Flame and shrinkage resistant fabric blends

Abstract

The present disclosure relates to flame resistant fabrics that comprise a plurality of inherently flame resistant fibers and a plurality of cellulosic fibers containing a flame retardant compound. In one arrangement, the inherently flame resistant fibers have been dyed and/or shrinkage controlled with a dye-assistant such that the fabric contains a residual amount of a dye-assistant selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, N,N-diethylbenzamide, hexadecyltrimethyl ammonium salt, N,N-dimethylbenzamide, N,N-diethyl-m-toluamide, N-octylpyrrolidone, aryl ether, an approximately 50/50 blend of N,N-dimethylcaprylamide and N,N-dimethylcapramide, and mixtures thereof.

1 . A flame resistant fabric, comprising: 
 a plurality of inherently flame resistant fibers that were uncrystalized in fiber form; and    a plurality of cellulosic fibers containing a flame retardant compound;    wherein said inherently flame resistant fibers comprise a material selected from the group consisting of aromatic polyamide, polyamide imide, polyimide, and mixtures thereof;    wherein said cellulosic fibers comprise a material selected from the group consisting of rayon, acetate, triacetate, lyocell, and mixtures thereof.    
     
     
         2 . The fabric of  claim 1 , wherein said inherently flame resistant fibers are meta-aramid fibers.  
     
     
         3 . The fabric of  claim 1 , wherein said cellulosic fibers are rayon fibers.  
     
     
         4 . The fabric of  claim 1 , wherein said fabric contains a residual amount of dye-assistant selected from the group Consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and mixtures thereof.  
     
     
         5 . The fabric of  claim 1 , wherein said fabric contains a phosphorus compound flame retardant in a concentration of at least approximately 1.4% phosphorus by weight of cellulosic fiber component.  
     
     
         6 . The fabric of  claim 1 , wherein said fabric exhibits a duration of afterflame no greater than 2.0 seconds when subjected to a vertical flammability test conducted in accordance with FTMS 191 A Method 5903.1 using a three second exposure.  
     
     
         7 . The fabric of  claim 1 , wherein said fabric exhibits a shrinkage percentage of no greater than approximately 7% after 20 launderings conducted in accordance with AATCC Test Method 135-1992, Table I (3)(V)(A)(iii).  
     
     
         8 . The fabric of  claim 1 , wherein said inherently flame resistant fibers of said fabric have been dyed a shade of color which results in an L value between approximately 18 and the greige L value for said fabric if said inherently flame resistant fibers were used to form a fabric composed exclusively of said inherently flame resistant fibers.  
     
     
         9 . A flame resistant fabric, comprising: 
 a plurality of inherently flame resistant fibers; and    a plurality of cellulosic fibers that contain a flame retardant compound;    wherein said fabric contains a residual amount of a dye-assistant selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, N,N-diethylbenzamide, hexadecyltrimethyl ammonium salt, N,N-dimethylbenzamide, N,N-diethyl-m-toluamide, N-octylpyrrolidone, aryl ether, an approximately 50/50 blend of N,N-dimethylcaprylamide and N,N-dimethylcapramide, and mixtures thereof.    
     
     
         10 . The fabric of  claim 9 , wherein said dye-assistant is selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and mixtures thereof.  
     
     
         11 . The fabric of  claim 9 , wherein said inherently flame resistant fibers comprise a material selected from the group consisting of aromatic polyamide, polyamide imide, polyimide, and mixtures thereof.  
     
     
         12 . The fabric of  claim 9 , wherein said inherently flame resistant fibers are meta-aramid fibers.  
     
     
         13 . The fabric of  claim 9 , wherein said cellulosic fibers comprise rayon, acetate, triacetate, lyocell, or mixtures thereof.  
     
     
         14 . The fabric of  claim 9 , wherein said cellulosic fibers are rayon fibers.  
     
     
         15 . The fabric of  claim 9 , wherein said fabric contains a phosphorus compound flame retardant in a concentration of at least approximately 1.4% phosphorus by weight of cellulosic fiber component.  
     
     
         16 . The fabric of  claim 9 , wherein said fabric exhibits a duration of afterflame no greater than 2.0 seconds when subjected to a vertical flammability test conducted in accordance with FTMS 191 Method 5903.1 using a three second exposure.  
     
     
         17 . The fabric of  claim 9 , wherein said fabric exhibits a shrinkage percentage of no greater than approximately 7% after 20 launderings conducted in accordance with AATCC Test Method 135-1992, Table I (3)(V)(A)(iii).  
     
     
         18 . The fabric of  claim 9 , wherein said inherently flame resistant fibers of said fabric have been dyed a shade of color which would result in an L value between approximately 18 and the greige L value for said fabric if said inherently flame resistant fibers were used to form a fabric composed exclusively of said inherently flame resistant fibers.  
     
