JP2002525449A - Flame resistant fabric - Google Patents

Abstract

  (57) [Summary] The present invention provides a textile fire-resistant fabric comprising different warp and weft yarns, the warp yarns comprising staple or filament fibers, having an extreme oxygen index of at least 27, and the weft yarns comprising natural fibers. Where the ratio of the number of warp yarns to the number of weft yarns in the fabric is at least 1.0.

Description

DETAILED DESCRIPTION OF THE INVENTION

BACKGROUND OF THE INVENTION Fabrics made from high temperature and flame resistant fibers have been very useful in protective clothing. Although numerous advances have been made in the design of comfortable fabrics and garments made from these fibers, there are still certain aesthetic and subjective reasons for the desire for a fire resistant garment incorporating further natural fibers. . To meet this need, fabrics have been made from combination yarns, that is, yarns that include both natural fibers and staple fibers that withstand high temperatures and flames. Fabrics made from such combined yarns can be made into comfortable garments, but the fabric's resistance to high temperatures and flames can be reduced to the extent that flame retardants need to be added to increase the fabric's thermal barrier properties. Attenuated. Specifically, a flame retardant is applied as a local treatment to fabrics made from natural staple fibers or a combination of these yarns. Since fabrics treated in this way tend to lose this barrier due to washing and / or wearing cycles, the addition of a topical treatment not only provides a temporary effect, but also adds weight and often to the fabric. May add hardness.

It is an object of the present invention to provide a fabric that combines flame resistance and comfort that can be prepared in a manner that balances performance against heat and price.

[0003] Another object of the present invention is to provide a comfortable,
The purpose is to provide an inexpensive fabric that is flame resistant.

[0004] It is another object of the present invention to provide a tough fabric that can balance fire resistance and cost.

[0005] To achieve some fabric properties, fabrics have been made from combination yarns. U.S. Pat. Nos. 4,941,884 and 4,900,6 to Green
No. 13 was made from a warp yarn comprising a blend of at least 15% by weight high modulus fiber and at least 30% by weight low modulus fiber woven with a weft yarn containing low modulus fiber (usually cotton). It discloses a highly durable and comfortable fabric. Warp yarns required a blend of high modulus and low modulus fibers to provide adequate shrinkage to increase abrasion resistance.

[0006] Canadian Patent No. 1034842 discloses a different property with an asymmetrical weave that varies from one side of the fabric to the opposite side of the fabric to achieve energy absorption that varies through the depth of the fabric. Discloses a protective fabric comprising interwoven warp and weft yarns.

[0007] European Patent Application No. 310,199 discloses a bulletproof textile fabric having high strength and high modulus and made from filaments or yarns made of ultra-high molecular weight polymers, where warp filaments or yarns are disclosed. Consists of a different polymer than the weft filaments or yarns.

[0008] UK Patent Application No. 2,025,789 and JP-A-59-1984 (1984)
-9053 discloses a fabric which is reinforced by inserting or replacing the fabric with a certain frequency of tougher adjacent yarns in the warp and / or weft direction.
JP 62-26900 teaches a reinforced aramid fabric that includes a group of low strength yarns inserted or replaced in the fabric weave in the warp and / or weft direction. These reinforced fabrics are designed for increased tear resistance,
It was not designed for comfort or heat shielding.

SUMMARY OF THE INVENTION The present invention is directed to a woven flame resistant comprising different warp and weft yarns.
providing a dough, the warp comprising staple or filament fibers, having an extreme oxygen index of at least 27, and the weft comprising natural fibers, wherein the number of warp to the number of weft of the fabric is provided. The ratio is at least 1.0. Warp yarns having a limiting oxygen index of 28 or more are more preferred.

In the present invention, the warp fibers can have a modulus of about 100 to 800 g / dtex. However, for some applications, 100 to about 2
A fiber modulus of 50 g / dtex may be preferred.

[0011] The warp yarn includes a fiber selected from the group consisting of aramid, polybenzimidazole, polybenzoxazole, melamine, poly (phenylene sulfide), polybenzothiazole, polyimide, polyetherimide, polyamideimide, novaloid and modacrylic fiber. Preferably, the weft yarns are selected from the group consisting of cotton, silk, wool, rayon and FR rayon. The warp may be formed from fibers that are m-aramid or p-aramid fibers or a mixture of these fibers, and further comprise up to about 5% by weight of electrically conductive fibers, especially sheath-carbon-core (sh).
(East-Carabon-core) fibers can be incorporated.

