US20130288553A1

US20130288553A1 - Fabrics comprising inorganic fibers and uses in garments and coverings

Info

Publication number: US20130288553A1
Application number: US13/869,757
Authority: US
Inventors: David PENSAK
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-04-25
Filing date: 2013-04-24
Publication date: 2013-10-31

Abstract

Fabrics comprising inorganic fibers, or threads composed of such fibers, coated with a polymer composition sufficient to contain fiber particles within the fabric, are disclosed. Such fabric is suitable for use in garments and coverings for valuable objects, among many other utilities. Methods of making such fabric are also disclosed, as are garments and other articles made from such fabrics, and methods for their use.

Description

FIELD OF THE INVENTION

The invention relates to the field of utilitarian fabrics and garments. In particular, various embodiments of the invention provide fabrics comprising coated inorganic fibers, such as glass fibers, suitable for use in a variety of applications, including garments and coverings.

BACKGROUND

Inorganic fibers and fabrics are widely utilized in a variety of industries, due to their flexibility, strength and resistance to chemical and environmental damage, among other advantages. For instance, glass fiber (fiberglass) is naturally resistant to heat, fire, water, chemicals, pests and microorganisms. It is light and flexible, but still retains high tensile strength. In its typical usage, fiberglass fabric provides a framework to which a liquid resin is bonded, providing strength, form and durability to a product. Similarly, prior to discovering its causal link to lung cancer, asbestos fibers had been used extensively in the production of cloths, garments and other textiles for many centuries, as the mineral possesses superior resistance to heat, flame, acid and other corrosive elements.
Inorganic fibers and fabrics are utilized in composites or as laminated or coated materials rather than as stand-alone materials. In the instance of glass fibers and fabrics, coating the fabric or laminating it between other materials enables exploitation of the benefits of the material without exposure to its unpleasant or even hazardous features. Anyone who has worked with fiberglass without adequate protection knows that bits of glass fiber can break or shed from the fiberglass fabric or matting, causing skin and eye irritation due to mechanical action. In addition, though less noticeable, smaller glass fibers can be inhaled and deposited in the small air sacs of the lung. Unlike with asbestos, the alveoli do not close up and trap the glass fiber particles; rather, the particles are expelled from the alveoli and there is a rapid clearance from the lungs. Nevertheless, the lungs experience irritation upon exposure to glass fiber particles, as do the skin and eyes.
It is known in the art to coat fabrics made of inorganic fibers, particularly fiberglass. For instance, drapable fabrics comprising fiberglass have been disclosed for use in mattress ticking, upholstery drapery and the like (see, e.g., U.S. Pat. Nos. 4,526,830, 4,677,016, 4,801,493). Such fabrics tend to be fully coated with, or laminated to, a layer of rubber or other polymer. Such treatments can give the fabric a heavy, bulky, rubberized finish, rendering it unappealing for many uses, particularly in clothing and other fabric items that may come in contact with the skin.
Improvements in the coating of certain natural and synthetic fabrics (e.g., cotton, rayon, nylon) have resulted in coated fabrics that retain the feel of the uncoated fabric, yet have additional benefits such as water or wrinkle resistance. However, the application of such methods or devices have not been reported for inorganic fibers such as glass fibers or other fibers where one goal of such coating is to contain potentially irritating or hazardous inorganic fiber particles within the fabric.

SUMMARY OF THE INVENTION

One aspect of the present invention features a fabric comprising one or more types of inorganic fibers at least partially coated with a polymer coating agent. In one embodiment, the fabric comprises threads or yarns of inorganic fibers and the threads or yarns are at least partially coated with the polymer coating agent. In certain embodiments, the coating on the inorganic fibers substantially contains possibly irritating or hazardous particles that could be released from the fibers if they were not coated with the polymer coating agent.
The inorganic fiber can be of any type, for instance, it may comprise glass fiber, carbon fiber, rockwool fiber, wollastonite fiber, potassium titanate fiber, ceramic fiber, activated carbon fiber, magnesium silicate fiber, asbestos fiber, metal-coated organic fiber, metal coated inorganic fiber, blends thereof, and/or mixtures thereof. In one embodiment, the inorganic fiber is glass fiber.
The coating can comprise any suitable polymer. In one embodiment, the coating agent comprises a silicone polymer. The silicone polymer typically exhibits a viscosity greater than 1,000 cP and less than 2,000,000 cP at rest at 25° C. at a shear rate of 10 s⁻¹. In certain embodiments, the polymer coating agent is present on the coated fabric in the amount of from about 5% to about 200% by weight of the uncoated fabric. In certain embodiments, the fiber surface area covered by the polymer coating agent is at least about 80%.
The above-described fabric can comprise at least one additional material in certain embodiments. For instance, the additional material can be a fluorochemical, or it can be an antimicrobial agent.
Another aspect of the invention features a process for preparing fabric comprising inorganic fibers, or threads of inorganic fibers, coated with a polymer coating agent. In one embodiment particularly applicable to fabrics made of silicone-coated fibers, the process comprises the steps of: (1) providing an uncoated fabric comprising the inorganic fibers; (2) tensioning the uncoated fabric; (3) applying a curable silicone polymer composition thereto; and (4) moving a localized shear force over and against one surface of the tensioned fabric to distribute the curable silicone polymer composition within the fabric, resulting in the inorganic fibers or threads of inorganic fibers being at least partially coated with the curable silicone fiber. In an embodiment applicable to PTFE-coated fabrics, the process begins with a water dispersion of particulate material. Heat is applied to first drive off the water and then sinter the particles into a coating.
Another aspect of the invention features an article of manufacture comprising a fabric composed one or more types of inorganic fibers at least partially coated with a polymer coating agent. In one embodiment, the inorganic fiber is glass fiber. In certain embodiments, the polymer coating comprises silicone or PTFE. In a particular embodiment, the fabric comprises PTFE on one side and silicone on the other side. In several embodiments, the fabric is breathable. The fabric can comprise one or more additives in some embodiments.
The article of manufacture can be a garment or portion thereof, a drape, a blanket, a covering for inanimate objects, and/or a covering for a building or portion thereof. In one embodiment, the fabric is breathable and forms part or all of a garment. For instance, the garment can comprise sleeves or sleeve coverings made of the fabric. In another embodiment, the fabric is formed as a surgical drape or blanket and optionally comprises an antimicrobial agent. In another embodiment, the fabric is formed as a covering for an object, such as a object of artistic, historical, technical or other value. In certain embodiments, such objects are fragile, requiring a light, flexible and breathable cover, and the fabric is selected for such features.
Another aspect of the invention features a method comprising the steps of: (a) identifying an individual or object, or combination thereof, that is at risk of exposure to an environmental hazard; and (b) covering or shielding the individual or object with a fabric comprising polymer-coated inorganic fibers. In certain embodiments, the fabric comprises glass fibers and the polymer coating is selected from a silicone coating and a PTFE coating. The fabric is breathable in some embodiments, yet still offers some protection against airborne hazards. In various embodiments, the environmental hazards being protected against include one or more of flame, heat, smoke, water, noxious vapor or any combination thereof, and the fabric is partially or fully resistant to the environmental hazard.
In certain embodiments, the individual is a person or animal and the covering or shielding is performed by the individual donning a garment, at least a portion of which comprises the fabric, prior to or at the time of exposure to the hazard. In other embodiments, the object is an object of artistic, historic, technical or monetary value or significance and the covering or shielding is performed by cloaking the object with a cover or drape comprising the fabric prior to or at the time of exposure to the hazard. In certain embodiments, the covering or shielding is automated. In other embodiments, protection of both individuals and objects is sought. For instance, the individuals or objects may be located in a surgical theater and the covering or shielding is performed by installing surgical drapes or blankets into the surgical theater prior to the time of exposure to the hazard.
Another aspect of the invention features a kit comprising, in separate containers in a single package, or in separate containers in a virtual package: (a) an article of manufacture comprising a fabric composed one or more types of inorganic fibers at least partially coated with a polymer coating agent; and (b) instructions for using the article to protect the individual or object from an environmental hazard. Such kits can contain one or more additional components, for instance: hardware for assembling the article of manufacture; hardware for affixing the article of manufacture in proximity to an object to be protected; instrumentation for automating the covering or shielding of the individual or object; and/or instructions for assembly or use of the additional components.
Other features and advantages of the invention will be understood from the drawings, detailed description and examples that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a fabric comprising glass fibers coated with silicone polymer that was subjected to a torch flame.

