiber.
  • the term "flame retardant fabric”, as used herein, refers to a protective layer that has been woven, knitted or otherwise assembled using one or more different types of yarn that are either inherently flame retardant (or at least partly inherently flame retardant) or treated in fabric form to make them flame retardant (or at least partly flame retardant).
  • the term “flame retardant”, as used herein, is also referred to as “FR” and may also be refer to as “flame resistant”.
  • the term “inherently flame retardant”, as used herein, is also referred to as “IFR” and may also be referred as “inherently flame resistant”.
  • modified acrylic fiber refers to an acrylic synthetic fiber made from a polymer comprising residues of acrylonitrile, preferably primarily residues of acrylonitrile, e.g. polymers having 35-85% by weight of acrylonitrile units, and which may be modified by other monomers. Modacrylic fibers can be spun from an extensive range of copolymers of acrylonitrile.
  • the modacrylic fiber may contain residues of other monomers, including vinyl monomer, e.g. vinyl chloride, vinylidene chloride, vinyl bromide, etc.
  • the modacrylic fiber of the invention may comprise modacrylic FR fibers.
  • suitable modacrylic fibers include those sold under the names of PyroTex, Protex, e .g . Protex C, Protex M and Protex Q, Kanekalon, Sef and Panox.
  • the modacrylic fiber may be present in the flame retardant fabric of the invention in an amount of from 35, or from 38, or from 40, or from 43% by weight, up to 48, or up to 50, or up to 53, or up to 55% by weight.
  • the cellulosic fiber of the fabric of the invention may be selected from natural and/or synthetic cellulosic fibers.
  • suitable natural cellulosic fibers include cotton, flax, hemp, bast, linen, jute, hemp, ramie, bamboo, soy, and blends thereof.
  • suitable synthetic cellulosic fibers include rayon, lyocell, cellulosic acetate, viscose, and blends thereof.
  • the cellulosic fiber may be treated to render the fiber hydrophobic, hydrophilic, or oleophobic.
  • cellulosic fibers examples include those sold under the trade names of Giza Cotton, Pima Cotton, Supima Cotton, Tencel, Lenzing FR, Modal, Viscose and Visil.
  • the cellulosic fiber of the invention comprises natural cellulosic fibers, preferably cotton fiber, such as those sold under the trade names of Giza Cotton, Pima Cotton and Supima Cotton.
  • Natural and synthetic cellulosic fibers are usually not naturally resistant to flame.
  • one or more flame retardants may be incorporated into the fibers during the manufacturing process.
  • suitable flame retardants include phosphorus and antimony compounds.
  • the cellulosic fibers do not have to be rendered flame resistant, and the cellulosic fiber of the invention may be selected from FR and/or non-FR cellulosic fibers, preferably cotton.
  • the cellulosic fiber may be present in the flame retardant fabric of the invention in an amount of from 25, or from 28, or from 30, or from 32% by weight, up to 35, or up to 38, or up to 40, or up to 45% by weight.
  • polyamide fiber refers to a fiber consisting essentially of a polyamide synthetic polymer.
  • the polyamide fiber of the fabric of the invention may be selected polyamides comprising aromatic groups, e.g. aramids, paraaramid (p-aramid), meta-aramid (m-aramid) and p-phenylene terephthalamide.
  • suitable polyamide fibers include those sold under the trade names of Cordura, Kevlar, Nomex, Teijinconex, Twaron, Tecknora, Conex and Kermel.
  • the polyamide fiber may be present in the flame retardant fabric of the invention in an amount of from 10, or from 13, or from 15, or from 17% by weight, up to 18, or up to 20, or up to 23, or up to 25% by weight.
  • elastomeric fiber as used herein, also referred to as “elastomeric filament” and “elastic fiber”, refers to an elastomeric or elastic polymer formed into a fiber or filament.
  • the elastomeric fiber is a fiber with elastic capability, which usually possesses very high elongations at break, and which recover fully and rapidly from high elongations up to their breaking point.
  • the elastomeric fiber or filament of the fabric of the invention may be made from elastomeric polymers, e.g.
  • the elastomeric fiber of the invention may be selected from FR-modified and/or non-FR elastomeric fibers.
  • suitable elastomeric or elastic fibers include those sold under the trade names of XLANCE, XLA, Spandex, Lycra, Elastane, Polystretch, Buthane, Contro, Hi-Flex, Lactron, Lastex, and Laton.
  • the elastomeric fiber may be present in the flame retardant fabric of the invention in an amount of from 1 , or from 2 % by weight, or from 2.5% by weight, up to 3, or up to 4, or up to 5% by weight.
  • the antistatic fiber of the fabric of the invention may be used to reduce or eliminate static electricity on the surface of the fabric.
  • the fibers may be conductive in nature and dissipate any electrostatic charges generated to ensure the safety of the grounded wearer or user of apparel made from the fabric.
  • suitable antistatic fibers include carbon fibers and synthetic fibers containing carbon or silver.
  • the antistatic fibers may be selected from FR and/or non-FR antistatic fibers. Examples of suitable antistatic fibers include those sold under the trade names of No-Shock and Bekinox.