A preferred fabric for protective clothing is a fabric in which the warp fibers are sulfonated para-aramid fibers and the weft yarns are cotton. P-aramid fibers having a modulus of 100 to 200 g / dtex or less are particularly useful in fabrics for protective clothing and clothing applications.

[0013] The present invention also provides a protective garment comprising a woven flame resistant fabric comprising different warp and weft yarns, wherein the warp yarns comprise staple or filament fibers and have an extreme oxygen index of at least 27. And the weft comprises natural fibers, wherein the ratio of warp to weft in the fabric is at least 1.
0.

For apparel applications, the textile fabric consists of aramid, polybenzimidazole, polybenzoxazole, melamine, poly (phenylene sulfide), polybenzothiazole, polyimide, polyetherimide, polyamideimide, novaloid and modacrylic fibers. It is preferred that the warp fibers include a warp fiber selected from the group, and the weft fibers are selected from the group consisting of cotton, silk, wool, rayon, and FR rayon. Useful protective garments can be made where the warp fibers are m-aramid and the warp fibers are FR rayon. More preferred are protective garments in which the warp is a p-aramid fiber having a modulus of from 100 to about 250 g / dtex. Warp is sulfonated
Most preferred are protective garments which are aramid fibers and the weft fibers are cotton.

[0015] In the protective garment of claim 11, the warp further comprises up to about 5% by weight of electrically conductive fibers. And it is preferable that a warp is a staple fiber as protective clothing.

DETAILED DESCRIPTION The present invention provides a fire resistant woven fabric in which the yarns used for the warp and weft (or weft) are not similar. The fabric can be used in protective garments or for tents, tarpaulins and other applications where fabric hardness, fabric durability, high temperature, flame resistance, and low cost equilibrium are desired. .

In the subject fabric, the choice of warp fibers provides a fabric with high temperature and flame resistance, while the choice of weft provides comfort and price effectiveness. In these woven fabrics, the warp partially covers and protects the weft. Thus, it is believed that the warp shields the weft from flames and high temperatures. Thus, by selecting the warp yarns to be only yarns having an LOI of 27 or greater, the warp yarns provide thermal insulation to both the weft yarns and the fabric as a whole, and thus the weft yarns provide a comfortable fabric. And can be selected to have characteristics that make it cheaper.

In the present invention, the warp is made into high temperature and flame resistant fibers. The high temperature and flame resistant fibers have a limiting oxygen index of at least about 27, and preferably 28 or greater.
LOI). The preferred weft yarn is a yarn made from natural fibers, but the weft yarn could be selected from natural or synthetic fibers. Special consideration must be given to the choice of weft and warp yarns in order to provide a suitable fabric for protective clothing. Even with these special considerations, the fabric of the present invention encompasses a wide selection of yarns and provides a tough, comfortable and durable fabric that meets military and industry standards for high temperature and flame resistance.

As a fabric suitable for protective clothing, the weft yarn of the invention is selected from natural fibers. Natural fibers include fibers such as cotton and rayon, and fibers that appear to have some natural flame resistance, such as wool and silk, as well as other cellulosic-based fibers. Fibers discovered or derived. Rayon spans containing flame retardants (known as FR rayon) are particularly useful in the present invention. Nylon, polyester and other synthetic fibers that melt when exposed to high temperatures are not suitable when used as the primary component of weft yarns for protective garment fabrics. As these fibers melt when exposed to high temperatures, their presence can contribute to or worsen the burn.

In fabrics intended for uses other than protective clothing, fibers from polymers such as nylon and polyester are acceptable when mixed with natural fibers.

The weft yarns of the present invention can also include electrically conductive fibers such as synthetic sheath-carbon-core staple fibers or continuous filament fibers. These fibers reduce the likelihood of ignition and are much more preferred than fibers containing localized antistatic treatments. It is recommended that such sheath-carbon-core fibers be used at a concentration of 5% by weight.

The warp yarn in the present invention must have an LOI of 27 or more. High temperature and flame resistant fibers useful in the present invention for producing protective garment fabrics include, for example, aramid, polybenzimidazole, polybenzoxazole, melamine, poly (phenylene sulfide), polybenzothiazole, polyimide, polyetherimide. , Polyamide imide, novaloid and modacrylic fibers. These fibers decompose when exposed to the flame without producing toxic smoke. Useful fibers are trade names,
Kevlar (EI DuPont), NOMEX (EI DuPont)
, BASOFIL (BASF), TECHNORA (Azko), KYNOL (
Carborundum) and RYTON (Phillips Chemical)
l Company).

