JP2018502230A - Flame resistant fabric - Google Patents

Abstract

Flame resistant fabrics made from yarns of cellulose fibers, polyamide fibers, and oxidized polymer bi-regional fibers are provided. The fabric is from the group consisting of about 20 to about 90 weight percent cellulose fibers, about 3 to about 45 weight percent polyamide fibers, acrylonitrile homopolymer, acrylonitrile copolymer, acrylonitrile terpolymer, and combinations thereof. Selected from about 5 to about 35 weight percent oxidized polymer bi-regional fibers, including oxidized polymer.

Description

  The present disclosure relates to flame resistant fabrics made from yarns comprising cellulose fibers, polyamide fibers, and oxidized polymer bi-regional fibers.

  Flame resistant garments are worn by workers exposed to workplace heat and flame risks, such as heat, open fire, and electric arc flash, to reduce potential physical injuries.

Many flame resistant garments are made of 88/12 fabrics containing a blend of 88% cotton fibers and 12% nylon fibers. The fabric is typically treated with a phosphorus-based flame retardant chemical. The fabric meets industry standards for combustion performance requirements. In addition, since most of the fabric contains cotton fibers, the fabric is relatively inexpensive. In addition, because the addition of nylon fibers to the fabric provides a significant improvement in the wear resistance of the fabric, these fabrics are more likely to be used during commercial washing and wearing compared to 100% cotton fabric. Durable. 88/12 fabric is commercially available in weights of about 6.5 to 7.0 oz / yd ² or greater. An example of an 88/12 fabric is the UltraSoft® fabric manufactured by Westex Inc, a company of Milliken and Co.

However, there is a continuing need from end users for inexpensive flame retardant fabrics that weigh less than 6.5 oz / yd ² that are still durable for commercial laundry and wear. . Currently, 88/12 fabrics weighing less than 6.5 oz / yd ² exhibit defects in meeting industrial flammability standards.

  In order to meet these standards, inherently flame resistant fibers such as meta-aramid fibers that are commercially available as Nomex® fibers by Dupont Company are used for lightweight flame retardant fabrics. The

  US Pat. No. 6,358,608 discloses flame retardant and heat resistant yarns, fabrics, felts, and other that incorporate up to 99.9% oxidized polyacrylonitrile fibers, along with at least additional fibers such as p-aramid. A fiber blend is disclosed.

  Published US patent application 2011/0165397 discloses a stitchbonded flame resistant fabric comprising partially oxidized polyacrylonitrile fibers and / or yarns.

  Published US patent application 2011/0239618 discloses a flame retardant fabric made from oxidized polyacrylonitrile fibers having a fineness of about 0.5 to about 1.5 denier per fiber.

  Published US Patent Application No. 2014/0047625 is made from oxidized polyacrylonitrile or other high limiting oxygen index material in which the yarn is encapsulated or coated with a water repellent silicone polymer or other water repellent material. Apparel and fabric are disclosed.

  However, the fabrics described in the references mentioned above are expensive and uncomfortable to wear.

  WO 2010/135214 discloses a flame resistant fabric made from a blend of lyocell fibers and flame resistant fibers such as flame resistant (FR) cotton and FR treated rayon.

  WO 2011/050257 discloses blended yarns and fabrics containing 10 wt% to 85 wt% oxidized polymer bi-regional fibers such as oxidized polyacrylonitrile fibers. The disclosed yarn includes: FR rayon, FR-treated cellulose, m-aramid, p-aramid, modacrylic, novoloid, melamine, wool, nylon, regenerated cellulose, polyvinyl chloride, antistatic fiber, poly (p-phenylenebenzobisoxazole) ) (PBO), polybenzimidazole (PBI), and polysulfonamide (PSA) are blended with at least one synthetic fiber.

  Thus, it is durable to commercial laundry, comfortable to wear, affordable for the end user, and NFPA 70E ("Standard for Electrical Safety in the Workplace") and NFPA 2112 There is a need for a lightweight flame resistant fabric that complies with industry standards such as those described in “Standard on Flame-Resistant Garments for Protection of Industrial Person Against Flash Fire”.