  • the antistatic fiber may be present in the flame retardant fabric of the invention in an amount of from 0.5, or from 0.75, or from 1% by weight, up to 2, or up to 4, or up to 5% by weight.
  • the flame retardant fabric of the invention may also contain one or more other fibers, examples of which include anti-microbial fibers, polyester fibers, melamine fibers, and other non-FR, FR and IFR fibers. Such one or more other fibers may be present in minor amounts.
  • the term "basis weight”, as used herein, refers to a measure of the finished fabric weight per unit area. Typical units include grams per square meter.
  • the basis weight of the fabric of the invention may be from 225, or from 250, or from 275, or from 300 grams per square meter, up to 325, or to 350, or to 375, or up to 400 grams per square meter.
  • the Greige fabric weight, i.e. the weight of unfinished woven, knitted or otherwise assembled fabric that has not yet been bleached or dyed, is usually at least 200, or at least 210 grams per square meter.
  • the flame retardant fabric of the invention may comprise yarn having a certain yarn count, which is a numerical value that indicates the coarseness or fineness of the yarn. Count also indicates the relation between weight and length of a yarn. Using the British yarn count, expressed as “S”, in which a higher count indicates a finer yarn and a lower count indicates a thicker I coarser yarn, the flame retardant fabric of the invention may contain one or more yarns having a coarseness, or thickness, of at least 12 S, or at least 14 S, or at least 16 S, up to 18 S, or up to 20 S, or up to 24S.
  • the indicated values of yarn count refer to both warp yarn and weft yarn.
  • Denier is the most common Sl-based (grams and meters) unit to measure yarn thickness which is defined as the weight of yarn in grams per 9000 meters of yarn.
  • the flame retardant fabric of the invention may comprise one or more yarns having a yarn thickness of at least 220 D, or at least 270 D, or at least 300 D, or at least 350, up to 400 D, or up to 450 D.
  • the indicated values of denier refer to both warp yarn and weft yarn.
  • the flame retardant fabric of the invention may have anisotropic properties, i.e. different properties in different directions of the fabric, e.g. different properties in an x-y coordinate plane, e.g. in warp and weft directions, or different properties in an x-y-z coordinate plane, e.g. different properties on the body side of the fabric and the face side of the fabric.
  • This can be accomplished by providing one or more warp yarns having a first fiber composition and one or more weft yarns having a second fiber composition which is different from the first fiber composition.
  • the difference in fiber composition can be obtained by providing warp and weft yarns containing the same fibers but in different amounts and/or by providing warp and weft yarns containing different fibers.
  • This may also be accomplished by providing a knitted flame retardant fabric having different properties on each side of the fabric, or a flame retardant composite fabric having two or more layers of flame retardant fabric with different properties.
  • the flame retardant fabric of the invention may be a woven, knitted or otherwise assembled fabric, preferably a woven fabric.
  • a woven flame retardant fabric of the invention may comprise one or more warp yarns and one or more weft yarn.
  • the flame retardant fabric of the invention may comprise one or more warp yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, elastomeric fiber and antistatic fiber, suitable it comprises one or more warp yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber and antistatic fiber, and preferably the one or more warp yarns comprises no or essentially no elastomeric fiber.
  • the flame retardant fabric of the invention may comprise one or more weft yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, elastomeric fiber and antistatic fiber, suitably it comprises one or more weft yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, and elastomeric fiber, and preferably the one or more weft yarns comprises no or essentially no antistatic fiber.
  • flame retardant fabrics of the invention that are woven include twill weaves (2xl, 3xl, etc.), satin weaves (4xl, 5xl, etc.), plain weaves and denim weaves.
  • the fabric is a satin weave.
  • flame retardant fabrics of the invention that are knitted, or knit fabrics, include single and double knits, e.g. jersey, Swiss pique and interlock.
  • the flame retardant fabric of the invention exhibits excellent strength properties, including tensile and tear strengths.
  • the tensile strength in the warp direction may be at least 900 N (Newton), or at least 1000 N, or at least 1050 N, and it may be up to 1200 N, or up to 1250 N, and/or the tensile strength in the weft direction may be at least 250 N, or at least 300 N, or at least 350 N, and it is usually up to 450 N, or up to 500 N, as measured according to ISO 13934.
  • the tear strength may be at least 60 N, or at least 70 N, or at least 80 N on the warp side, and/or the tear strength may be at least 60 N, or at least 70 N, or at least 80 N on the weft side, as measured according to ISO13937-1 These values prove the robustness of the flame retardant fabric in a rugged environment.
  • Abrasion resistant fabric withstands surface wear from rubbing, extending the life of an apparel of the fabric and protecting the person who wears it.
  • the flame retardant fabric of the invention exhibits excellent abrasion resistance and can withstand at least 160,000, or at least 180,000, or at least 200,000 abrasion cycles as per ISO 12947.
  • the pilling rating of the flame retardant fabric of the invention may be up to 2-3, or up to 3-4, or up to 4-5 after 5000 cycles as per ISO 12945.
  • the flame retardant fabric of the invention may be a flame retardant composite fabric.