     
         19 . A flame resistant fabric, comprising: 
 a plurality of inherently flame resistant fibers that were uncrystalized in fiber a plurality of cellulosic fibers that contain a flame retardant compound;    wherein said fabric contains a phosphorus compound flame retardant in a concentration of at least approximately 1.4% phosphorus by weight of cellulosic fiber component.    
     
     
         20 . The fabric of  claim 19 , wherein said inherently flame resistant fibers comprise a material selected from the group consisting of aromatic polyamide, polyamide imide, polyimide, and mixtures thereof.  
     
     
         21 . The fabric of  claim 19 , wherein said inherently flame resistant fibers are meta-aramid fibers.  
     
     
         22 . The fabric of  claim 19 , wherein said cellulosic fibers comprise rayon, acetate, triacetate, lyocell, or mixtures thereof.  
     
     
         23 . The fabric of  claim 19 , wherein said cellulosic fibers are rayon fibers.  
     
     
         24 . The fabric of  claim 19 , wherein said fabric contains a residual amount of dye-assistant selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and mixtures thereof.  
     
     
         25 . The fabric of  claim 19 , wherein said fabric exhibits a duration of conducted in accordance with FTMS 191A Method 5903.1 using a three second exposure.  
     
     
         26 . The fabric of  claim 19 , wherein said fabric exhibits a shrinkage percentage of no greater than approximately 7% after 20 launderings conducted in accordance with AATCC Test Method 135-1992, Table I (3)(V)(A)(iii).  
     
     
         27 . The fabric of  claim 19 , wherein said inherently flame resistant fibers of said fabric have been dyed a shade of color which would result in an L value between approximately 18 and the greige L value for said fabric if said inherently flame resistant fibers were used to form a fabric composed exclusively of said inherently flame resistant fibers.  
     
     
         28 . A flame resistant fabric, comprising: 
 a plurality of inherently flame resistant fibers that were uncrystalized in fiber form; and    a plurality of cellulosic fibers that contain a flame retardant compound;    wherein said fabric exhibits a duration of afterflame no greater than 2.0 seconds when subjected to a vertical flammability test conducted in accordance with FTMS 191A Method 5903.1 using a three second exposure.    
     
     
         29 . The fabric of  claim 28 , wherein said inherently flame resistant fibers comprise a material selected from the group consisting of aromatic polyamide, polyamide imide, polyimide, and mixtures thereof.  
     
     
         30 . The fabric of  claim 28 , wherein said inherently flame resistant fibers are meta-aramid fibers.  
     
     
         31 . The fabric of  claim 28 , wherein said cellulosic fibers comprise rayon, acetate, triacetate, lyocell, or mixtures thereof.  
     
     
         32 . The fabric of  claim 28 , wherein said cellulosic fibers are rayon fibers.  
     
     
         33 . The fabric of  claim 28 , wherein said fabric contains a residual amount of dye-assistant selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and mixtures thereof.  
     
     
         34 . The fabric of  claim 28 , wherein said fabric exhibits a shrinkage percentage of no greater than approximately 7% after 20 launderings conducted in accordance with AATCC Test Method 135-1992, Table I (3)(V)(A)(iii).  
     
     
         35 . The fabric of  claim 28 , wherein said inherently flame resistant fibers of said fabric have been dyed a shade of color which would result in an L value between approximately 18 and the greige L value for said fabric if said inherently flame resistant fibers were used to form a fabric composed exclusively of said inherently flame resistant fibers.  
     
     
         36 . A flame resistant fabric, comprising: 
 a plurality of inherently flame resistant fibers that were uncrystalized in fiber form; and    a plurality of cellulosic fibers that contain a flame retardant compound;    wherein said fabric exhibits a shrinkage percentage of no greater than approximately 7% after 20 launderings conducted in accordance with AATCC Test Method 135-1992, Table I (3)(V)(A)(iii).    
     
     
         37 . The fabric of  claim 36 , wherein said inherently flame resistant fibers comprise a material selected from the group consisting of aromatic polyamide, polyamide imide, polyimide, and mixtures thereof.  
     
     
         38 . The fabric of  claim 36 , wherein said inherently flame resistant fibers are meta-aramid fibers.  
     
     
         39 . The fabric of  claim 36 , wherein said cellulosic fibers comprise rayon, acetate, triacetate, lyocell, or mixtures thereof.  
     
     
         40 . The fabric of  claim 36 , wherein said cellulosic fibers are rayon fibers.  
     
     
         41 . The fabric of  claim 36 , wherein said fabric contains a residual amount of dye-assistant selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and mixtures thereof.  
     
     
         42 . The fabric of  claim 36 , wherein said inherently flame resistant fibers of said fabric have been dyed a shade of color which would result in an L value between approximately 18 and the greige L value for said fabric approximately if said inherently flame resistant fibers were used to form a fabric composed exclusively of said inherently flame resistant fibers.  
     
