Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
  • C08L33/18—Homopolymers or copolymers of nitriles
  • C08L33/20—Homopolymers or copolymers of acrylonitrile
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
  • D02G3/04—Blended or other yarns or threads containing components made from different materials
  • D02G3/047—Blended or other yarns or threads containing components made from different materials including aramid fibres
• • A—HUMAN NECESSITIES
  • A41—WEARING APPAREL
  • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
  • A41D31/00—Materials specially adapted for outerwear
  • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
  • A41D31/08—Heat resistant; Fire retardant
• • A—HUMAN NECESSITIES
  • A62—LIFE-SAVING; FIRE-FIGHTING
  • A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
  • A62B17/00—Protective clothing affording protection against heat or harmful chemical agents or for use at high altitudes
  • A62B17/003—Fire-resistant or fire-fighters' clothes
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
  • D02G3/443—Heat-resistant, fireproof or flame-retardant yarns or threads
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/12—Applications used for fibers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
  • C08L2205/16—Fibres; Fibrils
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
  • C08L2666/66—Substances characterised by their function in the composition
  • C08L2666/86—Antistatics
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
  • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/02—Moisture-responsive characteristics
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S428/00—Stock material or miscellaneous articles
  • Y10S428/92—Fire or heat protection feature
  • Y10S428/921—Fire or flameproofing
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/249921—Web or sheet containing structurally defined element or component
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
  • Y10T442/3146—Strand material is composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
  • Y10T442/3976—Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
  • Y10T442/3984—Strand is other than glass and is heat or fire resistant
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
  • Y10T442/444—Strand is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material

Definitions

• the present invention generally relates to fiber blends. More particularly, the invention relates to fiber blends used for a balance of high thermal, abrasion resistance, and moisture management properties and to the yarns, fabrics, and garments made from the fiber blends.
• Flame-resistant fabrics are fabrics that, once ignited, tend not to sustain a flame when the source of ignition is removed.
• Flame-resistant clothing is often worn by workers involved in activities such as industrial manufacturing and processing (such as oil, gas, and steel industries), fire-fighting, electrical utility work, military work, and other endeavors that entail a significant risk of being exposed to open flame, flash fire, momentary electrical arcs, and/or molten metal splash.
• Non-flame resistant work clothes can ignite and will continue to burn even after the source of ignition has been removed. Untreated natural fabrics will continue to burn until the fabric is totally consumed and non-flame resistant synthetic fabrics will burn with melting and dripping causing severe contact burns to the skin, the majority of severe and fatal burn injuries are due to the individual's clothing igniting and continuing to burn, not by the exposure itself.
• the abrasion resistance of protective fabrics is also an important performance property, as garments which develop failures, such as holes and rips, can compromise the protective properties of the fabric.
• Flame-resistant fabrics include both fabrics that are treated to be flame-resistant as well as flame-resistant fabrics made from inherently flame-resistant fibers.
• the former types of fabrics are not themselves flame-resistant, but are made flame-resistant by applying to the fabric a chemical composition that renders the fabric resistant to flame. These types of fabrics are susceptible to losing their flame-resistance with repeated laundering because the flame-resistant composition tends to wash out. In contrast, inherently flame-resistant fabrics do not suffer from this drawback because they are made from fibers that are themselves flame-resistant.
• the use of flame resistant clothing provides thermal protection at the exposure area. The level of protection typically rests in the fabric weight and composition. After the source of the ignition is removed, flame resistant garments will self-extinguish, limiting the body burn percentage.
• FR fibers inherently flame-resistant fibers
• modacrylic fibers e.g., modacrylic fibers sold under the PROTEX name from Kaneka Corporation of Osaka, Japan
• aramid fibers e.g., meta-aramid fibers sold under the NOMEX name and para-aramid fibers sold under the KEVLAR name, both from E. I. Du Pont de Nemours and Company of Wilmington, Delaware
• FR rayon fibers oxidized polyacrylonitrile fibers, and others.
• the FR fibers render the blend flame-resistant even though some fibers in the blend may themselves be non-FR fibers, because when the FR fibers combust they release non-combustible gases that tend to displace oxygen and thereby extinguish any flame.