  • flame retardant composite fabric refers to composite fabric created via bonding two or more layers of flame retardant fabric together without the use of sewing, stitch-bonding, quilting, or other processes that utilize a stitch or interlace yarn to combine two or more fabric layers.
  • the two or more layers of the flame retardant fabric are suitably woven and/or knitted, preferably a woven fabric.
  • the flame retardant fabric of the invention exhibits excellent performance, including FR performance.
  • the fabric qualifies for EN ISO 1 1612 standards which is a measurement of fabric performance to protect against heat and flame.
  • the fabric passes the requirements with the A1A2B1 C1 D2E2F1 class.
  • the fabric also fulfils the requirements of EN ISO 1161 1 certification Class 1 , which calculate the performance of fabric for use in welding and allied processes.
  • EN 61 482-1 -1 which is a measurement of the protection against thermal hazard of an electric arc.
  • the EBT values are 9 with an ELIM of 7.2.
  • the fabric is certified for EN-13034 and EN-1149-3 standards, which are important certifications for a protective fabric.
  • the fabric is industrially launderable and meet the requirements of ISO 15797 with 75 degrees C temperature wash. Further, the fabric meets the requirements of Oeko-Tex Class-ll, thus being tested and certified for harmful substances, and approved for use in direct contact with skin. Finally, the fabric exhibits controlled shrinkages of +/-3% in both warp and weft direction, which means that it is highly stable to washing, and dimensionally stable.
  • the present invention further relates to a flame retardant apparel made from the flame retardant fabric of the invention as defined herein.
  • suitable flame retardant apparels include shirts, jackets, trousers, coveralls, uniforms, including military or industrial applications.
  • the present invention further relates to a method of manufacturing a flame retardant fabric which comprises manufacturing a fabric from 35-55% by weight of modacrylic fiber, 25-45% by weight of cellulosic fiber, 10-25% by weight of polyamide fiber, 1-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter.
  • the method may comprise weaving, knitting or otherwise assembling a fabric from the fibers and amounts defined herein.
  • the method comprises: providing one or more warp yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber and antistatic fiber, preferably the one or more warp yarns comprise no or essentially no elastomeric fiber, providing one or more weft yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber and elastomeric fiber, preferably the one or more weft yarns comprise no or essentially no antistatic fiber,
  • the flame retardant fabric may contain the fibers and amounts defined herein.
  • the yarns may be formed in conventional ways well known in the art.
  • the yarns may be spun yarns, e.g. air jet spun yarns, and may comprise a single yarn ortwo or more individual yarns that are twisted, or otherwise combined together.
  • the fibers are blended in the spinning stage so as to provide a uniform and homogenous distribution of fibers in the yarn and eventually in the fabric.
  • the fibers on the face side of the fabric will predominantly comprise the warp yarns and the fibers on the body side of the fabric will predominantly comprise the weft yarn.
  • the fabric may be construed with the warp and weft yarns in a variety of ways, e.g. twill weave (2xl, 3xl, etc.) and satin weave (4xl, 5xl, etc.) constructions, which are well known in the art.
  • a double knit-circular machine In a typical knitting method according to the invention, a double knit-circular machine is used. These machines have two needles, a dial needle and a cylinder needle, that work together to form the double-knit fabric. When utilized to make fabrics of the invention, different yarns can be used in each of the dial needle and cylinder needle such that the two yarns become inter-stitched with one yarn predominantly exposed on the one side of the knit fabric and the other yarn predominantly exposed ion the other side of the fabric.
  • Dyeing and printing of the fabrics may be carried out in accordance with standard methods, all of which are known in the art.
  • Parts and % relate to parts by weight and % by weight, respectively, and all suspensions are aqueous, unless otherwise stated.
  • This example illustrates the manufacture of a flame retardant fabric according to the invention.
  • the flame retardant fabric was manufactured from fibers comprising 45% by weight of modacrylic fiber (Protex), 33% by weight of natural cellulosic fiber (Giza Cotton), 18% by weight of polyamide fiber (Cordura), 3% elastomeric fiber (XLANCE), 1 % antistatic fiber (NoShock, Ascend).
  • the fibers for warp and weft yarns were blended in the spinning stage to get a uniform and homogenous distribution of fiber in the fabric.
  • the fibers were spun into yarns using conventional methods well known in the art.
  • the warp yarn consisted of modacrylic fiber, cellulosic fiber, polyamide fiber and antistatic fiber.
  • the weft yarn consisted of modacrylic fiber, cellulosic fiber, polyamide fiber and elastomeric fiber.
  • Both the warp yarn and weft yarn had a thickness of 14S, corresponding to around 384 D.
  • a fabric was manufactured by weaving a single warp yarn and a single weft yarn using conventional methods well known in the art.
  • the obtained flame retardant fabric showed the following results and properties:
  • the flame retardant fabric of the invention showed excellent properties and performance.

Abstract

The invention relates to a flame retardant fabric comprising 35-55% by weight of modacrylic fiber, 25-45% by weight of cellulosic fiber, 10-25% by weight of polyamide fiber, 0.5-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter. The invention also relates to a flame retardant apparel made from the flame retardant fabric according to the invention. The invention further relates to a method of manufacturing a flame retardant fabric comprising weaving or knitting the fabric according to the invention.