  Embodiments of the present invention comprise from about 20 to about 90 weight percent cellulose fibers, from about 3 to about 45 weight percent polyamide fibers, acrylonitrile-based homopolymer, acrylonitrile-based copolymer, acrylonitrile-based terpolymer, and combinations thereof And about 5 to about 35 weight percent bi-regional fibers comprising an oxidized polymer selected from the group.

In one non-limiting embodiment, the fabric has a basis weight of about 3.0 oz / yd ² to about 15 oz / yd ² .

  In one non-limiting embodiment, the fabric is treated with a flame retardant chemical.

In one non-limiting embodiment, the fabric has an arc thermal performance value of about 8 cal / cm ² or greater.

  In one non-limiting embodiment, the fabric has an arc thermal performance value to basis weight ratio of about 1.24 or greater.

  In one non-limiting embodiment, the fabric is woven and includes warp and weft yarns, wherein the weft yarns comprise bi-regional fibers.

Another aspect of the present invention is about 20 to about 90 weight percent cellulose fiber, about 3 to about 45 weight percent polyamide fiber, about 1 to about 9 weight percent para-aramid fiber, and about 1 to about About 5 to about 35 weight percent bi-regional comprising 20 weight percent FR rayon fiber and an oxidized polymer selected from the group consisting of acrylonitrile-based homopolymers, acrylonitrile-based copolymers, acrylonitrile-based terpolymers, and combinations thereof And a fabric having a basis weight of about 3.0 oz / yd ² to about 15 oz / yd ² , the fabric is woven and includes warp and weft, and the weft is FR Contains the majority of rayon, para-aramid and bi-regional fibers.

  From yarns comprising fibers from about 20 wt% to about 90 wt% cellulose fibers, from about 3 wt% to about 45 wt% polyamide fibers, and from about 5 wt% to about 35 wt% oxidized polymer bi-regional fibers A lightweight, inexpensive flame resistant fabric that is made is provided by the present disclosure. It is understood that all numerical values recited herein are modified by the term “about”.

  About 20% to about 90% by weight of sufficient cellulosic fibers are used in these fabrics to improve the comfort properties of the fabric and reduce material costs. Cellulose fibers refer to cotton fibers, other natural cellulose fibers, and synthetic cellulose fibers. Synthetic cellulose fibers include, but are not limited to, rayon and lyocell. In some preferred embodiments, the cellulose fibers are cotton fibers. Additional examples of cellulosic fibers useful in these fabrics include, but are not limited to, hemp, cannabis, bamboo, rayon, and jute.

  From about 3% to about 45% by weight polyamide fibers are included in the yarn to provide the fabric with a durability similar to or better than the 88/12 fabric. Nylon 6,6; nylon 6,6; nylon 6,12; nylon 6,10; nylon 6T; nylon 6I; nylon 9T; nylon DT (D = Dytek® A diamine) , 2-methyl-1,5-diaminopentane); nylon DI; nylon D6; nylon 7; nylon 11; nylon 12; nylon MXD-6, and / or combinations thereof, but are not limited to these. “A combination thereof” with respect to polyamide includes, but is not limited to, block copolymers, random copolymers, terpolymers, and melt blends. In some preferred embodiments, the polyamide fibers are nylon 6,6 fibers.

  The fabric of the present disclosure further comprises from about 5% to about 35% by weight oxidized polymer bi-regional fiber. Oxidized polymer bi-regional fibers are formed from rayon fibers, pitch fibers, and fibers formed from polymers selected from the group consisting of acrylonitrile homopolymers, acrylonitrile copolymers, acrylonitrile terpolymers, and combinations thereof. Including oxidized fibers. In some non-limiting embodiments, oxidized polyacrylonitrile fibers are used. Examples of oxidized polymer bi-regional fibers useful in these fabrics are described in WO 2011/050257 A2, the teachings of which are incorporated herein by reference. In one embodiment, about 5 wt% to about 35 wt% of intrinsic flame resistant oxidized polyacrylonitrile fiber is oxidized to provide these fabrics with excellent heat, flame, and electric arc flash protection performance. Used as polymer bi-regional fiber.