• US 2005/0025963 discloses an intimate blend of staple fibers having 10 to 75 parts by weight of at least one aramid fiber, 15 to 85 parts by weight of at least one modacrylic fiber, and 5 to 30 parts by weight of at least one polyamide fiber.
• Another blend of staple fibers is disclosed in US 2004/0192134, including at least about 60 percent FR fibers (modacrylic and/or aramid) and up to 40 percent synthetic or natural non-FR fibers such as cotton or wool.
• US-B-6,787,228 discloses a yarn formed of a blend of fibers including at least about 70 percent modacrylic fibers combined with at least about 3 percent high-performance, high-energy-absorptive fibers such as aramid.
• ASTM F1930-99 is is a full-scale mannequin test designed to test fabrics in completed garment form in a simulated flash fire.
• a mannequin, with up to 122 heat sensors spaced around its body, is dressed in the test garment, and then exposed to a flash fire for a pre-determined length of time.
• Tests are usually conducted at heat energies of 1.8-2 cal/cm 2 sec, and for durations of 2.5 to 5.0 seconds for single layer garments. Results are reported in percentage of body bum.
• the test method defines a standard garment size and configuration that must be used on each test.
• FR fabric In addition to the above-noted performance specifications of fabrics, other properties are also important if a fabric is to be practical and commercially viable, particularly for clothing. For instance, the fabric should be durable under repeated industrial launderings and should have good abrasion-resistance. Furthermore, the fabric should be comfortable to wear. Unfortunately, many of the FR blends are not comfortable under typical environmental conditions. In such cases, wearers tend to be less likely to be compliant and thereby decreasing the probability that the wearer will continue to use the garment as intended. Thus, it is beneficial if an FR fabric exhibits good moisture management properties, i.e., ability to wick away sweat and dry quickly so that the wearer does not become overheated or chilled, and/or the fabric does not irritate the wearer's skin.
• moisture management properties i.e., ability to wick away sweat and dry quickly so that the wearer does not become overheated or chilled, and/or the fabric does not irritate the wearer's skin.
• the invention relates generally to fiber blends and to fabrics and garments comprising the fiber blends that achieve a balance of high thermal properties and moisture management properties to provide both protection and comfort to the wearer. [0011] Accordingly, in one embodiment, the invention is directed to fiber blends, comprising:
• a hydrophobic fiber component comprising at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof;
• a hydrophilic fiber component comprising at least one polymer selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof;
• At least one structural fiber component comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, and combinations thereof; wherein said aramid polymer is present at a level of at least about 10%, by weight, based on the total weight of the fiber blend; and
• the invention is directed to yarns comprising the fiber blends described herein.
• the invention is directed to fabrics comprising the fiber blends described herein.
• the invention is directed to garments, especially outerwear, comprising the fabric formed from the fiber blends described herein.
• the term "formed substantially of means that the fabric includes at least 50% by weight, based on the total weight of the fabric, preferably at least 75% by weight, based on the total weight of the fabric, and more preferably at least 95% by weight, based on the total weight of the fabric of a specific fiber blend or yarn composition.
• modacrylic fiber refers to a acrylic synthetic fiber made from a polymer comprising primarily residues of acrylonitrile, especially polymers that have between 35 to 85% acrylonitrile units, and which may be modified by other monomers. Modacrylic fibers are spun from an extensive range of copolymers of acrylonitrile.
• the modacrylic fiber may contain the residues of other monomers, including vinyl monomer, especially halogen-containing vinyl monomers, such as but not limited to vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, and the like.
• the types of modacrylic fibers that can be produced within this broad category are capable of wide variation in properties, depending on their composition.
• Modacrylic fibers have excellent fire retardancy performance combined with non-melt, non-drip and self-extinguishing properties. These are critically important attributes in many working environments. If sufficiently high temperatures are reached on exposure to fire or explosion, a garment made with the inventive fiber blends of the invention will carbonize by forming a protective charred barrier. This prevents propagation of flames, thereby protecting the wearer from severe burn injuries.
