Firefighter garment outer shell fabric utilizing core-spun dref yarn

Abstract

The present invention is directed to a fabric that is particularly well suited for use as the outer shell fabric of the firefighter's garment. The preferred fabric is 40% Melamine formaldehyde (Basofil) and 60% Para-Aramid (Kevlar) woven of spun yarns and core-spun DREF yarns. The core spun yarn includes one or more filament cores selected from a polymer group consisting of PBO, Aramid, Liquid Crystal Polymer (LCP), Carbon and P-84, with or without a fine metallic wire co-core, and a staple sheath blend consisting of one or more fibers selected from a group consisting of Meta-Aramid, Para-Aramid, Copolymide, PBI, PBO, P-84, Carbon, Kynol, PFR Rayon and/or Modacrylic fibers.

1 . A textile fabric of interwoven yarns comprising: 
 a plurality of yarns that are spun yarns including staple fibers selected from the group consisting of PBI, PBO, melamine formaldehyde, P-84, Carbon and Kynol; and a plurality of core-spun DREF yarns comprised of a polymer sheath and at least one core filament.    
     
     
         2 . The fabric of  claim 1  wherein the core-spun DREF yarn core filament is selected from the polymer group consisting of PBO, Aramid, Liquid Crystal Polymer (LCP), Carbon and P-84.  
     
     
         3 . The fabric of  claim 1  wherein the core-spun DREF yarn has a sheath of staple fibers selected from the group consisting of Meta-Aramid, Para-Aramid, Copolymide, PBI, PBO, P-84, Carbon, Kynol, PFR Rayon and Modacrylic fibers.  
     
     
         4 . The fabric of  claim 1  wherein fabric has a weight ranging from 6 to 9 OSY.  
     
     
         5 . The fabric of  claim 1  wherein its weave is selected from the group consisting plain, twill, rip stop, satin, herringbone and oxford.  
     
     
         6 . The fabric of  claim 1  wherein the core-spun DREF yarn has a Tex ranging from 11 to 1100.  
     
     
         7 . The fabric of  claim 1  wherein the core filament of the core-spun DREF yarn has a Tex ranging from 6 to 600.  
     
     
         8 . The fabric of  claim 1  wherein the DREF yarn has weight ratio of core to sheath ranging from 90:10 to 10:90.  
     
     
         9 . A core spun Dref yarn comprised of: 
 at least one core filament yarn selected from the group consisting of PBO, Aramid, Liquid Crystal Polymer (LCP), Carbon and P-84; and    a sheath of staple yarns selected from the group consisting of Meta-Aramid, Para-Aramid, Copolyimide, PBI, PBO, P-84, Carbon, Kynol, PFR Rayon and/or Modacrylic fibers.    
     
     
         10 . The yarn of  claim 9  wherein the core includes at least one metallic filament.  
     
     
         11 . The yarn of  claim 9  wherein the sheath is comprised of at least two fibers selected from the group.  
     
     
         12 . The yarn of  claim 11  wherein the core includes at least one metallic filament.  
     
     
         13 . A firefighter's turnout garment having a layer of woven fabric comprising: 
 spun yarns having fibers selected from the group consisting of PBI, PBO, melamine formaldehyde, P-84, Carbon and Kynol; and    core-spun DREF yarns having at least one core filament and a sheath of fibers selected from the group consisting of Meta-Aramid, Para-Aramid, Copolymide, PBI, PBO, P-84, Carbon, Kynol, PFR Rayon and Modacrylic fibers.    
     
     
         14 . The firefighter's turnout garment of  claim 13  wherein the layer of woven fabric is an outermost layer.  
     
     
         15 . The firefighter's turnout garment of  claim 13  wherein the core yarn is metallic.  
     
     
         16 . The firefighter's turnout garment of  claim 15  wherein the layer of woven fabric is an outermost layer.  
     
     
         17 . The firefighter's turnout garment of  claim 13  wherein the layer of woven fabric is an outermost layer.  
     
     
         18 . The firefighter's turnout garment of  claim 13  wherein the spun yarn has a cotton count ranging from 36/2 to 12/2.  
     
     
         19 . The firefighter's turnout garment of  claim 13  wherein the spun yarn is a staple fiber blend of 40% Melamine formaldehyde (Basofil)/60% Para-Aramid (Kevlar).  
     
     
         20 . The firefighter's turnout garment of  claim 13  wherein the weave includes a rip stop yarn that is a 2-ply yarn consisting of two ends of DREF core spun singles yarn twisted with a twist multiplier of about 3.2.  
     
     
         21 . The firefighter's turnout garment of  claim 13  wherein the spun yarn has a cotton count of 16.3/2.  
     
     
         22 . The firefighter's turnout garment of  claim 21  wherein the weave includes a rip stop yarn that is a 2-ply yarn consisting of two ends of DREF core spun singles yarn twisted with a twist multiplier of about 3.2.  
     
     
         23 . The firefighter's turnout garment of  claim 22  wherein the layer of woven fabric is an outermost layer.