The warp as a whole must have an LOI of 27 or more for the fabric of the present invention.
The practical choice of fibers used to make the warp will be determined by the Thermal Insulation Test (TPP) or other criteria that the fabric is required to fill.
For example, practical exposure conditions or temperatures and length of exposure (time) will influence the choice of fibers used for warp and / or weft. In some cases, the warp may include up to 30% by weight of fibers having an LOI of less than 27, while the warp generally has an LOI of 27 or more.

[0024] The warp yarns of the present invention can also include electrically conductive fibers such as synthetic sheath-carbon-core staple fibers or continuous filament fibers. These fibers reduce the likelihood of ignition and are much more preferred than fibers containing a local antistatic treatment. Non-permanent topical treatments compromise the performance of the heat and flame resistant fabrics of the present invention. If the sheath-core electrically conductive fibers are incorporated into the warp, it is recommended that the concentration of these fibers be no more than about 5% by weight in the warp.

For maximum comfort, staple yarns are preferred as warp and weft.

In these fabrics, the modulus of the fibers is not an essential consideration,
High or low modulus fibers can be used in the warp yarns of the present invention. 1
Warp fibers having a modulus of from 00 to 800 g / dtex are suitable for use in the present invention. Less than 250 g / dtex or 100 to 200 g / dtex
Relatively low modulus fibers, which are fibers having a modulus in the range, are preferred as clothing fabrics that come into direct contact with the wearer because the fabric has adequate comfort. Higher modulus fibers may be acceptable for use in fabrics that are to be used for special purposes or in special areas in garments where wearer comfort is less important.

[0027] m- and p-aramid fibers are particularly useful in the fabrics of the present invention. These fibers include high modulus fibers as disclosed in U.S. Pat. No. 3,767,756 to Blades. Fibers having relatively low modulus are disclosed in US Pat. No. 5,336,734 to Bowen et al. And US Pat.
No. 0,698 and those made by the method disclosed in U.S. Pat. No. 3,671,542 to Kwolek. P-aramids having a modulus in the range of less than about 100 to 200 g / dtex are preferred, as the use of fibers having a relatively low modulus provides a fabric with improved comfort. US Patent 5,336,7
Sulfonated p-aramid prepared according to No. 34 is most preferred.

Aramid fibers can be made from homopolymers or copolymers. The only condition is that the warp has an LOI of 27 or more.

For strength and durability, it is desirable that the warp yarns are all made from fibers that are one type of high temperature and flame resistant polymer. For example, the warp has 100% by weight p
-It may be aramid. If the maximum mechanical strength is not critical, warps made from a mixture of high temperature and flame resistant fibers can be used. The use of mixed staple fibers may also provide additional comfort or help to provide additional thermal performance. For example, 5% by weight of p-aramid and 95
A commercial blend of yarns of wt-% m-aramid fiber is used over 100 wt-% m-aramid yarn due to its improved thermal performance. P- for warp
Another useful blend of and m-aramid fibers is 60% by weight p-aramid, 40% by weight m-aramid. Staple fibers made from stretch broken continuous filament fibers as well as cut staple fibers can be used in the production of the warp yarns of the present invention.

As long as the warp satisfies the LOI condition, the warp itself may have a different polymer composition or may be made from a ply of different staple or continuous filament fibers. The selection of the warp or fiber mixture for the warp used in the design of the fabric of the present invention can be used to achieve the overall fabric fire resistance that meets various industrial conditions or criteria. Thus, for special situations, fabrics with the desired comfort, durability, price and flame resistance can be designed according to the invention.

Unless the fabric is intended for non-garment applications, these fabric treatments are applied to fabrics as they tend to harden the fabric, reduce wearer comfort and tend to have transient properties. Flame resistant or flame retardant local treatments are not recommended for use in the present invention.

Again, in order to achieve the maximum fabric mechanical strength, the weft yarn according to the invention is specifically produced from one type of natural fiber, for example 100% cotton weft yarn. If maximum mechanical strength is not critical, a mixture of staple fibers can be used for weft yarns, for example, weft yarns including cotton and wool.

In the fabric of the present invention, the ratio of the number of warp yarns per inch to the number of weft yarns per inch is in the range of 1 to about 3, with 1 to 2.5 being preferred. For garment use, the ratio range is important because the warp and weft fibers work together to provide not only flame resistance and durability, but also comfort. In the present invention, it is preferred that all warp fibers are inherently flame resistant, i.e., that the warp comprises only fibers having an LOI of 27 or greater. Preferably, the weft yarn is made from natural fibers. There is no restriction on the LOI of the weft fibers, but the weft can have an LOI of 27 or more if desired.