DETAILED DESCRIPTION OF THE INVENTION

All percentages expressed herein are by weight of the total weight of the composition unless expressed otherwise. All ratios expressed herein are on a weight (w/w) basis unless expressed otherwise.
Ranges may be used herein in shorthand, to avoid having to list and describe each value within the range. Any appropriate value within the range can be selected, where appropriate, as the upper value, lower value, or the terminus of the range.
As used herein, the singular form of a word includes the plural, and vice versa, unless the context clearly dictates otherwise. Thus, the references “a”, “an”, and “the” are generally inclusive of the plurals of the respective terms. For example, reference to “a method” or “a fiber” includes a plurality of such “methods”, or “fibers.” Likewise the terms “include”, “including” and “or” should all be construed to be inclusive, unless such a construction is clearly prohibited from the context. Similarly, the term “examples,” particularly when followed by a listing of terms, is merely exemplary and illustrative and should not be deemed exclusive or comprehensive.
The term “comprising” is intended to include embodiments encompassed by the terms “consisting essentially of” and “consisting of”. Similarly, the term “consisting essentially of” is intended to include embodiments encompassed by the term “consisting of.”
The methods and compositions and other advances disclosed herein are not limited to particular equipment or processes described herein because such equipment or processes may vary. Further, the terminology used herein is for describing particular embodiments only and is not intended to limit the scope of that which is disclosed or claimed.
Unless defined otherwise, all technical and scientific terms, terms of art, and acronyms used herein have the meanings commonly understood by one of ordinary skill in the art in the field(s) of the invention, or in the field(s) where the term is used. Although any compositions, methods, articles of manufacture, or other means or materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred compositions, methods, articles of manufacture, or other means or materials are described herein.
All patents, patent applications, publications, technical and/or scholarly articles, and other references cited or referred to herein are in their entirety incorporated herein by reference to the extent allowed by law. The discussion of those references is intended merely to summarize the assertions made therein. No admission is made that any such patents, patent applications, publications or references, or any portion thereof, are relevant, material, or prior art. The right to challenge the accuracy and pertinence of any assertion of such patents, patent applications, publications, and other references as relevant, material, or prior art is specifically reserved.
The term “non-flammable fabric” means that the fabric is either flame-resistant or flame-retardant. Generally, a flame-retardant material delays the onset of combustion while a flame resistant material does not support combustion at all.
“Breathable” means generally that a fabric is at least somewhat permeable to gases. As used herein, the term “breathable” or “breathability” may be used comparatively. For instance, a fabric comprising coated inorganic fibers retains a portion of the breathability of the fabric prior to coating.
“Water resistant” means that the fabric is generally resistant to transport of fluids even under moderate pressure. Water-resistance includes waterproofing and water-repelling ability of the fabric.
An “inorganic fiber” is a fiber composed of compounds that substantially lack carbon-hydrogen (CH) molecules; more particularly lacking carbohydrate (CHO). A carbon fiber is considered an inorganic fiber in the instant application because it substantially lacks CH and CHO.
The term “fabric” means a woven or a non-woven fabric of fibers that is a single-ply or a multi-ply structure. The term “fabric” and “web” may be used interchangeably in the present specification. The term “fabric” or “web” as used herein refers to a sheet-like structure (woven or non-woven) comprised of fibers, or threads or yarns made of fibers. Included with the fibers can be non-fibrous elements, such as particulate fillers, binders, dyes, sizes and the like in amounts that do not substantially affect the porosity or flexibility of the fabric.
In one embodiment, at least 50 weight percent of a fabric used in the practice of the present invention is composed of the inorganic fiber. In other embodiments, fabrics have at least about 85 weight percent of their structure as the inorganic fiber. It is presently preferred that fabrics are untreated with any sizing agent, coating, or the like, except as taught herein. The fabric may comprise more than one layer, e.g., a woven fabric laminated onto a non-woven porous substrate.
The term “fiber” as used herein refers to a long, optionally pliable, cohesive, material, typically having a length at least 100 times its diameter. Fibers can be formed by known techniques into filaments, threads or yarns, which are used to make woven or non-woven fabrics, e.g., by weaving, knitting, braiding, felting, twisting, matting, needling, pressing, and the like. Preferably, fibers have a length of at least about 5 mm.
The term “filament” as used herein refers to a single fibril of natural or synthetic textile fiber, of indefinite length.
The term “thread” or “yarn” as used herein refers to a continuous strand comprised of a multiplicity of fibers, filaments, or the like in a bundled form, such as may be suitable for knitting, weaving or otherwise used to form a fabric. Thread or yarn typically comprises a number of fibers that are twisted together (e.g., spun yarn) or a number of filaments that are laid together without twist (e.g., zero-twist yarn).
The term “coating” as used herein, refers to a partially or fully continuous film or layer formed by a material over or on a surface.
The term “envelop,” “envelope,” “encapsulate” or “enrobe” as used herein, refers to the partial or complete surrounding, encasement, or enclosing by a discrete layer, film, coating, or the like, of exposed surface portions of at least some individual fibers or threads within a fabric, or prior to formation of a fabric.
The term “elastomeric” as used herein refers to the ability of a fabric to stretch and return to its original state.
The term “curing”, or “cure”, as used herein, refers to a change in state, condition, and/or structure in a material, such as a curable silicone polymer composition that is usually, but not necessarily, induced by at least one applied variable, such as time, temperature, radiation, presence and quantity in such material of a curing catalyst or curing accelerator, or the like. In the occurrence of curing in any case, such as the curing of such a polymer composition used in the present invention, the components of such a composition may experience occurrence of one or more of complete or partial (a) polymerization, (b) cross-linking, or (c) other reaction, depending upon the nature of the composition being cured, application variables, and/or other factors.
The term “thixotropy” refers herein to liquid flow behavior in which the viscosity of a liquid is reduced by shear agitation or stirring. In one embodiment, the viscosity is reduced by shearing—a process referred to herein as “shear-thinning.”