• Modacrylics have a high so-called LOI value as compared with other fibers. The LOI represents the minimum oxygen concentration of an O2/N2 mix required to sustain combustion of a material. The LOI is determined by the ASTM Test D 2862-77. Modacrylics have an LOI value preferably between about 28 and 33 while conventional polyesters have a much lower value of about 20 to 22.
• fluoropolymer refers to a fluorocarbon-based polymer with at least one, but preferably multiple, strong carbon-fluorine bonds, including, but not limited to, polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), or fluorinated ethylene-propylene (FEP).
• PTFE polytetrafluoroethylene
• PFA perfluoroalkoxy polymer
• FEP fluorinated ethylene-propylene
• aramid fiber refers to a manufactured fiber in which the fiber-forming substance is a long-chain synthetic polyamide in which at least 8 5 % of the amide linkages, (-CO-NH-), are attached directly to two aromatic rings, including, but not limited to, para-aramid ( -aramid) and meta-aramid (m-aramid).
• para-aramids include, but are not limited to, (poly(p-phenylene terephthalamide), e.g., KEVLAR® (E.I. du Pont de Nemours and Company), TWARON® (Teijin Twaron BV), and TECHNORA by Teijin Company.
• KEVLAR is a para-aramid fiber having a very high tenacity of between 28 and 32 grams/denier and outstanding heat resistance.
• meta-aramids include, but are not limited to, (poly(m-phenylene isophthalamide), such as NOMEX® (E.I. du Pont de Nemours and Company) and CONEX® (Teijin Twaron BV).
• the structural fiber is >-aramid, microdenier />-aramid.
• Such structural fibers feature excellent thermal stability and are virtually non-flammable.
• These fibers have a very high resistance to heat and are resistant to melting, dripping and burning at a temperature of at least 700°F.
• their LOI value is preferably in the range of between about 28 and about 30.
• melamine fiber is a manufactured fiber in which the fiber-forming substance is a synthetic polymer composed of at least 50% by weight of a crosslinked non-thermoplastic melamine polymer of melamine units joined by methylene and dimethylene ether linkages. In the polymerization reaction, methylol derivatives of melamine react with each other to form a three-dimensional structure. This structure is the basis for the fiber's heat stability, solvent resistance, and flame resistance.
• antistatic fiber refers to a fiber, when incorporated into a fabric or other material, eliminates or reduces static electricity.
• Suitable fibers include, but are not limited to, metal fibers (steel, copper or other metal), metal-plated polymeric fibers, and polymeric fibers incorporating carbon black on the surface and/or in the interior of the fiber, such as those described in US-A-3,803,4 3, US-A-4.035,441, US-A-4,107,129, and the like.
• Antistatic carbon fiber is a preferred antistatic fiber.
• One example of such conductive fiber is NEGASTAT® produced by E.I.
• du Pont de Nemours and Company a carbon fiber comprising a carbon core of conductive carbon surrounded by non-conductive polymer cover, either nylon or polyester.
• RESISTAT® made Shakespeare Conductive Fibers LLC, a fiber where the fine carbon particles are embossed on the surface of a nylon filament.
• the yarns of both such fibers are available in a denier of at least 40.
• a steel wire is available under the names BEKINOX and BEKITEX from Bekaert S.A. in a diameter as small as 0.03 5 millimeter.
• Another antistatic fiber is the product X- static made by Noble Fiber Technologies, a nylon fiber coated with a metal (silver) layer.
• the X-static fibers may be blended with other fibers, such as modacryhcs, in the process of yarn spinning.
• structural carbon fiber refers to fibers of about 0.005- 0.010 mm in diameter and formed primarily of carbon atoms.
• the carbon atoms are bonded together in microscopic crystals that are more or less aligned parallel to the long axis of the fiber.
• Each carbon filament is produced from a precursor polymer.
• Common precursor polymers include commonly rayon, polyacrylonitrile (PAN), and petroleum pitch.
• PAN polyacrylonitrile
• the precursor is first spun into filaments, using chemical and mechanical processes to initially align the polymer atoms in a way to enhance the final physical properties of the completed carbon fiber.
• the polymer fibers After drawing or spinning, the polymer fibers are then heated to drive off non-carbon atoms (carbonization), producing the final carbon fiber.