Description

FLAME RETARDANT FABRIC AND APPAREL
Field of the Invention
The present invention relates to an inherently flame retardant fabric and apparel made from such a fabric as well as a method of manufacturing a flame retardant fabric.
Background of the Invention
Fire-retardant and flame-retardant fabrics are two different classes of material. Each class has unique attributes that make them advantageous for intense heat or open flame applications, but they use different mechanisms to do so. Fire-retardant fabrics, also known as chemically flame retardant fabrics, are standard fabrics that have been treated with various flame-retardant chemicals. These fabrics will burn, but at a much slower rate than untreated standard fabrics. The chemically treated fabrics have a certain life and wash durability and the fabrics keep on losing their flame and fire-retardant attributes with each wash.
Flame-retardant fabrics are typically made up of fibers that resist ignition under prolonged exposure to flame or heat. Because of this construction, they are also referred to as inherently flame-retardant (IFR) fabrics. Instead of burning, these fabrics will eventually begin to melt. In IFR fabrics, the flame retardant (FR) performance provides continued protection for the wearer, and the fibers retain their FR properties throughout life of the garment. The attributes most important to wearers of flame retardant apparel are protection, comfort and durability. The durability of FR performance and physical performance of these fabrics is crucial. IFR fabrics are usually made from a fiber blend which contains different IFR fibers of an aromatic nature, FR cellulosic and modacrylics. Non-FR fibers may also be incorporated in a small amount to provide other attributes without essentially adversely affecting the FR properties.
So far, FR performance have been at focus for both chemically treated and IFR fabrics, and not much attention has been paid towards the comfort and robustness of the fabric. Most of the chemically treated and IFR fabrics are heavy, without stretch, and exhibit poor moisture management due to the chemicals or fibers present.
It would be desirable to provide a flame-retardant fabric and apparel made thereof which have a combination of advantageous properties such as a high strength, stretch, abrasion resistance, comfort and softness; provide a smooth and lustrous feeling, good air permeability and wicking and moisture transport properties, and where the fabric and apparel made thereof are dyeable, printable, industrial launderable and show a controlled shrinkage. It would also be desirable to provide a thicker fabric and/or fabric made of thicker yarn as well as apparel made thereof showing a combination of the advantageous properties mentioned above, in particular high strength, high abrasion resistance, comfort, softness and air permeability. It would also be desirable to provide a method of manufacturing such fabrics and apparel.
Summary of the Invention
It is an object of the present invention to provide an improved flame retardant fabric and apparel. More specifically, it is an object of the present invention to provide an inherently flame retardant fabric and apparel which have high strength, stretch, abrasion resistance, comfort, softness and air permeability; good wicking and moisture transport properties; provide a smooth and lustrous feeling; and where the fabric and apparel are dyeable, printable, industrially launderable and show a controlled shrinkage. In particular, the present invention provides a flame retardant fabric and apparel made from such fabric exhibiting high or improved strength properties, such as e.g. tensile strength and tear strength, high or improved stretch, abrasion and/or pilling resistance, and where the fabric and apparel are industrially launderable.
It is another object of the invention to provide a method of manufacturing a flame retardant fabric and apparel which have the above-mentioned combination of advantageous properties.
The present invention makes it possible to provide a comfortable, soft, flame retardant fabric and apparel having a combination and balance of advantages properties such as, for example, high strength, abrasion resistance, stretch, robustness and durability, such that the fabric substantially moves with body movement and thereby provides a comfort level to the wearer. The flame retardant fabric and apparel made thereof according to the invention also exhibit excellent FR and IFR properties and performance. Hereby the present invention provides an improved flame retardant fabric and apparel made thereof, in particular in a rugged environment and for demanding and industrial and military applications.
Accordingly, in one aspect, the present invention relates to a flame retardant fabric comprising 35-55% by weight of modacrylic fiber, 25-45% by weight of cellulosic fiber, 10- 25% by weight of polyamide fiber, 1-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter. In another aspect, the present invention relates to a flame retardant apparel made from the flame retardant fabric as defined above and herein.
In yet another aspect, the present invention relates to a method of manufacturing a flame retardant fabric comprising making a fabric from 35-55% by weight of modacrylic fiber, 25- 45% by weight of cellulosic fiber, 10-25% by weight of polyamide fiber, 1-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter.
These and other objects and aspects of the invention will be described in further detail hereinafter.
Detailed Description of the Invention
The present invention relates to a flame retardant fabric, and apparel made thereof, comprising a fiber and/or filament blend comprising modacrylic fiber, cellulosic fiber, polyamide fiber, elastomeric fiber and antistatic fiber. The term "flame retardant fabric", as used herein, refers to a protective layer that has been woven, knitted or otherwise assembled using one or more different types of yarn that are either inherently flame retardant (or at least partly inherently flame retardant) or treated in fabric form to make them flame retardant (or at least partly flame retardant). The term “flame retardant”, as used herein, is also referred to as “FR” and may also be refer to as “flame resistant”. The term “inherently flame retardant”, as used herein, is also referred to as “IFR” and may also be referred as “inherently flame resistant”.