The term “single package” means that the components of a kit are physically associated, in or with one or more containers, and considered a unit for manufacture, distribution, sale and/or use. Containers include, but are not limited to, bags, boxes or cartons, packages of any type or design or material, over-wrap, shrink-wrap, affixed components (e.g., stapled, adhered, or the like), or combinations of any of the foregoing.
The term “virtual package” means that the components of a kit are associated by directions on one or more physical or virtual kit components instructing the user how to obtain the other components, e.g., in a bag or other container containing one component and directions instructing the user to go to a website, contact a recorded message or a fax-back service, or view a visual message, for example, instructions on how to use the kit, or safety or technical information about one or more components of a kit. Examples of information that can be provided as part of a virtual kit include instructions for assembly, instructions for use, and safety information such as material safety data sheets.
The present invention springs in part from the inventor's development of fabrics comprising inorganic fibers, such as glass fibers, that have all the beneficial features known to inorganic fiber fabrics, yet are sufficiently light, flexible and, in some embodiments breathable, to be wearable as apparel or used in applications involving repeated or routine contact with the skin. These latter features arise from applying a polymer or elastomer coating to the fabric, or to the fibers, threads or yarns comprising the fabric, such that the fibers themselves, or threads/yarns comprising the fibers, are sufficiently enrobed by the polymer to prevent the escape of potentially irritating or hazardous fiber shards or particles, yet not so heavy or dense to sacrifice the breathability, flexibility and/or appealing finish of the fabric.
Thus, one aspect of the invention is directed to a fabric comprising inorganic fibers, or threads composed of such fibers, that are coated with a polymer composition as described below. The coating is sufficient to contain fiber particles and the like within the fabric, yet light enough to impart desirable features to the fabric, such as an appealing finish or feel, breathability, flexibility and lightness. Generally, the fabric is comprised of a plurality of associated or inter-engaged fibers or threads of fibers having interstices defined therebetween. The fabrics can be woven, or non-woven.
In one embodiment, the coated inorganic fiber-containing fabric is used as a single-layer product. In another embodiment, two or more layers of the fabric are used together. They may simply be stacked one on another, or they may be joined by any method known in the art, such as by sewing, quilting, gluing, welding and similar means. In other embodiments, the fabric is layered with and/or joined to a different type of fabric. For instance, the coated inorganic fiber fabric may have a covering fabric attached to it, which can be colored, printed upon (e.g., for camouflage), or which provides some other benefit, such as insulation, resistance to airborne pathogens or toxins. Additionally or alternatively, the coated inorganic fiber fabric may be lined to provide an additional layer between the fabric and the wearer, e.g. to improve wicking or insulation properties and/or for other benefits. A layer of polyester (or equivalent) material to which a coating has been applied to reflect heat is also an embodiment of the present invention.
In one embodiment, the starting material of the inventive product comprises a planar porous fabric with opposing parallel-facing surfaces, substantially comprised of at least one type of inorganic fiber. At a microscopic level, such fabric is a three-dimensional structure comprised of a plurality of fibers, or a plurality of threads composed of the fibers, with interstices therebetween. Non-fibrous elements, such as particulate fillers, binders, dyes, sizes and the like can be added to the starting material of the fabric. In certain embodiments, the fabrics have at least about 85% of their structure comprised of at least one inorganic fiber such as glass fibers that is untreated with any sizing agent, coating, or the like. In another embodiment, the starting material comprises the fibers, threads, yarns and the like that will be woven, knitted, meshed and the like to form the fabric.
The inorganic fiber in the fabric can be composed of one or more fibers including but not limited to: glass fiber, ceramic fiber, other mineral wool or rockwool fibers, wollastonite fiber, potassium titanate fiber, carbon fiber, activated carbon fiber, magnesium silicate fiber, asbestos fiber, blends thereof, and/or mixtures thereof.
Glass fibers can be short fibers and/or microglass. Ceramic fibers are continuous fibers of metal oxides or refractory oxides that are resistant to high temperatures (for example, 2000-3000° F.). Ceramic fibers includes alumina, silica, aluminosilicate, beryllia, magnesia, thoria, zirconia, silicon carbide, quartz, boron fibers, boron nitride, alkaline earth silicates, and high silica reinforcements. Many ceramic fibers are polycrystalline, and many are non-crystalline. Polycrystalline fiber is made of aggregation of crystal, and is heatproof. Refractory ceramic fibers (RCFs) can also include fillers such as kaolin clay and oxides such as TiO₂, Cr₂O₃, Fe₂O₃, and MgO. Alkaline earth metals include beryllium, magnesium, calcium, strontium, barium, and radium. Beryllium aluminum silicate and calcium magnesium silicate or asbestos are examples of silicates based on alkaline earth metals. In other embodiments, the ceramic fibers used in the fabric of the present invention include silica zirconia, silicon carbide with core, boron oxide, calcium silicate, boratesiliconalumina, boron-tungsten fibers. Physical mixtures of the ceramics are also used to produce ceramic fibers and subsequent fabrics.
Wollastonite and potassium titanate are single crystal fibers. Rockwool is an amorphous fiber. Amorphous fiber is still hard with low elasticity because there is no grain boundary.
In one embodiment, by inorganic fibers also include metal-coated organic fibers. While these fibers are technically not inorganic fibers, in that, their core is that of an organic polymer, the present invention clearly envisions a fiber coated with metal. In another embodiment, the present invention also includes an inorganic fiber that is coated with metals.
The uncoated fabric or thread contains the inorganic fiber(s) as a substantial component. In certain embodiments, about 50% of the fabric by weight is the inorganic fiber. In one embodiment, the at least one inorganic fiber weight percent in the fabric can also be at least 50, 50.5, 51, 51.5, 52, 52.5, 53, 53.5, 54, 54.5, 55, 55.5, 56, 56.5, 57, 57.5, 58, 58.5, 59, 59.5, 60, 60.5, 61, 61.5, 62, 62.5, 63, 63.5, 64, 64.5, 65, 65.5, 66, 66.5, 67, 67.5, 68, 68.5, 69, 69.5, 70, 70.5, 71, 71.5, 72, 72.5, 73, 73.5, 74, 74.5, 75, 75.5, 76, 76.5, 77, 77.5, 78, 78.5, 79, 79.5, 80, 80.5, 81, 81.5, 82, 82.5, 83, 83.5, 84, 84.5, 85, 85.5, 86, 86.5, 87, 87.5, 88, 88.5, 89, 89.5, 90, 90.5, 91, 91.5, 92, 92.5, 93, 93.5, 94, 94.5, 95, 95.5, 96, 96.5, 97, 97.5, 98, 98.5, 99, 99.5, or 100 wt % of the fabric.
In another embodiment, the weight percent of the at least one inorganic fiber in the fabric is a number within a range defined by any two numbers listed above.