• Suitable structural fibers are available from Zoltek, SGL Carbon, Fortafil, Sumitomo, and Kureha Corporation.
• Basis weight refers to a measure of the weight of a fabric per unit area. Typical units include ounces per square yard and grams per square centimeter.
• the term “garment” refers to any article of clothing or clothing accessory worn by a person, including, but not limited to shirt, pants, underwear, outer wear, footwear, headwear, swimwear, belts, gloves, headbands, and wristbands.
• the term “linen” refers to any article used to cover a worker or seating equipment used by workers, including, but not limited to sheets, blankets, upholstery covering, vehicle upholstery covering, and mattress covering.
• the term "intimate blend,” when used in conjunction with a yarn, refers to a statistically random mixture of the staple fiber components in the yarn.
• the invention is directed to fiber blends, comprising:
• a hydrophobic fiber component comprising at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof;
• a hydrophilic fiber component comprising at least one polymer selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof;
• At least one structural fiber component comprising at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, and combinations thereof; wherein said aramid fiber is present at a level of at least about 10%, by weight, based on the total weight of the fiber blend; and
• the fabric when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric provides protection against second and third degree burns on less than about 35% of the wearer, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM F 1930-2000. In preferred embodiments, fabric provides protection against second and third degree burns on less than about 25% of the wearer, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM F 1930-2000. In more preferred embodiments, fabric provides protection against second and third degree burns on less than about 15% of the wearer, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM F 1930-2000.
• the fabric when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric has a char length less than about 5 inches, preferably less than about 4 inches, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM 6413.
• the fabric when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric has a water vapor transmission of at least about 1100, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM E96 for Water Vapor Transmission, and a vertical wicking of at least about 6 cm/5 minutes, when tested in accordance with Natick Internal Method No. 4.
• the fabric when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric has a wet tear value of at least equal to or greater than a corresponding dry tear value, when tested in accordance with the American Society for Testing and Materials Standard Test ASTM D 1424 (condition 1 dry; condition 2 wet).
• the fabric when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric has a wet abrasion resistance of greater than about 4000 random abrasion cycles with a 9KPa load, and greater than about 5,000 dry random abrasion cycles with a 9KPa load using wet/dry 600 grit ultrafrne sandpaper to simulate field usage, when tested in accordance with American Society for Testing and Materials Standard Test ASTM D 4966 Abrasion Resistance of Textile Fabrics - Martindale Abrasion Test Method.
• the fabric when the fiber blend is formed into a fabric formed substantially of said fiber blend, the fabric has a heat and thermal shrinkage resistance value of less than about 5%, when tested in accordance with the National Fire Prevention Association NFPA 1971 and a thermal protective performance value of at least about 5, preferably at least about 5.7 (initial) and at least about 6.7 (after 3x washing), when tested in accordance with the National Fire Prevention Association NFPA 1971 (without spacer).
• the hydrophobic fiber component of the fiber blend of the invention is present at a level of about 30-70%, by weight, based on the total weight of the fiber blend, and comprises at least one polymer selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, and combinations thereof.
• the hydrophobic fiber component is present at about 40-60%, by weight, based on the total weight of the fiber blend.
• the hydrophobic fiber component is present at about 40-50%, by weight, based on the total weight of the fiber blend.
• the hydrophobic fiber component is modacrylic or copolymer thereof.
• the fluoropolymer is selected from the group consisting of polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), fluorinated ethylene-propylene (FEP), and mixtures thereof.
• PTFE polytetrafluoroethylene
• PFA perfluoroalkoxy polymer
• FEP fluorinated ethylene-propylene
• the hydrophilic fiber component of the fiber blend of the invention is present at a level of about 15-45%, by weight, based on the total weight of the fiber blend, and comprises at least one polymer selected from the group consisting of cellulose, cellulose derivatives (such as cotton, viscose, linen, rayon, fire-resistant rayon, or a combination thereof), wool, and copolymers thereof, and combinations thereof.
• the hydrophilic fiber component is present at about 25-40%, by weight, based on the total weight of the fiber blend.