  The fabric comprising the disclosed fiber blend is durable, comfortable, inexpensive and flame resistant.

  In one non-limiting embodiment, the fabric is woven and includes warp and weft yarns, wherein the weft yarns comprise bi-regional fibers. The inventor believes that the majority of polyamide fibers are in the warp so that they are distributed on the surface size of the twill or satin fabric, while the majority of the bi-regional fibers are in the transverse direction so that they are the fabric. I found that it is advantageous to ensure that it is behind the scenes. This is because bi-regional fibers may not be dyeable and can remain hidden, which improves the durability, appearance, and applicability of the fabric.

  In one non-limiting embodiment, the fabric is woven and includes warp and weft yarns, wherein the weft yarns comprise about 50 to about 100 weight percent bi-regional fibers in the fabric.

  In another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, the weft yarns comprising at least about 75 weight percent bi-regional fibers in the fabric.

  In yet another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, wherein the weft yarns comprise about 100 weight percent bi-regional fibers in the fabric.

  In one non-limiting embodiment, the fabric further comprises about 1 to about 9 weight percent para-aramid fibers. In another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, the weft yarns comprising about 50 to about 100 weight percent para-aramid and bi-regional fibers. In yet another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, the weft yarns comprising about 100 weight percent para-aramid fibers and bi-regional fibers.

  In one non-limiting embodiment, the fabric further comprises about 1 to about 20 weight percent FR rayon fibers. In another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, the weft yarns including from about 50 to about 100 weight percent FR rayon fibers and bi-regional fibers. In yet another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, wherein the weft yarns comprise about 100 weight percent FR rayon fibers and bi-regional fibers.

  In one non-limiting embodiment, the fabric further comprises about 1 to about 9 weight percent para-aramid fiber and about 1 to about 20 weight percent FR rayon fiber. In another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, the weft yarns comprising about 50 to about 100 weight percent FR rayon fibers, para-aramid fibers, and bi-regional fibers. . In yet another non-limiting embodiment, the fabric is woven and includes warp and weft yarns, the weft yarns comprising about 100 weight percent FR rayon fibers, para-aramid fibers, and bi-regional fibers.

Furthermore, fabrics made in accordance with the present disclosure are lightweight and durable for commercial laundry and wear. In one embodiment, the weight of the fabric is from about 3.0 oz / yd ² to about 15 oz / yd ² . In one embodiment, the weight of the fabric is less than about 6.5 oz / yd ² , such as from about 3 oz / yd ² to about 6.5 oz / yd ² .

Another aspect of the present invention is about 20 to about 90 weight percent cellulose fibers, about 3 to about 45 weight percent polyamide fibers, about 1 to about 9 weight percent para-aramid fibers, and about 1 to about About 5 to about 35 weight percent bi-regional comprising 20 weight percent FR rayon fiber and an oxidized polymer selected from the group consisting of acrylonitrile-based homopolymers, acrylonitrile-based copolymers, acrylonitrile-based terpolymers, and combinations thereof A fabric having a basis weight of about 3.0 oz / yd ² to about 15 oz / yd ² , the fabric is woven and includes warp and weft yarns;
The weft contains the majority of FR rayon, para-aramid, and bi-regional fibers.

  In a non-limiting embodiment of this aspect, the weft yarn comprises about 100 weight percent FR rayon fiber, para-aramid fiber, and bi-regional fiber.

  Fabrics produced in accordance with the present disclosure include, but are not limited to, knitted, woven, and non-woven fabrics having the fiber blends disclosed herein. It can be used to make a variety of flame resistant garments for thermal, flame and electric arc flash protection applications. Woven structures can include, but are not limited to, plain weaves, basket weaves, twill weaves, satin or saten weaves, and more durable ripstop weaves. In some embodiments, the fabric is formed from yarns produced by various types of spinning techniques such as, but not limited to, ring spinning, open end (OE), air jet, vortex, core span, and others. be able to.