In a particular embodiment, the inorganic fiber comprises glass fiber and the fabric is made of woven or non-woven glass fibers, or threads/yarns of glass fiber. In particular embodiments, such fabrics are of a weight and composition suitable for use as clothing, blankets or the like, once treated in accordance with the present invention. For instance, a suitable weight range of 0.1 oz to 25 oz per square yard, with the lighter fabric being more suitable for very lightweight clothing, or linings of clothing, or articles in which several layers of fabric are used together, and the heavier fabric being more suitable for heavy garments, coats, blankets, protective shrouding for large objects, and the like. In certain embodiments, the fabric is at least about 0.1 oz, 0.2 oz, 0.3 oz, 0.4 oz, 0.5 oz, 0.6 oz, 0.7 oz, 0.8 oz, 0.9 oz, 1 oz, 1.5 oz, 2 oz, 2.5 oz, 3 oz, 3.5 oz, 4 oz, 4.5 oz, 5 oz, 5.5 oz, 6 oz, 6.5 oz, 7 oz, 7.5 oz, 8 oz, 8.5 oz, 9 oz, 9.5 oz, 10 oz, 10.5 oz, 11 oz, 11.5 oz, 12 oz, 12.5 oz, 13 oz, 13.5 oz, 14 oz, 14.5 oz, 15 oz, 15.5 oz, 16 oz, 16.5 oz, 17 oz, 17.5 oz, 18 oz, 18.5 oz, 19 oz, 19.5 oz or 20 oz per square yard. In other embodiments, the fabric is of a weight not more than about 5 oz, 5.5 oz, 6 oz, 6.5 oz, 7 oz, 7.5 oz, 8 oz, 8.5 oz, 9 oz, 9.5 oz, 10 oz, 10.5 oz, 11 oz, 11.5 oz, 12 oz, 12.5 oz, 13 oz, 13.5 oz, 14 oz, 14.5 oz, 15 oz, 15.5 oz, 16 oz, 16.5 oz, 17 oz, 17.5 oz, 18 oz, 18.5 oz, 19 oz, 19.5 oz, 20 oz, 20.5 oz, 21 oz, 21.5 oz, 22 oz, 22.5 oz, 23 oz, 23.5 oz, 24 oz, 24.5 oz or 25 oz per square yard. In particular embodiments, the fabric is between about 0.1 oz and about 25 oz per square yard, or between about 0.5 oz and about 20 oz per square yard, or between about 1 oz and about 15 oz per square yard, or between about 1.5 oz and about 10 oz per square yard, or between about 2 oz and about 5 oz per square yard. In certain embodiments, the weave of the fabric can range from open to tight, depending on the intended use. A looser or more porous weave (sometimes typical for a lighter weight fabric) may be more useful when the coating is applied to the fabric after the fabric has been formed. In other embodiments, tightness of weave may not be a concern if the fibers and threads are coated prior to weaving, knitting, or other fabric construction method. Fabrics of the various weights and meshes are available from a wide variety of commercial sources.
In addition to the at least one type of inorganic fiber, the fabric or threads may comprise a synthetic organic polymer and/or natural fibrous materials. Preferred synthetic polymers include polyamides (nylons), polyesters, such as polyethylene terephthalate, polyolefins such as polypropylene and polyethylene, acrylics, regenerated cellulose, cellulose acetates, and the like. Preferred natural fibers include cotton, linen, wool, and silk. Blends of these fibers, for example, polyester/cotton can also be used.
The polymer used to coat the threads or fabric comprised of the inorganic fiber is a polymer or mixture of polymers that possesses viscosity characteristics that enable a suitably thin yet enrobing amount of polymer to be applied to the inorganic fiber, or to threads or fabrics comprising the inorganic fiber, to impart the desired feel, breathability and the like to the fabrics, while substantially preventing the shedding or dispersal of fiber particles from the fabric. Suitable polymers include silicone polymers, polyvinyl butyral, fluoropolymers, fluoro elastomers, organic elastomers filled with fluoropolymers (e.g., PTFE), and combinations thereof. Suitable polymers typically have one, two, three or more of the following properties once applied to the inorganic fiber: flexibility, stretchability, stability to chemical exposure, stability to ultraviolet irradiation, low crystallinity and thermal stability.
The quantity of polymer in the fabric can vary widely, as long as it is present in an amount that is sufficient to achieve sufficient enrobing of the inorganic fiber or threads comprising the inorganic fiber, as described above. In the case of glass fiber, as a nonlimiting example, this amount is generally in the range of about 5 to about 200 weight percent of the weight of the untreated fabric. In particular embodiments, the weight percent of the polymer is at least 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 1313, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 1414, 143, 144, 145, 146, 147, 148, 149, 150, 151, 1515, 153, 154, 155, 156, 157, 158, 159, 160, 161, 1616, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, or 200 wt % of the untreated fabric.
In one embodiment, thixotropic behavior is built into a coating by either polymer design or additive/filler design. For example, thixotropic behavior can be accentuated by introducing into a silicone polymer composition certain additives that are believed to impart enhanced thixotropy to the resulting composition. A lower viscosity at high shear rates (during application to a fabric) is believed to facilitate polymer flow and application to a fabric.
Measurements of the degree of envelopment of the inorganic fibers or threads within a fabric can be made by microscopy, for instance, by conventional scanning electron microscopy (SEM) techniques.
It will be understood that the present invention is not limited to polymeric or prepolymeric materials that exhibit thixotropic behavior. In fact, the present invention also includes embodiments wherein the coating agent is a low-molecular weight polymer, an oligomer, or a monomer, which can undergo polymerization and/or crosslinking upon being subjected to curing conditions. For example, in one embodiment of the present invention, the coating agent is a monomeric, low-viscosity fluid, that need not undergo thioxtropy to penetrate the interstices of the fabric to produce an internally-coated fabric. Low viscosity materials (monomeric, oligomeric, polymeric) that exhibit viscosity in the range of from about 0.5 cP to about 1000 cP, even when not in a position to thixotropically shear-thin, will be amenable to interstitial penetration, and coating of the inorganic fiber or threads within the fabric. Only a thin film of the low viscosity material will remain on the surface of the fibers. Upon curing, such film will polymerize or cross-link to provide the final product with the same tactile feel, and at least one of the fabric properties identified herein. For example, the skilled person could use a thermosetting material that will demonstrate low viscosity, which would be highly suitable for deep penetration of the fabric for coating the fibers or threads therein. Similarly, the skilled person could use a lower molecular weight polymerizable polymer that has sufficiently low viscosity that the physical characteristic of the coating agent should not disqualify the material as a result of the (non-thixotropic) viscosity. The low viscosity material could utilize the process technology of the present invention to produce desired results, and without a significant loss of the inorganic fiber's physical properties.
In a particular embodiment, the coating comprises a silicone polymer. Types of silicone polymers suitable for use in the invention are described in U.S. Pat. Nos. 5,418,051; 6,129,978; 6,289,841; and 5,876,792. Other suitable silicone polymer compositions that can be used as coatings on the inrorganic fiber surfaces are disclosed in the U.S. Pat. Nos. 4,032,502; 4,108,825; 4,162,243; 4,250,075; 4,427,801; 4,500,659; 4,585,830; 4,753,978; 4,785,047; 4,329,274; and 4,442,060.