The term “modacrylic fiber”, as used herein, also referred to as “modified acrylic fiber”, refers to an acrylic synthetic fiber made from a polymer comprising residues of acrylonitrile, preferably primarily residues of acrylonitrile, e.g. polymers having 35-85% by weight of acrylonitrile units, and which may be modified by other monomers. Modacrylic fibers can be spun from an extensive range of copolymers of acrylonitrile. The modacrylic fiber may contain residues of other monomers, including vinyl monomer, e.g. vinyl chloride, vinylidene chloride, vinyl bromide, etc. The modacrylic fiber of the invention may comprise modacrylic FR fibers. Examples of suitable modacrylic fibers include those sold under the names of PyroTex, Protex, e .g . Protex C, Protex M and Protex Q, Kanekalon, Sef and Panox. The modacrylic fiber may be present in the flame retardant fabric of the invention in an amount of from 35, or from 38, or from 40, or from 43% by weight, up to 48, or up to 50, or up to 53, or up to 55% by weight.
The cellulosic fiber of the fabric of the invention may be selected from natural and/or synthetic cellulosic fibers. Examples of suitable natural cellulosic fibers include cotton, flax, hemp, bast, linen, jute, hemp, ramie, bamboo, soy, and blends thereof. Examples of suitable synthetic cellulosic fibers include rayon, lyocell, cellulosic acetate, viscose, and blends thereof. The cellulosic fiber may be treated to render the fiber hydrophobic, hydrophilic, or oleophobic. Examples of suitable cellulosic fibers include those sold under the trade names of Giza Cotton, Pima Cotton, Supima Cotton, Tencel, Lenzing FR, Modal, Viscose and Visil. Preferably, the cellulosic fiber of the invention comprises natural cellulosic fibers, preferably cotton fiber, such as those sold under the trade names of Giza Cotton, Pima Cotton and Supima Cotton.
Natural and synthetic cellulosic fibers are usually not naturally resistant to flame. To increase the FR properties of such fibers, one or more flame retardants may be incorporated into the fibers during the manufacturing process. Examples of suitable flame retardants include phosphorus and antimony compounds. However, for the purpose of the invention, the cellulosic fibers do not have to be rendered flame resistant, and the cellulosic fiber of the invention may be selected from FR and/or non-FR cellulosic fibers, preferably cotton.
The cellulosic fiber may be present in the flame retardant fabric of the invention in an amount of from 25, or from 28, or from 30, or from 32% by weight, up to 35, or up to 38, or up to 40, or up to 45% by weight.
The term “polyamide fiber”, as used herein, also referred to as “nylon fiber”, refers to a fiber consisting essentially of a polyamide synthetic polymer. The polyamide fiber of the fabric of the invention may be selected polyamides comprising aromatic groups, e.g. aramids, paraaramid (p-aramid), meta-aramid (m-aramid) and p-phenylene terephthalamide. Examples of suitable polyamide fibers include those sold under the trade names of Cordura, Kevlar, Nomex, Teijinconex, Twaron, Tecknora, Conex and Kermel.
The polyamide fiber may be present in the flame retardant fabric of the invention in an amount of from 10, or from 13, or from 15, or from 17% by weight, up to 18, or up to 20, or up to 23, or up to 25% by weight. The term "elastomeric fiber", as used herein, also referred to as “elastomeric filament” and “elastic fiber”, refers to an elastomeric or elastic polymer formed into a fiber or filament. The elastomeric fiber is a fiber with elastic capability, which usually possesses very high elongations at break, and which recover fully and rapidly from high elongations up to their breaking point. The elastomeric fiber or filament of the fabric of the invention may be made from elastomeric polymers, e.g. polyurethanes, polyurethane-polyurea copolymers, polysilicones, fluoro elastomers, rubbers, etc., and from crosslinked polyolefin-based polymers. The elastomeric fiber of the invention may be selected from FR-modified and/or non-FR elastomeric fibers. Examples of suitable elastomeric or elastic fibers include those sold under the trade names of XLANCE, XLA, Spandex, Lycra, Elastane, Polystretch, Buthane, Contro, Hi-Flex, Lactron, Lastex, and Laton.
The elastomeric fiber may be present in the flame retardant fabric of the invention in an amount of from 1 , or from 2 % by weight, or from 2.5% by weight, up to 3, or up to 4, or up to 5% by weight.
The antistatic fiber of the fabric of the invention may be used to reduce or eliminate static electricity on the surface of the fabric. The fibers may be conductive in nature and dissipate any electrostatic charges generated to ensure the safety of the grounded wearer or user of apparel made from the fabric. Examples of suitable antistatic fibers include carbon fibers and synthetic fibers containing carbon or silver. The antistatic fibers may be selected from FR and/or non-FR antistatic fibers. Examples of suitable antistatic fibers include those sold under the trade names of No-Shock and Bekinox.
The antistatic fiber may be present in the flame retardant fabric of the invention in an amount of from 0.5, or from 0.75, or from 1% by weight, up to 2, or up to 4, or up to 5% by weight.