• the hydrophilic fiber component is present at about 25-35%, by weight, based on the total weight of the fiber blend.
• the cellulose derivative is cotton, viscose, linen, rayon, or a combination thereof.
• a preferred hydrophilic fiber component is cotton or fire-resistant rayon, or a combination thereof.
• the structural component of the fiber blend of the invention is present at a level of about 10-30%, by weight, based on the total weight of the fiber blend.
• the structural fiber component comprises at least one polymer selected from the group consisting of aramid fiber, melamine fiber, nylon fiber, structural carbon fiber, and combinations thereof; wherein said aramid fiber is present at a level of at least about 10%, by weight, based on the total weight of the fiber blend.
• the structural component is present at about 20-30%, by weight, based on the total weight of the fiber blend.
• the structural component is present at about 2 5 -30%, by weight, based on the total weight of the fiber blend.
• the structural component is aramid fiber, such as m-aramid polymer fiber or p-aramid polymer fiber. In certain embodiments, the aramid fiber is present at a level of about 27-30%, by weight, based on the total weight of the fiber blend. In other embodiments, the structural component is a combination of nylon fiber and aramid fiber, particularly p-aramid fiber. In certain other embodiments, the structural component is a combination of nylon fiber and aramid fiber, particularly p-aramid fiber, where both components are preferably present at a level of about 10%, by weight, based on the total weight of the fiber blend.
• an optional antistatic fiber is present at a level of about 0.1-3%, by weight, based on the total weight of the fiber blend.
• the antistatic fiber is an antistatic carbon fiber.
• the hydrophobic fiber component is modacrylic or a copolymer thereof
• the hydrophilic fiber component is cellulose or a cellulose derivative, or a combinations thereof.
• the structural fiber component is aramid fiber, nylon fiber, or a combination thereof.
• the fiber blend is:
• the fiber blend is:
• the invention is directed to yarns comprising the various fiber blends described herein, wherein said hydrophobic fiber component, said hydrophilic fiber component, said structural fiber component, and said optional antistatic fiber are intimately blended.
• the invention is directed to fabrics formed from the yarns comprising the various blends described herein.
• the fabrics may be either woven or knitted.
• the fabric has a basis weight of less than about 8.0 ounces/square yard (OPSY). In certain other embodiments, the fabric has a basis weight of less than about 6.0 ounces/square yard (OPSY).
• the fabric may be formed into a garment.
• the fabric forms at least one outer portion of the garment because of the protection it provides.
• the fabric is useful in garments such as outwear, including, but not limited to coats, coveralls, overalls, shirts, and pants, and is particularly useful in firefighter turnout coats.
• the fabric is formed into a garment, such as an undershirt, in a single tubular design to eliminate or reduce the number of seams and failure points.
• linen may be formed from the fabric of the invention.
• This test determines the performance of fabrics when exposed to heat in an oven at 500 °F. Observations of ignition, melting, dripping, or separation are recorded and reported for each specimen. The percent change in the width and length direction of the specimen is calculated. Results are recorded and reported as the average of three specimens.
• Specimen marking and measurements are conducted in accordance with the procedure specified in AATCC 135 Dimensional Change in Automatic Home Laundering of Woven and Knit Fabrics.
• the specimen is suspended by metal hooks at the top and centered in the oven so that the entire specimen is not less than 50 mm from any oven surface or other specimen, and air is parallel to the plane of the material.
• the specimen, mounted as specified, shall be exposed in the test oven for 5 minutes at 500°F.
• This test method determines the response of textiles to a standard ignition source, deriving measurement values for after-flame time, afterglow time, and char length.
• the vertical flame resistance as determined by this test method, only relates to a specified flame exposure and application time.
• This test method maintains the specimen in a static, draft- free, vertical position and does not involve movement except that resulting from the exposure.
• Test Method D6413 has been adopted from Federal Test Standard No. 191A method 5903.1, which has been used for many years in acceptance testing.
• Samples cut from fabric to be tested are mounted in a frame that hangs vertically from inside the flame chamber.
• a controlled flame is exposed to the sample for a specified period of time.