A curable silicone polymer utilized in the practice of this invention preferably has a viscosity that is sufficient to achieve a coating of the inorganic fibers in the fabric to the extent needed to contain fiber particles. Generally, the viscosity is greater than about 1000 centipoise and less than about 2,000,000 centipoise at a shear rate of 10 reciprocal seconds. In particular, the silicone polymer can have a viscosity in the range of about 5,000 to about 10,000 centipoise at 25° C. In addition, such a composition can contain less than about 1% by weight of volatile material. Typical silicone polymers can comprise a mixture of co-curable polymers, oligomers, and/or monomers. A catalyst can also be present, and is often a platinum or a platinum compound, such as a platinum salt.
In particular embodiments, fabrics of the present invention contain a curable silicone polymer that is present as a film, or coating, or layer within a fabric that envelopes at least a portion of the fibers or threads of the fibers. The thickness of the film, coating or layer is generally in the range of 0.01 to 50 microns. This thickness does not include the fabric that is coated.
The coating or enveloping of the inorganic fiber such as glass fibers in the fabric with silicone polymer, as measured by the percentage of the at least one inorganic fiber surface area covered is at least about 80%. In one embodiment, the percentage of the glass fibers surface area covered is at least about 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100%.
In certain embodiments, the coated inorganic fiber-containing fabrics can be treated with additional agents to impart further benefits. For example, agents such as ultraviolet light absorbers, dulling agents, reflectivity enhancers, and the like, which modify a fabric's response to light and radiation are desirably located substantially upon the surfaces of the fabric's fibers or threads.
In one embodiment, the fabrics can be treated with one or more fluorochemicals to impart additional resistance to soil, grease and/or water. Suitable fluorochemicals include, but are not limited to, perfluoro ethers, copolymers of organic and fluoro monomers and copolymers of silicones and fluoro monomers, just to name a few. When present, the quantity of fluorochemical is in the range of about 0.01 to about 5 wt % of the untreated fabric.
In a particular embodiment, when a fabric substantially comprising of an inorganic fiber such as glass fibers incorporates both a fluorochemical and a silicone polymer, they are present in an amount sufficient to achieve coating of the fibers or threads as described above. Generally, the total weight of fluoro chemical and silicone polymer is in the range of about 5 to about 200 weight percent of the weight of the untreated fabric.
Fabrics made in accordance with the present invention will exhibit the beneficial features specific to the type of inorganic fiber used, as well as other benefits imparted by the coating agent and/or supplemental components. In particular, depending on the type of inorganic fiber used and the coating applied, the fabric of the present invention exhibits one or more of the following characteristics: (1) resistant or retardant to flame; (2) breathable; (3) water resistant; (4) resistant to mold or bacterial growth; (6) chemical resistant; (7) thermal (heat or cold) resistant; (8) abrasion resistant, (9) ozone/UV resistant; (10) electrically insulating; (11) dimensionally stable; (12) durable; (13) wearable as apparel; (14) flexible; and (15) rewashable.
Fabrics as described herein can be made by a variety of methods familiar to the person skilled in the art. Any method is suitable, as long as it results the fibers, threads or yarns comprising the fabric being sufficiently enrobed by the coating agent to inhibit or substantially prevent escape of potentially irritating or hazardous fiber shards or particles. Accordingly, the polymer coating may be applied to the fibers themselves, or to threads or yarns of the fibers, either before or after construction into the fabric. The coating agent can be applied by spraying, dipping, rolling, painting, or scraping the agent onto the fibers, threads and/or fabrics. If needed or desired, after the coating is applied to the thread or fabric, it can be softened with a suitable solvent, such as alcohol (e.g., isopropanol), methyl ethyl ketone or mineral spirits to enable an additional amount of coating to penetrate the threads or fibers.
In one embodiment, the coating agent is applied to the fibers or threads prior to construction into the fabric. In another embodiment, the coating agent is applied to the fabric. Methods and apparati suitable for use on fabrics include, but are not limited to those described in U.S. Pat. Nos. 6,289,841 and 7,980,283. Briefly, the process described therein involves: (1) applying localized tension to a portion of the fabric to expand the intersices of the fabric; (2) applying the coating agent to the tensioned fabric; and (3) moving a localized shear force over and against one surface of the tensioned fabric. The shear force uniformly distributes the coating agent within the fabric, individually enveloping, at least partially, the surface of at least some of the fibers, threads or passageways through the fabric matrix in a internal region of the fabric. In one embodiment, the shear force is sufficient to shear-thin a thixotropic polymer. Shear-thinning helps distribute the polymer composition within the fabric as an internal coating in a region extending generally in spaced, parallel relationship to at least one face of the fabric. Shear thinning also aids in enveloping at least partial surface area of at least some of the fibers of the fabric. The fabric can be stored for a later curing step, or is immediately subjected to curing conditions such as heat, moisture and/or radiation.
More specifically, in a continuous operation utilizing a glass fiber fabric and a silicone polymer as a coating agent, the process comprises the following successive steps: (1) optionally treating the fabric with an additive, such as a fluorochemical; (2) longitudinally tensioning the additive-treated fabric; (3) sequentially, first applying to one surface thereof, a curable silicone polymer composition; (4) concurrently with step (3), applying a transversely-exerted localized compressive force against the surface; (5) moving over the surface of the fabric a substantially rigid shearing device, such as a knife, that exerts transversely an applied, localized shear force against the surface, and wipes away exposed portions of silicone polymer composition on the surface, thereby forming an internal layer of silicone polymer while enveloping at least some of the fibers, threads or passageways through the fabric matrix; and (6) curing the silicone polymer composition in the fabric. The additive treatment is generally carried out by the following steps: (1) substantially completely saturating the fabric with a solution or dispersion of the additive in a carrier liquid; (2) compressing the saturated fabric to remove excess portions of the solution or dispersion; and (3) heating and/or drying the fabric to evaporate the carrier liquid therefrom. However, any convenient process can be used for accomplishing additive pretreatment of the fabric.