  The fabric can be dyed by commercially available dyeing methods in some embodiments.

  Further, in some embodiments, fabrics produced in accordance with the present disclosure are treated with phosphorus-based flame retardant chemicals and / or other flame retardant chemicals. In one non-limiting embodiment, the fabric is treated with a phosphorus-based flame retardant chemical in the presence of urea / ammonia.

These fabrics provide excellent flame and thermal protection performance for flame resistant applications according to industry standard testing methods. Even lower lightweight fabrics, such as about 6.5 oz / yd ² , or less than 6.0 oz / yd ² , in some embodiments, have an arc rating of about 8.0 or greater, which is ASTM F1959. Meet or exceed performance requirements in arc grades according to “Standard Test Method for Determinating the Arc Rating of Materials for Closing”. Fabrics of about 6.5 oz / yd ² have a ratio of arc grade (arc thermal performance value) to fabric weight of about 1.24 or greater, while fabrics of less than about 6.0 oz / yd ² are about 1.36. The ratio of arc grade (arc thermal performance value) to fabric weight is as described above. Fabrics having a ratio of arc grade to fabric weight of about 1.24 to about 1.36 or even greater provide superior electrical arc flash protection performance to wearers of garments, comfortable protective garments. Fabric of some embodiments of about 6.5 oz / yd ² or about 6.0oz / yd even lower weight, such as less than ^2, is, National Fire Protection Association Standard (NFPA ) 2112 (2012), "Standard on Flame -Meet or exceed performance requirements for flash flame protection applications in accordance with Resistance Garments for Protection of Industrial Person Against Flash Fire. Furthermore, the lightweight fabrics of the present disclosure have been demonstrated to have a carbonization length of less than 4 inches in a vertical flammability test according to ASTM D6413: Standard Test Method for Flame Resistance of Textiles (Vertical Test). In addition, the fabrics of the present disclosure can be found in NFPA 2112: (National Fire Protection Association) Standard on Flame-Resident Garments for Protection of Industrial Person Against Flash. In accordance with Section 8.2 (Heat Transfer Performance), a thermal conductivity performance (HTP) rating of more than 8.0 cal / cm ² and ASTM F1930: Standard Test Method for Affection of Flame Resistant Criteria. It was demonstrated to have an average predicted body burn of less than 50 percent. Thus, the lightweight fabric of the disclosed fabric meets both the electrical arc grade performance requirements for HRC level II in NFPA standard 70E (2012) and the flash flame protection performance requirement in NFPA 2112 (2012) standard. Further, some embodiments of these lightweight fabrics may be double certified fabrics for both NFPA 70E HRC Level II and NFPA 2112 (2012).

  Articles formed from the fabrics of the present disclosure are also disclosed. In some embodiments, articles include but are not limited to clothes, shirts, pants, jackets, and coveralls.

  The following sections provide further illustrations of the fabrics of the present invention. These examples are illustrative only and are not intended to limit the scope of the invention in any way.

Example 1: Fabric and Yarn Samples Table 1 lists a plurality of fabric and yarn samples. Fabric sample 1 is an embodiment of the present invention. Fabric samples 2 and 3 are comparative examples. All three fabric samples were woven fabrics having a twill structure. Fabric sample 1 comprises 47% by weight cellulose fiber, 14% by weight FR rayon fiber, 16% by weight polyamide fiber, 6% by weight para-aramid fiber, and 17% by weight oxidized polymer bi-regional fiber. , Woven with yarn containing. Fabric sample 1 consisted of warp yarns containing cellulose fibers and polyamide fibers and weft yarns containing FR rayon fibers, polyamide fibers, para-aramid fibers, and bi-regional fibers. Thus, most of the polyamide fibers were distributed over the surface size of the twill fabric, while many oxidized bi-regional polyacrylonitrile fibers and para-aramid fibers that were not dyeable were hidden behind the twill fabric. It was. As a result, the durability and appearance of the fabric was substantially improved.