The flame retardant fabric of the invention may also contain one or more other fibers, examples of which include anti-microbial fibers, polyester fibers, melamine fibers, and other non-FR, FR and IFR fibers. Such one or more other fibers may be present in minor amounts.
The term "basis weight", as used herein, refers to a measure of the finished fabric weight per unit area. Typical units include grams per square meter. The basis weight of the fabric of the invention may be from 225, or from 250, or from 275, or from 300 grams per square meter, up to 325, or to 350, or to 375, or up to 400 grams per square meter. The Greige fabric weight, i.e. the weight of unfinished woven, knitted or otherwise assembled fabric that has not yet been bleached or dyed, is usually at least 200, or at least 210 grams per square meter.
The flame retardant fabric of the invention may comprise yarn having a certain yarn count, which is a numerical value that indicates the coarseness or fineness of the yarn. Count also indicates the relation between weight and length of a yarn. Using the British yarn count, expressed as “S”, in which a higher count indicates a finer yarn and a lower count indicates a thicker I coarser yarn, the flame retardant fabric of the invention may contain one or more yarns having a coarseness, or thickness, of at least 12 S, or at least 14 S, or at least 16 S, up to 18 S, or up to 20 S, or up to 24S. Preferably, the indicated values of yarn count refer to both warp yarn and weft yarn. Denier is the most common Sl-based (grams and meters) unit to measure yarn thickness which is defined as the weight of yarn in grams per 9000 meters of yarn. When converting the mentioned numerical values of S to denier (D), the flame retardant fabric of the invention may comprise one or more yarns having a yarn thickness of at least 220 D, or at least 270 D, or at least 300 D, or at least 350, up to 400 D, or up to 450 D. Preferably, the indicated values of denier refer to both warp yarn and weft yarn.
The flame retardant fabric of the invention may have anisotropic properties, i.e. different properties in different directions of the fabric, e.g. different properties in an x-y coordinate plane, e.g. in warp and weft directions, or different properties in an x-y-z coordinate plane, e.g. different properties on the body side of the fabric and the face side of the fabric. This can be accomplished by providing one or more warp yarns having a first fiber composition and one or more weft yarns having a second fiber composition which is different from the first fiber composition. The difference in fiber composition can be obtained by providing warp and weft yarns containing the same fibers but in different amounts and/or by providing warp and weft yarns containing different fibers. This may also be accomplished by providing a knitted flame retardant fabric having different properties on each side of the fabric, or a flame retardant composite fabric having two or more layers of flame retardant fabric with different properties.
The flame retardant fabric of the invention may be a woven, knitted or otherwise assembled fabric, preferably a woven fabric. A woven flame retardant fabric of the invention may comprise one or more warp yarns and one or more weft yarn. The flame retardant fabric of the invention may comprise one or more warp yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, elastomeric fiber and antistatic fiber, suitable it comprises one or more warp yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber and antistatic fiber, and preferably the one or more warp yarns comprises no or essentially no elastomeric fiber. The flame retardant fabric of the invention may comprise one or more weft yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, elastomeric fiber and antistatic fiber, suitably it comprises one or more weft yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, and elastomeric fiber, and preferably the one or more weft yarns comprises no or essentially no antistatic fiber.
Examples of flame retardant fabrics of the invention that are woven include twill weaves (2xl, 3xl, etc.), satin weaves (4xl, 5xl, etc.), plain weaves and denim weaves. Preferably, the fabric is a satin weave. Examples of flame retardant fabrics of the invention that are knitted, or knit fabrics, include single and double knits, e.g. jersey, Swiss pique and interlock.
The flame retardant fabric of the invention exhibits excellent strength properties, including tensile and tear strengths. The tensile strength in the warp direction may be at least 900 N (Newton), or at least 1000 N, or at least 1050 N, and it may be up to 1200 N, or up to 1250 N, and/or the tensile strength in the weft direction may be at least 250 N, or at least 300 N, or at least 350 N, and it is usually up to 450 N, or up to 500 N, as measured according to ISO 13934. The tear strength may be at least 60 N, or at least 70 N, or at least 80 N on the warp side, and/or the tear strength may be at least 60 N, or at least 70 N, or at least 80 N on the weft side, as measured according to ISO13937-1 These values prove the robustness of the flame retardant fabric in a rugged environment.
Wear or abrasion might initially only influence the appearance, but eventually might lead to the destruction of a fabric. Abrasion resistant fabric withstands surface wear from rubbing, extending the life of an apparel of the fabric and protecting the person who wears it. The flame retardant fabric of the invention exhibits excellent abrasion resistance and can withstand at least 160,000, or at least 180,000, or at least 200,000 abrasion cycles as per ISO 12947. The pilling rating of the flame retardant fabric of the invention may be up to 2-3, or up to 3-4, or up to 4-5 after 5000 cycles as per ISO 12945.
The flame retardant fabric of the invention may be a flame retardant composite fabric. The term "flame retardant composite fabric", as used herein, refers to composite fabric created via bonding two or more layers of flame retardant fabric together without the use of sewing, stitch-bonding, quilting, or other processes that utilize a stitch or interlace yarn to combine two or more fabric layers. The two or more layers of the flame retardant fabric are suitably woven and/or knitted, preferably a woven fabric.