The present invention provides an inexpensive flame resistant fabric that can be designed for both comfort and mechanical performance.

The fabrics of the present invention are useful in a variety of protective garments, including firefighter outfits, military uniforms, and various types of protective garments. In addition, these fabrics can be manufactured into shirts, trousers, and other clothing commonly worn in industrial or hazardous environments. The fabrics of the present invention may also be useful in non-garment applications where it is desired to balance heat shielding and cost. Tarpaulins, tents or other fabrics used to cover and shield people or substances can be made from the fabrics of the present invention.

The present invention is illustrated in the following examples, which are not intended to limit the invention.

[0037]

【Example】

From the following yarn, a plain weave ripstop fabric was prepared and MIL-C-4436 was prepared.
Weaved according to.

The yarns are as follows: the yarn identified as m-aramid is a staple fiber yarn of 100% poly (phenylene isophthalamide), and the yarn identified as Z200 is E.I. of Wilmington, DE. I. A staple yarn of sulfonated p-aramid fiber sold by DuPont as Z200, FR rayon refers to a flame resistant rayon staple yarn, and the blend of fibers in the staple yarn is identified by the fiber in the blend. These are nylon / cotton, m-aramid / cotton blends and m-aramid / cotton / Z200 blends and Z200 / cotton blends (NOMEX is a registered trademark of EI DuPont).

The resulting dough has a grab strength (ASTM-D-5034, the result is pounds (l
bs)), trapezoidal tear strength (ASTM-D-5733, results reported in pounds (lbs)), Elemdorf tear strength (ASTM D1424, results reported in pounds (lbs)) Tabor abrasion test (ASTM-D-1044, results reported in cycles to failure) and thermal barrier properties, TPP (Fire Tech)
nology V. 13N. 1 Feb. The method reported in 1977,
(Reported in seconds x 2 (s x 2) for degree brown).

The control fabric was a commercial fabric of 50% nylon and 50% cotton yarn in both the warp and weft directions. This fabric was selected as a control because it is a durable, comfortable fabric used to make military, industrial and general workwear. It is a tough, durable and comfortable fabric, but does not provide heat shielding. As the following table shows, the use of warp yarns according to the present invention results in a fabric with surprising heat shielding properties that combines strength and durability.

The data is summarized in the following table.

Table Evaluation of Dough Dough Sample A B C D E Control Weft 100% FR rayon 97/3 * 100% 70/30 50/50 50/50 FR rayon / cotton Z200 / m-aramit ミ / nylon / nylon cotton cotton cotton warp 100% 100% Z-200 70/30 50/50 50/50 m-aramit ゛ m-aramit ゛ Z200 / m-aramit ゛ / nylon / cotton cotton cotton fabric weight 7.0 7.1 6.0 4.5 6.1 6.8 w / f 2.5 / 1 2.5 / 1 1.9 / 1 1.5 / 1 2.3 / 1 2/1 Grab strength w / f 284/73 268/77 285/42 130/63 98/90 264/165 Trapezoidal tear 95/14 91/27 55/6 17/12 15 / 7.5 60/24 strength, w / f Elemtolf tear strength, w / f 8.3 / 11 8.9 / 19 14 + 12.2 13/10 7.6 / 6.3 14/12 Tahoe test 588 − 760 465 - 1300 TPP sec 12.8 14.1 11.5 10.0 - - atmosphere firing N N N Y Y Y * weft was FR rayon containing Firameto yarn ripstop nylon.

The total composition weight% of the weft was 97% by weight FR rayon and 3% by weight nylon filament.

In the table, the fabric weight is given as oz / yd ² , the grab strength (Grab), trapezoidal tear strength (trap tear) and Elemdorf tear strength are in pounds, and the Tabor abrasion test (Tabor) is the number of cycles to failure. It is. The term w / f means the result reported in the warp direction and then in the weft direction. The warp and weft compositions are reported in weight percent of each yarn. The ratios are given as percentages by weight of the figures indicated. For example, 50/50 nylon / cotton means that 50% by weight of the nylon fiber mix was used along with 50% by weight of the cotton fiber mix for the production of the yarn. Atmospheric ignition means atmospheric ignition. Results are reported either with (Y) or without (N). If the dough does not ignite,
It means that the dough did not ignite after being exposed to the flame for 3 to 5 seconds and did not keep burning.

