WO2006113351A2

WO2006113351A2 - Durable outer shell textile fabrics

Info

Publication number: WO2006113351A2
Application number: PCT/US2006/013865
Authority: WO
Inventors: François LAPIERRE; Michel Mondoux; Daniel Lamarche; Pierre Joubert; Andre Arbour
Original assignee: Pgi Polymer, Inc.
Priority date: 2005-04-13
Filing date: 2006-04-13
Publication date: 2006-10-26
Also published as: WO2006113351A3

Abstract

The present invention is directed to a durable textile flame resistant fabric. This fabric is preferably used as the outer shell fabric for protective apparel, including a firefighter's garment. The fabric includes a woven fabric of 100% flame resistant spun yarns. Spun yarn is known in the art. Spun yarns may be cut into short lengths and prepared like staple fibers. Yarns are further known to be twisted to give them strength and smoothness; a clockwise twist is known as the Z twist and a counterclockwise twist is known as the S twist. Two or more strands twisted together form ply yarns. In slub yarns areas are left untwisted to vary the diameter for ornamental effects.

Description

DURABLE OUTER SHELL TEXTILE FABRICS Cross-reference to Related Application

[0001] This application claims the benefit of priority Provisional Application No. 60/670,729, filed April 13, 2005, the disclosure of which is incorporated herein by reference.

Technical Field

[0002] The present invention generally relates to durable textile fabrics, and more specifically, to flame resistant woven fabrics that exhibit suitable durability for use as outer shell protective garment fabrics even after 10 washing cycles, wherein the washing cycles are performed in accordance with AATCC 135-1-IV-Aii.

Background of the Invention

[0003] Woven flame resistant fabrics are known in the art to be useful in protective apparel, specifically outer shell fabrics for firefighting garments. The outer shell fabrics need to be durable enough to protect the wearer in multiple exposures to adverse conditions of extreme environments. Fabrics subjected to such conditions need not only exhibit flame resistance, but should also exhibit suitable tensile strength, tear resistance, and abrasion resistance.

[0004] Flame resistant outer shell fabrics currently available have utilized a combination of filaments and spun yarns of one or more flame resistant fibers within a woven pattern to achieve high durability. Unfortunately, the addition of filaments to the weave tends to compromises the overall physical performance of the woven fabric, as the filament and spun yarns have dissimilar fiber characteristics, including elongation and seam slippage. Repeated washings of these fabrics can further compromise fabric performance, affecting the durability and protective quality of the fabric. A need remains for a flame resistant textile fabric suitable for firefighting gear, as well as other protective garments, that exhibit suitable durability even after at least 10 washing cycles.

Summary of the Invention

[0005] The present invention is directed to a durable textile flame resistant fabric. This fabric is preferably used as the outer shell fabric for protective apparel, including a firefighter's garment. The fabric includes a woven fabric of 100% flame resistant spun yarns. Spun yarn is known in the art. Spun yarns may be cut into short lengths and prepared like staple fibers. Yarns are further known to be twisted to give them strength and smoothness; a clockwise twist is known as the Z twist and a counterclockwise twist is known as the S twist. Two or more strands twisted together form ply yarns. In slub yarns areas are left untwisted to vary the diameter for ornamental effects. _ , , .

[0006] In one embodiment, the flame resistant fabric of the present invention is a rip-stop weave, which further includes a blend of 100% flame resistant spun fibers that exhibit suitable durability characteristics, such as breaking load, after at least 10 washing cycles in accordance with AATCC 135-1 -IV-AiL

Detailed Description

[0007] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.

[0008] In accordance with the present invention, the flame resistant textile fabric exhibits improved durability, wherein the breaking load of the fabric is minimally affected after 10 wash cycles. The fabric was washed in accordance with standardized test method AATCC 135-1-IV-Aii and results are shown in Table 1. Fabrics A and C are comparative commercially available flame resistant fabrics, while fabric B represents an embodiment of the fabric made in accordance with the principles of the present invention.