  Fabric sample 2 is a baseline fabric for comparison with fabric sample 1. Fabric sample 2 was woven with the same weft but different warp when compared to fabric sample 1. Fabric sample 2 comprises 35% by weight FR rayon fiber, 2% by weight polyamide fiber, 15% by weight para-aramid fiber, 29% by weight modacrylic fiber, and 19% by weight oxidized polymer bi-regional fiber. It was made up of.

  Fabric sample 3 is another baseline fabric for comparison with fabric sample 1. Fabric sample 3 was woven with the same warp and different weft when compared to fabric sample 1. Fabric sample 3 consisted of 88% by weight cotton fibers and 12% by weight polyamide fibers.

Example 2
Test Methods The test methods used to evaluate the fabrics of the present invention included:

  ASTM D6413: Standard Test Method for Frame Resistance of Textiles (Vertical Test);

  NFPA 2112 (2012): (National Fire Protection Association) Standard on Flame-Resident, Garments for Protection of Industrial Person Again Flash. Section 8.2 (Heat Transfer Performance);

  NFPA 2112 (2012): (National Fire Protection Association) Standard on Flame-Resistant Garments for Protection of Industrial Person Against Flash. Section 8.4 (Thermal Shrinkage Resistance);

  ASTM F1930: Standard Test Method for Evaluation of Frame Resistant Closing for Protection Against Fire Simulations Using an Insulated Manikin;

  ASTM F1959: Standard Test Method for Determinating the Arc Rating of Materials for Closing; and

  NFPA 70E (2012): Standard for Electrical Safety in the Workplace

  As used herein, the term HTP refers to Heat Transfer Performance.

  As used herein, the term ATPV refers to Arc Thermal Performance value.

  Table 2 lists the test results for the fabric samples of Example 1.

  All fabric samples met or exceeded performance requirements for the intended end use application according to NFPA 70E and NFPA 2112.

Fabric sample 1 was woven with the same weft and different warp yarns as fabric sample 2. Fabric sample 1 was made with more cellulose fibers and less para-aramid fibers, including additional cotton fibers, than fabric sample 2. The ratio of ATPV to fabric weight of fabric sample 1 (1.72) was much higher than that determined for fabric sample 2 (1.21). Fabric sample 1 was woven with the same weft and different warp yarns as fabric sample 3. Approximately 17% by weight of oxidized bi-regional polyacrylonitrile fiber was included in fabric sample 1, which was greater than that determined for fabric sample 3 (1.23) of the ATPV versus fabric weight of fabric sample 1. This resulted in a higher ratio (1.72). The fiber blend used for fabric sample 1 is a lightweight cotton / nylon / oxidized bio treated with a flame retardant chemical that meets the electrical arc grade performance requirements for HRC Level II in NFPA Standard 70 E (2012) It makes it possible to produce regional polyacrylonitrile blended fabrics.

Claims (29)