• After-flame time the length of time the material continues to burn after removal of the burner, and after-glow time, the length of time the material glows after the flame extinguishes, are both recorded.
• the specimen is tom by use of weights and the char length, the distance from the edge of the fabric that was exposed to the flame to the end of the area affected by the flame, is measured.
• Fabric samples and blotting paper should be conditioned at 6 5 +/- 2 % relative humidity and 21+/-1°C (70+/-2°F) for a minimum of 4 hours before testing.
• the overall drying time is calculated by averaging the dry time of all three specimens.
• a 500 ml Erlenmeyer flasks are filled with 200 ml colored water. 6 inch by 1 inch strip are cut from the fabrics to be tested. The top edge of strip is pierced with a long, straight pen. The strip is suspended from pin, in flask filled with 200 ml colored water. At standard intervals, the strip is removed from the flask and water level on the strip is measured and recorded.
• Analytical balances accurate to 0.0001 gram.
• Each bank of 4 balances is interfaced with a computer that utilizes Labview data acquisition software for collecting test data
• Built- in draft shield on the balance is used to minimize drafts, with only the top open to allow for drying.
• Vertical specimen stand is 3 inches wide and 6 inches tall.
• Samples are conditioned in the conditioning room at temperature of 70°F and 55% relative humidity for at least 4 hours prior to test.
• Option B Saturated, (note: This is essentially the Natick sample preparation protocol) 1. Weigh the conditioned sample using a laboratory balance, accurate to 0.0001 g.
• the test is complete once the specimen weight has reached a designated stopping moisture level vs. the dry conditioned weight.
• the stopping moisture level is typically 1% to 2.5% for cotton blend & cotton fabrics and 0.5% for polyester.
• the test is ended by stopping data acquisition in Lab View.
• Total drying time is the time it takes the specimen to reach the stopping weight.
• Total water release rate (“WRR,” g/min) is calculated as follows:
• Total WRR (wet specimen weight - ending specimen weight)/(total drying time) [0062] ⁇ WRR, total (%) is calculated from the respective total WRR values as follows:
• Comfort Zone drying time (minutes) is the time it takes the specimen's moisture content to decrease from 15% to 0.5% (polyester) or 20% to 1-1.5% (cotton).
• Comfort Zone WRR ( g/min) is calculated as follows:
• Active WRR (wet specimen weight - ending specimen weight)/("active" drying time)
• ⁇ WRR (Comfort Zone) is calculated in the same manner as for ⁇ WRR(total) except using test and control WRR (Comfort Zone) values.
• ASTM E96 is used to measure moisture vapor transmission.
• a 4 " x 4 " fabric specimen is prepared.
• a cup is filled with distilled water leaving a small gap (0.7 “ to 0.25") of air space between the specimen and the water. The cup is then sealed to prevent vapor loss except through the test sample.
• An initial weight is taken of the apparatus and then periodically weighed over time until results become linear.
• the Air Force tiger stripe print base fabric is twill fabric with diagonal weave (7.6 oz./sq. yd.) prepared from yarn of an intimate fiber blend of 50% Protex® M modacrylic fiber/30% Pima cotton 10% nylon/ 10% Twaron® para-aramid.
• the Air Force tiger stripe print base fabric a twill fabric with diagonal weave (7.58 oz./sq. yd.), was prepared from yarn of an intimate fiber blend of 50% Protex® C modacrylic fiber/30% Pima cotton/10% nylon/ 10% Twaron® para-aramid.
• the sample was tested for air permeability in accordance with ASTM-D737.
• the resulting measured air permeability is 20.1 foot'/minute/foot 2 .
• a rip stop woven fabric (5.75 oz./sq. yd.) was prepared from a yarn of an intimate fiber blend of 41% modacrylic/30% cotton/27% para-aramid/2% antistatic carbon fiber. The woven fabric was tested and the results are shown in the following table.
• a woven twill fabric (7.6 oz./sq. yd.) was prepared from a yarn of an intimate fiber blend of 50% modacrylic/30% cotton/10% nylon/10% para-aramid. The woven twill fabric was tested and the results are shown in the following table.