[0009] The fabric of the present invention includes 100% fire resistant spun yarns, preferably 100% para-aramid or a para-aramid blend, which may include meta- aramid fibers. Suitable flame resistant fibers may further include, polybenzimidazol fibers, polyamidimid fibers, poly(paraphephenylene benzobisaxazole) fibers, phenol-formaldehyde fibers, melamine fibers, natural fibers, synthetic fibers, artificial fibers, glass fibers, carbon fibers, metal fibers, and composites thereof. Exemplary commercially available fibers include Kevlar® and Nomex®, made commercially available by DuPont., Technora®, Twaron®, Aramet® and Cόnex®, as made available by Teijin, polybenzimidazole (PBI), made commercially available by PBI Performance Products, Inc., Basofil®, as available by Basofil Fibers LLC, and P84, made available by lnspec Fibers, as well as the combinations and derivatives thereof.

[0010] Suitable weave patterns include plain weaves, plain weave rip-stops, and combinations thereof. In one embodiment, the para-aramid spun yarns are woven in a rip stop weave. A rip-stop weave is commonly used to increase a fabric's tear resistance. In such an embodiment, it is believed that the inherent strength of the aramid spun yarns configured in a rip-stop weave pattern lends to the fabric durability, wherein the fabric is capable of maintaining a desirable breaking load, tear resistance, and abrasion resistance after at least 10 washing cycles. [0011] Fabrics of the present invention have a preferred basis weight range between about 4 osy and about 10 osy, and most preferably about 6.5 and about 8.0 osy. Such fabrics are suitable for protective garments, especially firefighting garments, including but not limited to coveralls, trousers, and jackets. Other contemplated end-uses include military protective garments, as well as tarps, tents, bags or packs, and the like.

[0012] Textile fabrics made in accordance with the present invention meet requirements as set forth in NFPA-1971. The National Fire Protection Association (NFPA) provides guidelines as to the strength a fabric must have in order to be used in the construction of outer shells. According to NFPA 1971 , 2000 edition, the fabric must exhibit a tensile strength of at least 140 pounds (lbs.) in the warp and filling directions, and a trapezoidal tear strength of at least 22 lbs. in the warp and filling directions. The NFPA provides detailed guidelines as to the manner in which testing is to be conducted to determine both tensile strength and tear strength.

Test Methods

[0013] Textile fabrics made in accordance with the present invention meet requirements as set forth in NFPA-1971. Fabrics of Table 1 were constructed of a 65% Kevlar®/35% PBI flame resistant fiber blend. Fabric B, one embodiment of the present invention, was configured in a rip-stop weave pattern. All fabrics in Table 1 underwent testing prior to washing and were subjected to the same testing after 10 washing cycles. As previously mentioned, washing cycles were performed as outlined in AATCC 135-1 -IV-AiL

[0014] The breaking load was tested on fabric B before washing compliant with standardized test method NFPA-1971 ; 6-50 and after 10 wash cycles. As recorded in Table 1 , fabrics A and C exhibit a noticeable reduction in strength in both the warp and weft direction, while fabric B exhibits an insignificant loss in strength in the warp direction and exhibits improved strength in the weft direction. Further, noted in Table 1 is the comparative tear resistance performance. Tear resistance testing was performed in accordance with standardized test method NFPA-1971 ; 6-12. Fabric B outperforms fabric C in tear resistance in addition to breaking load after at least 10 washings.

[0015] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims. Tests results Research Center Table 1

Claims

What Is Claimed Is:

1. A durable textile fabric comprising a woven material of 100% fire resistant spun yarns with a breaking load of at least 300 lbs. in the weft direction after at least 10 wash cycles as performed in accordance with AATCC 135-1 -IV-AiL

2. A durable textile fabric as in claim 1 , wherein said fabric comprises 100% aramid woven spun yarns.

3. A durable textile fabric as in claim 2, wherein said 100% aramid woven spun yarns are para-aramid yarns.

4. A durable textile fabric as in claim 1 , wherein said fabric comprises a para- aramid blend

5. A durable textile fabric as in claim 1 , wherein the woven fabric has a weave selected from the group consisting plain weaves, plain weave rip-stops, and combinations thereof.

6. A durable textile fabric as in claim 1 , wherein the woven fabric is a rip-stop weave.

7. A durable textile fabric as in claim 1 , wherein said fabric is an outer shell fabric of a firefighter garment.

8. A fire resistant garment, comprising a woven material of 100% fire resistant spun yarns with a breaking load of at least 300 lbs. in the weft direction after at least 10 wash cycles as performed in accordance with AATCC 135-1-IV-Aii.