A fabric,
a) about 20 to about 90 weight percent cellulose fibers;
b) about 3 to about 45 weight percent polyamide fiber;
c) about 5 to about 35 weight percent oxidized polymer bi-regional fibers, including an oxidized polymer, selected from the group consisting of acrylonitrile-based homopolymers, acrylonitrile-based copolymers, acrylonitrile-based terpolymers, and combinations thereof , Fabric.   The fabric of claim 1, wherein the polyamide fiber comprises nylon 6,6.   The fabric of claim 1, wherein the oxidized polymer bi-regional fiber comprises oxidized polyacrylonitrile fiber. The fabric of claim 1, wherein the fabric has a basis weight of about 3.0 oz / yd ² to about 15 oz / yd ² . The fabric of claim 1, wherein the fabric has a basis weight of about 3.0 oz / yd ² to about 6.5 oz / yd ² .   The fabric of claim 1, wherein the fabric is treated with a flame retardant chemical. The fabric of claim 6, wherein the fabric has an arc thermal performance value of about 8 cal / cm ² or greater.   The fabric of claim 6, wherein the fabric has a ratio of arc thermal performance value to basis weight of about 1.24 or greater.   The fabric according to claim 1, wherein the fabric is woven and includes warp and weft, and the weft includes the bi-regional fiber.   The fabric of claim 1, wherein the fabric is woven and comprises warp and weft yarns, wherein the weft yarn comprises from about 50 to about 100 weight percent of the bi-regional fibers in the fabric.   The fabric of claim 1, wherein the fabric is woven and includes warp and weft yarns, wherein the weft yarn comprises at least about 75 weight percent of the bi-regional fibers in the fabric.   The fabric of claim 1, wherein the fabric is woven and comprises warp and weft yarns, wherein the weft yarn comprises about 100 weight percent of the bi-regional fibers in the fabric.   The fabric of claim 1, further comprising from about 1 to about 9 weight percent para-aramid fibers.   14. The fabric of claim 13, wherein the fabric is woven and comprises warp and weft yarns, wherein the weft yarn comprises from about 50 to about 100 weight percent of the para-aramid and the bi-regional fibers.   The fabric of claim 13, wherein the fabric is woven and includes warp and weft yarns, wherein the weft yarn comprises about 100 weight percent of the para-aramid fibers and the bi-regional fibers.   The fabric of claim 1, further comprising from about 1 to about 20 weight percent FR rayon fibers.   The fabric of claim 15, wherein the fabric is woven and includes warp and weft yarns, wherein the weft yarn comprises from about 50 to about 100 weight percent of the FR rayon fibers and the bi-regional fibers.   16. The fabric of claim 15, wherein the fabric is woven and comprises warp and weft yarns, wherein the weft yarn comprises about 100 weight percent of the FR rayon fibers and the bi-regional fibers.   The fabric of claim 1, further comprising about 1 to about 9 weight percent para-aramid fibers, and about 1 to about 20 weight percent FR rayon fibers.   20. The fabric according to claim 19, wherein the fabric is woven and comprises warp and weft yarns, wherein the weft yarn comprises from about 50 to about 100 weight percent of the FR rayon fibers, the para-aramid fibers, and the bi-regional fibers. The fabric described.   20. The fabric of claim 19, wherein the fabric is woven and comprises warp and weft yarns, wherein the weft yarn comprises about 100 weight percent of the FR rayon fiber, the para-aramid fiber, and the bi-regional fiber. . A fabric,
a) about 20 to about 90 weight percent cellulose fibers;
b) about 3 to about 45 weight percent polyamide fiber;
c) about 1 to about 9 weight percent para-aramid fiber;
d) about 1 to about 20 weight percent FR rayon fiber;
e) from about 5 to about 35 weight percent bi-regional fibers comprising an oxidized polymer selected from the group consisting of acrylonitrile-based homopolymers, acrylonitrile-based copolymers, acrylonitrile-based terpolymers, and combinations thereof;
The fabric has a basis weight of about 3.0 oz / yd ² to about 15 oz / yd ² , the fabric is woven and includes warp and weft yarns, the weft yarns comprising the FR rayon, para-aramid And a fabric comprising a majority of said bi-regional fibers.   23. The fabric of claim 22, wherein the polyamide fiber comprises nylon 6,6.   23. The fabric of claim 22, wherein the oxidized polymer bi-regional fiber comprises oxidized polyacrylonitrile fiber. It said fabric has a basis weight of about 3.0 oz / yd ² ~ about 6.5 oz / yd ^2, the fabric of claim 22.   23. The fabric of claim 22, wherein the weft yarn comprises about 100 weight percent of the FR rayon fiber, the para-aramid fiber, and the bi-regional fiber.   23. The fabric of claim 22, wherein the fabric is treated with a flame retardant chemical. 28. The fabric of claim 27, wherein the fabric has an arc thermal performance value of about 8 cal / cm < ² > or greater. 28. The fabric of claim 27, wherein the fabric has a ratio of arc thermal performance value to basis weight of about 1.24 or greater.