     
         43 . A flame resistant fabric, comprising: 
 a plurality of inherently flame resistant fibers that were uncrystalized in fiber form; and    a plurality of cellulosic fibers that contained a flame retardant compound in fiber form.    
     
     
         44 . The fabric of  claim 43 , wherein said fabric contains a residual amount of a dye-assistant selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, N-N-diethylbenzamide, hexadecyltrimethyl ammonium salt, N,N-dimethylbenzamide, N,N-diethyl-m-toluamide, N-octylpyrrolidone, aryl ether, an approximately 50/50 blend of N,N-dimethylcaprylamide and N,N-dimethylcapramide, and mixtures thereof.  
     
     
         45 . The fabric of  claim 43 , wherein said dye-assistant is selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and mixtures thereof.  
     
     
         46 . The fabric of  claim 43 , wherein said inherently flame resistant fibers comprise a material selected from the group consisting of aromatic polyamide, polyamide imide, polyimide, and mixtures thereof.  
     
     
         47 . The fabric of  claim 43 , wherein said inherently flame resistant fibers are meta-aramid fibers.  
     
     
         48 . The fabric of  claim 43 , wherein said cellulosic fibers comprise rayon, acetate, triacetate, lyocell, or mixtures thereof.  
     
     
         49 . The fabric of  claim 43 , wherein said cellulosic fibers are rayon fibers.  
     
     
         50 . The fabric of  claim 43 , wherein said fabric contains a phosphorus compound flame retardant in a concentration of at least approximately 1.4% phosphorus by weight of cellulosic fiber component.  
     
     
         51 . The fabric of  claim 43 , wherein said fabric exhibits a duration of afterflame no greater than 2.0 seconds when subjected to a vertical flammability test conducted in accordance with FTMS 1431 Method 5903.1 using a three second exposure.  
     
     
         52 . The fabric of  claim 43 , wherein said fabric exhibits a shrinkage percentage of no greater than approximately 7% after 20 launderings conducted in accordance with AATCC Test Method 135-1992, Table I (3)(V)(A)(iii).  
     
     
         53 . The fabric of  claim 43 , wherein said inherently flame resistant fibers of said fabric have been dyed a shade of color which would result in an L value between approximately 18 and the greige L value for said fabric if said inherently flame resistant fibers were used to form a fabric composed exclusively of said inherently flame resistant fibers.  
     
     
         54 . A flame resistant fabric, comprising: 
 a plurality of dyed, inherently flame resistant fibers that were uncolored in fiber a plurality of cellulosic fibers that contained a flame retardant compound in fiber form.    
     
     
         55 . The fabric of  claim 54 , wherein said fabric contains a residual amount of a dye-assistant selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, N,N-diethylbenzamide, hexadecyltrimethyl ammonium salt, N,N-dimethylbenzamide, N,N-diethyl-m-toluamide, N-octylpyrrolidone, aryl ether, an approximately 50/50 blend of N,N-dimethylcaprylamide and N,N-dimethylcapramide, and mixtures thereof.  
     
     
         56 . The fabric of  claim 54 , wherein said dye-assistant is selected from the group consisting of N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and mixtures thereof.  
     
     
         57 . The fabric of  claim 54 , wherein said inherently flame resistant fibers comprise a material selected from the group consisting of aromatic polyamide, polyamide imide, polyimide, and mixtures thereof.  
     
     
         58 . The fabric of  claim 54 , wherein said inherently flame resistant fibers are meta-aramid fibers.  
     
     
         59 . The fabric of  claim 54 , wherein said cellulosic fibers comprise rayon, acetate, triacetate, lyocell, or mixtures thereof.  
     
     
         60 . The fabric of  claim 54 , wherein said cellulosic fibers are rayon fibers.  
     
     
         61 . The fabric of  claim 54 , wherein said fabric contains a phosphorus compound flame retardant in a concentration of at least approximately 1.4% phosphorus by weight of cellulosic fiber component.  
     
     
         62 . The fabric of  claim 54 , wherein said fabric exhibits a duration of afterflame no greater than 2.0 seconds when subjected to a vertical flammability test conducted in accordance with FTMS 1431 Method 5903.1 using a three second exposure.  
     
     
         63 . The fabric of  claim 54 , wherein said fabric exhibits a shrinkage percentage of no greater than approximately 7% after 20 launderings conducted in accordance with AATCC Test Method 135-1992, Table I (3)(V)(A)(iii).  
     
     
         64 . The fabric of  claim 54 , wherein said inherently flame resistant fibers of said fabric have been dyed a shade of color which would result in an L value between approximately 18 and the greige L value for said fabric if said inherently flame resistant fibers were used to form a fabric composed exclusively of said inherently flame resistant fibers.