Thus, the fabrics described herein have all the beneficial features known to inorganic fiber fabrics, yet are sufficiently light and flexible to be wearable as apparel or used in applications involving repeated or routine contact with the skin. As mentioned above, these latter features arise from applying a coating to the fabric, or to the fibers, threads or yarns comprising the fabric, sufficient to substantially trap potentially irritating or hazardous fiber shards or particles, yet maintain the breathability, flexibility and/or appealing finish of the fabric.
Another aspect of the invention features an article of manufacture that includes fabrics comprising polymer-coated inorganic fibers. These fabrics can be used in a variety of applications. In some applications, the coated inorganic fiber fabric is used as a single-layer product while other applications utilize two or more layers. They may simply be stacked together or they can be joined by any method known in the art, such as by sewing, quilting, gluing welding and similar means. In other applications, the fabric is layered with and/or joined to a different type of fabric, such as: (1) a covering fabric that can be colored, printed upon (e.g., for camouflage), or that provides some other benefit, such as insulation, heat reflection, resistance to airborne pathogens or toxins; or (2) a liner or internal layer, e.g. to improve wicking or insulation properties and/or for other benefits.
Many of the fabrics described herein are utilized for their non-flammability, due primarily to the intrinsic non-flammability of the inorganic fibers of which they are composed. This is certainly the case for glass fiber, which is naturally resistant to heat, fire, water, chemicals, pests and microorganisms and is also light and flexible, but still retains high tensile strength. Accordingly, for simplicity, the applications set forth below are sometimes described with respect to an exemplary fabric comprising coated glass fiber. However, the skilled artisan will understand that additional or alternative benefits may be gained by using fabrics comprising other inorganic fibers, singly or in combination.
In one embodiment, the article of manufacture utilizes a fabric prepared in the manner described above, for instance a fabric comprising silicone-coated glass fibers. In another embodiment, the article of manufacture utilizes a fabric comprising polytetrafluoroethylene (PTFE)-coated inorganic fibers, particularly glass fibers. Many such fabrics, as well as threads for stitching such fabrics, are commercially available (e.g., Precision Coating, Dedham Mass.; Taconic, Petersburgh N.Y.; W.F. Lake Corp., Glens Falls N.Y.). Lightweight, breathable PTFE-coated inorganic fibers such as those described above are particularly suitable for many of the articles of manufacture of the present invention.
In certain embodiments, inorganic fiber fabrics can be coated with different types of polymers to achieve different results. For instance, an inorganic fiber fabric can be coated with PTFE on one side and silicone on the other side.
Fabrics comprising polymer-coated inorganic fibers of the type described herein are used to advantage in protective wear, particularly garments, blankets, shrouds, coverings and other articles designed to protect the wearer or object from flames, extreme heat, extreme cold, irradiation, and other environmental hazards. Garments include, but are not limited to, jackets, coats, vests, trousers, jump-suits, shirts, socks, footwear or footwear covering, gloves, mitts, ponchos, and similar articles. The entire garment or just a portion of the garment, e.g., sleeves, can be made of the fabrics made of polymer-coated inorganic fibers.
In certain embodiments, a coated inorganic fiber fabric is used alone or layered with other fabrics in hazard wear for the military (for example as protection against fireballs generated by detonation of explosive devices). The material is breathable and as such is comfortable to wear even in elevated temperature situations. A distinction is drawn from currently used fireproof materials, which are heavy and infeasible for use in hot or humid conditions because of weight, flexibility, or bulk. Similarly, the material can be used in garments worn by fire fighters, where it would provide the same advantages of breathability, lightness and flexibility under conditions of extreme heat and/or humidity. Likewise, the fabric can be used as every-day apparel for people who are in an environment where there is the possibility of fire such as police, emergency service workers, and the like. The fabric can also be used to protect firefighters' or other emergency workers' equipment, for instance as a covering for large fire hoses, which could otherwise be damaged by flames or heat. In addition, the fabric can be used in garments to provide additional protection for a racecar driver in case of a crash. Not only will it be a flame barrier, it will slow the spread of the very flammable fuels in case of a tank rupture. Likewise the fabric can be used to surround a fuel tank. If the tank is cracked or broken, the fabric remains substantially intact, reducing fuel leakage. In addition, the fabric is extremely light so it does not put cars that use it at any measurable weight disadvantage.
In certain embodiments, the article of manufacture comprises apparel to be worn by chefs and other food preparation professionals who have to be working in or around high temperature ovens and may have to reach into them or are in close proximity to open flames on cooktops or comparable food warming devices. In this embodiment, an entire chef's or cook's jacket can be produced, o r a jacket in which the sleeves are made of the fabric can be made. Alternatively, sleeve covers can be fashioned to slip onto the wearer's arms or over other clothing. Of course, oven mitts comprising the fabric will also be particularly useful. Another type of article is a coat or jacket comprising polymer-coated inorganic fibers for laboratory personnel who may be exposed to hazardous conditions, such as fire or spillage of laboratory materials on them. Current lab coats are cotton or poly-cotton and do not provide nearly the protection offered by a polymer-coated inorganic fiber fabric as described herein.
In any of the foregoing garments and protective wear, the skilled artisan will understand that layering a fabric comprising polymer-coated inorganic fibers with another useful fabric, e.g., a material that can be printed upon or dyed for camouflage, a vapor barrier to prevent intrusion of toxic fumes, a reflective barrier to reflect heat, an insulating layer to keep heat in or out, or a wicking layer to wick body moisture.
Drapes for internal use, such as surgical drapes, hospital room drapes, residential drapes and the like can be fashioned from fabric comprising polymer-coated inorganic fiber. This type of fabric is particularly suitable for use in the surgical theater because it is non-flammable, water-resistant, breathable, pathogen resistant, dimensionally stable, washable, and flexible. Additionally, the material can be sterilized by autoclaving. In certain embodiments, a blanket or drape to be placed on a patient can be made from a double-coated inorganic fiber fabric in which one side is coated with PTFE and the other side is coated with silicone. The silicone-coated side of the fabric is placed proximal to the patient. Because the silicone-coated side of the fabric is less slippery than the PTFE-coated side, the blanket or drape remains in place on the patient. As an added benefit, because the PTFE-coating is slick, it will resist being displaced by inadvertent contact from a physician or other practitioner.