• Green colored, knitted fabric formed from a fiber blend of 80% PROTEXTM modacrylic/15% cotton/5% TWARONTM para-aramid was tested in accordance with NFPA 1975 (heat and thermal shrinkage resistance for station/work uniforms for fire and emergency services) (test temperature: 500°F; test exposure time: 5 minutes). Three samples were tested. Immediately after exposure specified, the specimens were removed and examined for evidence of charring, embrittlement, ignition (i.e., initiation of combustion, as set forth in ASTM D6413 flame resistance of textiles), melting and dripping or separation. Knit fabrics were pulled to original dimensions and allowed to relax for five minutes prior to measurement to determine pass or fail. [0082] Results: All three samples failed, when evaluated after heat at 500°F.
• Green colored, knitted fabric formed from a fiber blend of 75% PROTEX CTM modacrylic/15% Pima cotton/10% BASOFILTM melamine fiber was tested in accordance with NFPA 1975 (heat and thermal shrinkage resistance for station/work uniforms for fire and emergency services) (test temperature: 500°F; test exposure time: 5 minutes). Three samples were tested. Immediately after exposure specified, the specimens were removed and examined for evidence of charring, embrittlement, ignition (i.e., initiation of combustion, as set forth in ASTM D6413 flame resistance of textiles), melting and dripping or separation. Knit fabrics were pulled to original dimensions and allowed to relax for five minutes prior to measurement to determine pass or fail.
• Green colored, knitted fabric formed from a fiber blend of 80% PROTEX CTM modacrylic/15% Pima cotton/5% BASOFILTM melamine fiber was tested in accordance with NFPA 1975 (heat and thermal shrinkage resistance for station/work uniforms for fire and emergency services) (test temperature: 500°F; test exposure time: 5 minutes). Three samples were tested. Immediately after exposure specified, the specimens were removed and examined for evidence of charring, embrittlement, ignition (i.e., initiation of combustion, as set forth in ASTM D6413 flame resistance of textiles), melting and dripping or separation. Knit fabrics were pulled to original dimensions and allowed to relax for five minutes prior to measurement to determine pass or fail.
• NFPA 1975 heat and thermal shrinkage resistance for station/work uniforms for fire and emergency services
• Green colored, knitted fabric formed from a fiber blend of 85% PROTEX CTM modacrylic/15% cotton was tested in accordance with NFPA 1975 (heat and thermal shrinkage resistance for station work uniforms for fire and emergency services) (test temperature: 500°F; test exposure time: 5 minutes). Three samples were tested. Immediately after exposure specified, the specimens were removed and examined for evidence of charring, embrittlement, ignition (i.e., initiation of combustion, as set forth in ASTM D6413 flame resistance of textiles), melting and dripping or separation. Knit fabrics were pulled to original dimensions and allowed to relax for five minutes prior to measurement to determine pass or fail.
• Knitted fabric formed from a fiber blend of 75% PROTEXTM modacrylic/25% cotton was tested in accordance with NFPA 1971-07 (heat and thermal shrinkage resistance test; modified to use 7 inch specimens with 5 inch benchmarks). Three samples were tested as received. Immediately after exposure specified, the specimens were removed and examined for evidence of melting, dripping or separation, or ignition ⁇ i.e., initiation of combustion, as set forth in ASTM D6413 flame resistance of textiles).
• Results There was no melting, dripping, separation, or ignition of any of the samples. The samples exhibited severe color change. The dimension stability measurements were difficult to obtain due to the material gathering into small wrinkles and folds.
• Abrasion of the fabric can lead to a reduction weight, thickness, and eventually the failure of the fabric with a hole forming which exposes the wearer directly to an electric arc or fire threat.
• Having fabrics made of improved abrasion resistance yarns can result in longer lasting protective garments.
• These improved blends provide improved moisture management (water release rate) without sacrificing dry and wet abrasion resistance.
• Example 13 [0095] A khaki-colored plain woven fabric (5.75 oz./sq. yd.) was prepared from a yarn of an intimate fiber blend of 40% modacrylic/31% cotton/27% para-aramid 2% antistat. The plain woven fabric was tested and the results are shown in the following table.

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