Dough samples A, B and C are the doughs of the present invention. Samples D and E are present to compare the dough of the present invention with dough made according to prior art methods of making heat shield dough. Samples D and E are woven from uniformly blended staple yarns.

Comparing Samples C and D, it is observed that both fabrics have approximately the same weight ratio of Z200 to cotton in the fabric, but the distribution of high LOI fibers is distinctly different. In C, the high LOI fibers are distributed on the fabric surface, with the cotton on the inner weft, while in D, unlike C, the cotton is present on the fabric surface and is evenly distributed. Further, in C, the warp yarns are all Z200, while the weft yarns are all cotton. These warp and weft yarns are tougher than D uniformly blended staple yarns. For example, comparing the average of the warp and weft data, C
/ D, the following grab strength, 164/96, trapezoidal tear strength, 3
1/14 and Elemdorf tear strength, 14/12. Listing the results of the test, the difference in surface flammability measured by the atmospheric ignition test is very different for C compared to D.

Comparing the strength data for C and D by averaging the warp and weft values reported above, C is a tougher fabric than D. In the TPP test both fabrics are roughly equivalent to each other.

Compared to E, doughs A and B show similar differences as the comparisons of C and D, indicating that each is a tougher dough that does not ignite in air.

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Claims (18)

[Claims] 1. A fire-resistant fabric of a textile comprising different warp and weft yarns, wherein the warp yarns comprise staple or filament fibers, have an extreme oxygen index of at least 27, and the weft yarns comprise natural fibers. Wherein the ratio of the number of warp yarns to the number of weft yarns of the fabric is at least 1.0. 2. The fabric of claim 1 wherein the warp has an extreme oxygen index of 28 or greater. 3. The fabric of claim 1 wherein the warp fibers have a modulus of about 100 to 800 g / dtex. 4. The fabric of claim 1 wherein the warp fibers have a modulus of from 100 to about 250 g / dtex. 5. A warp yarn comprising aramid, polybenzimidazole, polybenzoxazole, melamine, poly (phenylene sulfide), polybenzothiazole,
2. The method of claim 1, wherein the fibers comprise fibers selected from the group consisting of polyimide, polyetherimide, polyamideimide, novaloid and modacrylic fibers, and the weft fibers are selected from the group consisting of cotton, silk, wool, rayon and FR rayon. Cloth. 6. The fabric of claim 1, wherein the warp fibers are m-aramid or p-aramid fibers or a mixture of these fibers. 7. The warp yarn incorporates up to about 5% by weight of electrically conductive fibers.
The fabric of claim 1. 8. The fabric according to claim 6, wherein 60% by weight of the warp fiber is p-aramid and 40% by weight is m-aramid fiber. 9. The fabric of claim 1, wherein the warp fibers are sulfonated para-aramid fibers and the weft yarns are cotton. 10. The warp fiber is m-aramid or p-aramid fiber or a mixture of these fibers, and the p-aramid fiber is 100 to 200 g / d.
2. The dough of claim 1 having a modulus of less than or equal to tex. 11. The fabric of claim 1, wherein the warp fibers are m-aramid and the weft fibers are FR rayon. 12. A protective garment comprising a woven flame resistant fabric having different warp and weft yarns, wherein the warp yarns comprise staple fibers or filament fibers, have an extreme oxygen index of at least 27, and the weft yarns. A protective garment comprising natural fibers, wherein the ratio of the number of warp yarns to the number of weft yarns in the fabric is at least 1.0. 13. The textile fabric is selected from the group consisting of aramid, polybenzimidazole, polybenzoxazole, melamine, poly (phenylene sulfide), polybenzothiazole, polyimide, polyetherimide, polyamideimide, novaloid and modacrylic fiber. 2. The warp fibers of claim 1, wherein the weft fibers are selected from the group consisting of cotton, silk, wool, rayon and FR rayon.
2 protective clothing. 14. The protective garment of claim 12, wherein the warp fibers are m-aramid and the weft fibers are FR rayon. 15. The protective garment of claim 12, wherein the warp fiber is p-aramid, wherein the p-aramid fiber has a modulus of from 100 to about 250 g / dtex. 16. The protective garment of claim 12, wherein the warp yarn further comprises up to about 5% by weight of electrically conductive fibers. 17. The protective garment of claim 12, wherein the warp is a staple fiber. 18. A tarpaulin or tent comprising the fabric according to claim 1.