Another article of manufacture suitable for use in a hospital, trauma center or field setting is a portable, localized hyperbaric oxygen treatment system composed of a breathable, typically single-layered fabric composed of polymer-coated inorganic fibers. Additionally, such fabrics, particularly PTFE-coated fabrics, are suitable for use as a wound dressing. The material is strong enough to help hold the site of the injury together but being non-stick will not adhere when it is removed at a suitable medical facility.
In various embodiments, the intrinsic antimicrobial characteristics of the inorganic fiber can be supplemented through the application of additional materials to produce fabric of particular utility in applications requiring sterility or an extreme barrier to microbial pathogens. For instance, the fabric or threads can be additionally coated, impregnated or otherwise treated with a substance that imparts antimicrobial properties, including but not limited to: vinyl phosphonic acid, tannic acid, silver ion (alone or as a functional substituent), cyclodextrin, octadecyldimethylammonium ions, butane -tetracarboxylic acid, chitosan, zinc oxide, Bostrycin, polymers with quaternary nitrogen atoms (including aromatic and heterocyclic structures, acrylic and methacrylic polymers, cationic conjugated polyelectrolytes, polysiloxanes, hyperbranched and dendritic polymers and oxazolines), guanadine containing polymers, polymers that mimic natural peptides (including synthetic peptides arylamide and phenylene ethylylene backbone polymers and polynorbornene derivatives), halogenated polymers (including fluorinated polymers, chlorinated phenylmethacrylic polymers and polymeric N-halamines), polymers containing phosphor- and sulfo-derivatives, polymers containing benzoic acid derivatives, organometallic polymers and/or other polymers containing known antimicrobial organic or inorganic compounds (the latter including silver, titanium, and/or other metal oxides). In one embodiment, antimicrobial coatings produced by “tethering” biocides to the coating matrix can be used. Such coatings and methods are known in the art, e.g., as reviewed by Kugel, A. et al. (2011, Prog. Org. Coatings 72: 222-252).
Another embodiment features articles of manufacture comprising polymer-coated inorganic fibers made into protective coverings to cover and protect possessions of value, such as artwork, sculpture, books, valuable plants, technical equipment and the like, in the event of fire. Fabrics suitable for use in this embodiment are porous fabrics that are breathable but nevertheless flame-, heat- and water-resistant, and also offer substantial smoke resistance. A lightweight, slightly open-weave inorganic fiber, such as fiberglass, comprising a thin PTFE coating, is particularly suitable. The material is used as a protective drape or covering for items on shelves, in display areas, or in storage or work areas. It not only mitigates against fire hazard, it mitigates against damage when sprinklers are triggered or when a fire is extinguished with water or chemical agents. Polyethylene drop cloths, which are often used currently for such purposes, are neither fire resistant, heat resistant, nor breathable.
Coverings for valuable possessions can be fashioned in a variety of forms. For example, for items disposed on shelves, they can be formed as a pull down or automatic roll, such as a window shade or roman shade. Such roll configurations can be pulled down by hand or connected to sensors and automatically activated, for instance when sprinklers or a fire alarm is activated. Alternatively, coverings can be formed as simple drop-cloths. In another embodiment suitable for sculpture or other irregularly-shaped objects, the coverings can be cut and joined or stitched in a more-or-less form fitting shape for the particular object. In any of these embodiments, the covering can be affixed to walls, shelves, floors, tables and the like, by any means available to the person of skill in the art. These include, but are not limited to, weights, hooks, snaps, grommets, magnets and adhesives, to name just a few.
Another embodiment features articles of manufacture comprising fabrics composed of polymer-coated inorganic fibers that are made into protective coverings for buildings and components of buildings, such as roof, wall and floor barriers, either built in to a construction or applied later. In one use, the fabric is rolled out onto the roof before the shingles are installed and will provide a barrier, that is, even if the shingles burn, the flames will not get to the structure below. For existing buildings, a large roll system, similar to a window shade, will enable a the protective barrier be pulled down over the roof and walls of a building on demand, such as in the case of a fire and then rolled back up when the danger is past. In one embodiment, the fabric used to protect buildings or valuable items, particularly beneath roofs and as wall covering, can be coated with anti-mold agents. In another embodiment, the fabric is incorporated as a component of flooring systems to delay or prevent the spread of fire to upper floors if the room below is burning. In another embodiment, fabrics composed of polymer-coated inorganic fibers are used to wrap steam pipes, either to prevent or to patch leaks.
Another aspect of the invention features methods of protecting persons, animals, plants or inanimate objects from environmental hazards such as fire, heat, smoke, water, microbes, noxious materials and the like. The methods comprise covering or otherwise placing a barrier comprising a fabric composed of polymer-coated inorganic fibers between the person or object and the hazard. The methods generally comprise identifying persons, animals, plants or objects that are at risk of exposure to one or more such hazards, and applying the covering comprising a fabric made of polymer-coated inorganic fibers. The covering can be applied as a preventative measure, e.g., as a garment for someone at risk of being burned or as a built-in shield for a building, as discussed above. Alternatively, the covering can be applied at the time the hazard occurs, e.g., by covering valuable objects when fire is detected in a building. In this embodiment, the covering can be done manually or can be triggered automatically, such as when a fire alarm or sprinkler system is triggered.
In a further aspect, the invention provides kits suitable for protecting an individual or object from an environmental hazard. The kits comprise, in separate containers in a single package, or in separate containers in a virtual package, an article of manufacture as described above, and instructions for using the article to protect the individual or object from the hazard. In various embodiments, the kit may additionally contain ancillary components, e.g., hardware for assembling an article of manufacture and/or affixing it proximity to an object to be protected, instrumentation for automating the covering of an individual or object, and instructions for such assembly and use.
The following examples are provided to describe the invention in greater detail. They are intended to illustrate, not to limit, the invention.