The flame retardant fabric of the invention exhibits excellent performance, including FR performance. For example, the fabric qualifies for EN ISO 1 1612 standards which is a measurement of fabric performance to protect against heat and flame. The fabric passes the requirements with the A1A2B1 C1 D2E2F1 class. The fabric also fulfils the requirements of EN ISO 1161 1 certification Class 1 , which calculate the performance of fabric for use in welding and allied processes. The fabric also qualifies for EN 61 482-1 -1 , which is a measurement of the protection against thermal hazard of an electric arc. The EBT values are 9 with an ELIM of 7.2. further, the fabric is certified for EN-13034 and EN-1149-3 standards, which are important certifications for a protective fabric. The fabric is industrially launderable and meet the requirements of ISO 15797 with 75 degrees C temperature wash. Further, the fabric meets the requirements of Oeko-Tex Class-ll, thus being tested and certified for harmful substances, and approved for use in direct contact with skin. Finally, the fabric exhibits controlled shrinkages of +/-3% in both warp and weft direction, which means that it is highly stable to washing, and dimensionally stable.
The present invention further relates to a flame retardant apparel made from the flame retardant fabric of the invention as defined herein. Examples of suitable flame retardant apparels include shirts, jackets, trousers, coveralls, uniforms, including military or industrial applications.
The present invention further relates to a method of manufacturing a flame retardant fabric which comprises manufacturing a fabric from 35-55% by weight of modacrylic fiber, 25-45% by weight of cellulosic fiber, 10-25% by weight of polyamide fiber, 1-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter. The method may comprise weaving, knitting or otherwise assembling a fabric from the fibers and amounts defined herein.
In a preferred embodiment, the method comprises: providing one or more warp yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber and antistatic fiber, preferably the one or more warp yarns comprise no or essentially no elastomeric fiber, providing one or more weft yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber and elastomeric fiber, preferably the one or more weft yarns comprise no or essentially no antistatic fiber,
- weaving the one or more warp yarns and the one or more weft yarns to form a woven fabric, wherein the obtained fabric comprises 35-55% by weight of modacrylic fiber, 25-40% by weight of cellulosic fiber, 10-25% by weight of polyamide fiber, 0.5-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, and wherein the weight of the fabric is from 250 to 350 grams per square meter. The flame retardant fabric may contain the fibers and amounts defined herein. The yarns may be formed in conventional ways well known in the art. The yarns may be spun yarns, e.g. air jet spun yarns, and may comprise a single yarn ortwo or more individual yarns that are twisted, or otherwise combined together. Preferably, the fibers are blended in the spinning stage so as to provide a uniform and homogenous distribution of fibers in the yarn and eventually in the fabric.
In a typical weaving method according to the invention, the fibers on the face side of the fabric will predominantly comprise the warp yarns and the fibers on the body side of the fabric will predominantly comprise the weft yarn. The fabric may be construed with the warp and weft yarns in a variety of ways, e.g. twill weave (2xl, 3xl, etc.) and satin weave (4xl, 5xl, etc.) constructions, which are well known in the art.
In a typical knitting method according to the invention, a double knit-circular machine is used. These machines have two needles, a dial needle and a cylinder needle, that work together to form the double-knit fabric. When utilized to make fabrics of the invention, different yarns can be used in each of the dial needle and cylinder needle such that the two yarns become inter-stitched with one yarn predominantly exposed on the one side of the knit fabric and the other yarn predominantly exposed ion the other side of the fabric.
Dyeing and printing of the fabrics may be carried out in accordance with standard methods, all of which are known in the art.
Examples
The invention is further illustrated in the following examples which, however, are not intended to limit the same. Parts and % relate to parts by weight and % by weight, respectively, and all suspensions are aqueous, unless otherwise stated.
Example 1
This example illustrates the manufacture of a flame retardant fabric according to the invention.
The flame retardant fabric was manufactured from fibers comprising 45% by weight of modacrylic fiber (Protex), 33% by weight of natural cellulosic fiber (Giza Cotton), 18% by weight of polyamide fiber (Cordura), 3% elastomeric fiber (XLANCE), 1 % antistatic fiber (NoShock, Ascend). The fibers for warp and weft yarns were blended in the spinning stage to get a uniform and homogenous distribution of fiber in the fabric. The fibers were spun into yarns using conventional methods well known in the art. The warp yarn consisted of modacrylic fiber, cellulosic fiber, polyamide fiber and antistatic fiber. The weft yarn consisted of modacrylic fiber, cellulosic fiber, polyamide fiber and elastomeric fiber. Both the warp yarn and weft yarn had a thickness of 14S, corresponding to around 384 D. A fabric was manufactured by weaving a single warp yarn and a single weft yarn using conventional methods well known in the art. The obtained flame retardant fabric showed the following results and properties:
Figure imgf000011_0001
As is evident from the above values and results, the flame retardant fabric of the invention showed excellent properties and performance.