EXAMPLE 1

Woven glass fiber fabric of about 2.5 oz per square yard, originally manufactured/sold by BFG Industries, Inc., Greensboro N.C., was purchased. In one procedure, a commercially available silicone sealant was mixed with acetone to the consistency of a thin fluid. The fabric was immersed in the silicone solution and hung to dry.
FIG. 1 shows a photograph of the silicone-coated glass fiber fabric with a stitched seam in it (cotton thread). The fabric was subjected to 25 seconds of a propane torch being swung back and forth over a three inch segment (that included the seam) from a distance of two inches. Virtually no damage to the fabric was observed. Additionally, the cotton thread used to make the seam was protected from combustion.

EXAMPLE 2

The same fabric and silicone material as described in Example 1 were used. A thicker silicone solution was prepared by mixing the sealant with less acetone. The material was applied by dipping the fabric into the solution and scraping away the excess with a blade, using localized tension as described in part in U.S. Pat. No. 6,298,841. Following drying, portions of the fabric in which the coating had been thickly applied were sprayed with acetone to remove some of the coating, thereby improving porosity of the fabric while still maintaining the appropriate coating of the threads.

EXAMPLE 3

Glass fiber fabric as described in Example 1 was sent to a commercial source for silicone coating in accordance with U.S. Pat. No. 6,298,841.
Four or five samples of the treated fabric laminated to a weather resistant nylon fabric (Peak nylon) were tested for weight, tear strength, tensile strength and flame resistance, in accordance with the American Society for Testing and Materials (ASTM) fabric performance standards. Results are shown below as averages for the samples.


Weight (ASTM D-3776):	5.2 oz/yd²
Tear Strength (ASTM D-1424):	12.9 lbs (warp), 12.8 lbs (fill)
Tensile Strength (ASTM D-5034):	118 lbs (warp), 81 lbs (fill)

Flame Resistance (ASTM D-6413) initial:

After-flame	39.3 sec (warp), 24.2 sec (fill)
Char Length	12 in (warp), 1.9 in (fill)
Afterglow	1.0 sec (warp), 0.0 sec (fill)

Flame Resistance (after 5 launderings):

After-flame	32.6 sec (warp), 35.9 sec (fill)
Char Length	12 in (warp), 4.7 in (fill)
Afterglow	3.8 sec (warp), 3.0 sec (fill)

The present invention is not limited to the embodiments described and exemplified herein, but is capable of variation and modification within the scope of the appended claims.

Claims

I claim:

1. An article of manufacture comprising a fabric composed one or more types of inorganic fibers at least partially coated with a polymer coating agent.

2. The article of claim 1, wherein the inorganic fiber is glass fiber.

3. The article of claim 1, wherein the polymer coating comprises silicone or PTFE.

4. The article of claim 1, wherein the fabric is breathable.

5. The article of claim 1, wherein the fabric further comprises an additive.

6. The article of claim 1, selected from the group consisting of: a garment or portion thereof, a drape, a blanket, a covering for inanimate objects, and a covering for a building or portion thereof.

7. The article of claim 6, wherein the fabric is breathable and forms part or all of a garment.

8. The article of claim 7, wherein the garment comprises sleeves or sleeve coverings made of the fabric.

9. The article of claim 6, wherein the fabric comprises an antimicrobial agent and is formed as a surgical drape or blanket.

10. The article of claim 6, wherein the fabric is breathable and is formed as a covering for an object.

11. A method comprising the steps of (a) identifying an individual or object, or combination thereof, that is at risk of exposure to an environmental hazard; and (b) covering or shielding the individual or object with a fabric comprising polymer-coated inorganic fibers.

12. The method of claim 11, wherein the fabric comprises glass fibers and the polymer coating is selected from a silicone coating and a PTFE coating.

13. The method of claim 11, wherein the fabric is breathable.

14. The method of claim 11, wherein the environmental hazard is selected from flame, heat, smoke, water, noxious airborne particles or any combination thereof, and the fabric is partially or fully resistant to the environmental hazard.

15. The method of claim 11, wherein the individual is a person or animal and the covering or shielding is performed by the individual donning a garment, at least a portion of which comprises the fabric, prior to or at the time of exposure to the hazard.

16. The method of claim 11, wherein the object is an object of artistic, historic, technical or monetary value or significance and the covering or shielding is performed by cloaking the object with a cover or drape comprising the fabric prior to or at the time of exposure to the hazard.

17. The method of claim 16, wherein the covering or shielding is automated.

18. The method of claim 11, wherein the individuals or objects are located in a surgical theater and the covering or shielding is performed by installing surgical drapes or blankets into the surgical theater prior to the time of exposure to the hazard.

19. A kit comprising, in separate containers in a single package, or in separate containers in a virtual package: (a) an article of manufacture comprising a fabric composed one or more types of inorganic fibers at least partially coated with a polymer coating agent; and (b) instructions for using the article to protect the individual or object from an environmental hazard.

20. The kit of claim 19, comprising one or more additional components selected from: (c) hardware for assembling the article of manufacture; (d) hardware for affixing the article of manufacture in proximity to an object to be protected; (e) instrumentation for automating the covering or shielding of the individual or object; and (f) instructions for assembly or use of the additional components.