Claims

Claims A flame retardant fabric comprising 35-55% by weight of modacrylic fiber, 25-45% by weight of cellulosic fiber, 10-25% by weight of polyamide fiber, 0.5-5% by weight of elastomeric fiber, and 0.5-5% by weight of antistatic fiber, wherein the fabric has a basis weight of from 225 to 400 grams per square meter. The flame retardant fabric according to claim 1 , wherein the fabric comprises the modacrylic fiber in an amount of from 35, or from 38, or from 40, or from 43% by weight, up to 48, or up to 50, or up to 53, or up to 55% by weight, preferably the modacrylic fiber is an acrylonitrile copolymer. The flame retardant fabric according to any one of claims 1 and 2, wherein the fabric comprises the cellulosic fiber in an amount of from 25, or from 28, or from 30, or from 32% by weight, up to 35, or up to 38, or up to 40, or up to 45% by weight, preferably the cellulosic fiber is cotton. The flame retardant fabric according to any one of the preceding claims, wherein the fabric comprises the polyamide fiber in an amount of from 10, or from 13, or from 15, or from 17% by weight, up to 18, or up to 20, or up to 23, or up to 25% by weight, preferably the polyamide fiber comprises aromatic groups. The flame retardant fabric according to any one of the preceding claims, wherein the fabric comprises the elastomeric fiber in an amount of from 1 , or from 2 % by weight, or from 2.5% by weight, up to 3, or up to 4, or up to 5% by weight. The flame retardant fabric according to any one of the preceding claims, wherein the fabric comprises the antistatic fiber in an amount of from 0.5, or from 0.75, or from 1 % by weight, up to 2, or up to 4, or up to 5% by weight. The flame retardant fabric according to any one of the preceding claims, wherein the fabric has a basis weight of from 225, or from 250, or from 275, or from 300 grams per square meter, up to 325, or up to 350, or up to 375, or up to 400 grams per square meter. The flame retardant fabric according to any one of the preceding claims, wherein the fabric is woven, knitted, a composite fabric, or otherwise assembled, preferably a woven fabric.
9. The flame retardant fabric according to any one of the preceding claims, wherein the fabric has anisotropic properties, preferably the fabric has different properties in an x-y coordinate plane, or different properties in an x-y-z coordinate plane.
10. The flame retardant fabric according to any one of the preceding claims, wherein the fabric comprises one or more warp yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, and antistatic fibers, preferably the one or more warp yarns comprises no or essentially no elastomeric fiber.
1 1 . The flame retardant fabric according to any one of the preceding claims, wherein the fabric comprises one or more weft yarns comprising modacrylic fiber, cellulosic fiber, polyamide fiber, and elastomeric fiber, preferably the one or more weft yarns comprises no or essentially no antistatic fiber.
12. The flame retardant fabric according to any one of the preceding claims, wherein the fabric has a tensile strength in a warp direction of at least 900 N, or at least 1000 N, or at least 1050 N, and/or a tensile strength in a weft direction of at least 250 N, or at least 300 N, or at least 350 N, and/or a tear strength of at least 60 N, or at least 70 N, or at least 80 N on a warp side, and/or a tear strength of at least 60 N, or at least 70 N, or at least 80 N on a weft side, preferably a tensile strength in a warp direction of at least 900 N and a tensile strength in a weft direction of at least 250 N, more preferably a tensile strength in a warp direction of at least 1000 N and a tensile strength in a weft direction of at least of at least 300 N.
13. The flame retardant fabric according to any one of the preceding claims, wherein the fabric comprises one or more yarns having a yarn thickness of at least 220 D, or at least 270 D, or at least 300 D, or at least 350, up to 400 D, or up to 450 D, preferably a warp yarn having a thickness of at least 220 D, or at least 270 D, or at least 300 D, or at least 350, up to 400 D, or up to 450 D and/or a weft yarn having a thickness of at least 220 D, or at least 270 D, or at least 300 D, or at least 350, up to 400 D, or up to 450 D.
14. The flame retardant fabric according to any one of the preceding claims, wherein the fabric contains one or more yarns having a coarseness of at least 12 S, or at least 14 S, or at least 16 S, up to 18 S, or up to 20 S, or up to 24S, preferably a warp yarn having a coarseness at least 12 S, or at least 14 S, or at least 16 S, up to 18 S, or up to 20 S, or up to 24S, and/or a weft yarn having a coarseness at least 12 S, or at least 14 S, or at least 16 S, up to 18 S, or up to 20 S, or up to 24S. The flame retardant fabric according to any one of the preceding claims, wherein the fabric comprises yarn having a yarn thickness of at least 270 D, or at least 300 D, or at least 350 D, up to 400 D, or up to 450 D, preferably the yarn thickness relates to both warp yarn and weft yarn. A flame retardant apparel made from a flame retardant fabric according to any one of the claims 1 to 15. A method of manufacturing a flame retardant fabric comprising weaving or knitting a fabric according to any one of the claims 1 to 15, preferably the method comprises providing one or more warp yarns, providing one or more weft yarns, and weaving the one or more warp yarns and the one or more weft yarns to form a fabric.
PCT/NO2023/050137 2022-06-30 2023-06-13 Flame retardant fabric and apparel WO2024005644A1 (en)

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