Flame-resistant fiber blend, yarn, and fabric, and method for making same

Abstract

A fiber blend, a yarn spun from the fiber blend, and a fabric made from the yarn, wherein the fiber blend comprises: (a) about 40 wt.% to about 65 wt.% modacrylic fibers containing antimony, or FR acrylic fibers; (b) about 10 wt.% to about 50 wt.% cotton fibers or FR cotton fibers; (c) up to about 25 wt.% nylon fibers; and (d) greater than about 3 wt.% and less than 10 wt.% para-aramid fibers. The fabric is over 90 percent dyeable and is capable of achieving ASTM F1506 certification with an Arc Thermal Performance Value greater than 8.0 cal/cm 2 . The fabric is woven or knitted, and has a weight of about 4.0 oz./yd. 2 to about 10.5 oz./yd. 2 . The fabric is suitable for garments worn during activities in which there is potential for exposure to flame and/or electrical arc.

1 . A flame-resistant fabric, the fabric being formed with yarn comprising a blend of fibers, the blend comprising: 
 about 40 wt.% to about 65 wt.% modacrylic fibers containing antimony;    about 10 wt.% to about 50 wt.% cotton fibers;    up to about 25 wt.% nylon fibers; and    greater than about 3 wt.% and less than 10 wt.% para-aramid fibers.    
   
   
       2 . The flame-resistant fabric of  claim 1 , wherein the modacrylic fibers contain at least about 7 wt.% antimony based on the weight of the modacrylic.  
   
   
       3 . The flame-resistant fabric of  claim 1 , wherein the blend comprises: 
 about 45 wt.% to about 55 wt.% modacrylic fibers;    about 20 wt.% to about 30 wt.% cotton fibers;    about 15 wt.% to about 20 wt.% nylon fibers; and    about 5 wt.% to about 9 wt.% para-aramid fibers.    
   
   
       4 . The flame-resistant fabric of  claim 1 , wherein the blend comprises: 
 about 50 wt.% to about 55 wt.% modacrylic fibers;    about 20 wt.% to about 25 wt.% cotton fibers;    about 15 wt.% to about 20 wt % nylon fibers; and    about 5 wt.% to about 7 wt.% para-aramid fibers.    
   
   
       5 . The flame-resistant fabric of  claim 1 , having a weight of about 4.0 oz./yd. 2  to about 10.5 oz./yd. 2 .  
   
   
       6 . The flame-resistant fabric of  claim 1 , having a weight of about 7.0 oz./yd. 2  to about 9.0 oz./yd. 2 .  
   
   
       7 . The flame-resistant fabric of  claim 1 , wherein the fabric is woven.  
   
   
       8 . The flame-resistant fabric of  claim 1 , wherein the fabric is knit.  
   
   
       9 . The flame-resistant fabric of  claim 1 , wherein the fibers are dyed with basic dye to dye the modacrylic fibers and/or are dyed with fiber reactive or direct dye to dye the cotton fibers.  
   
   
       10 . A garment constructed from the flame-resistant fabric of  claim 1 .  
   
   
       11 . A method of making a flame-resistant fabric, comprising the steps of: 
 forming an intimate blend of staple fibers comprising: 
 about 40 wt.% to about 65 wt.% modacrylic fibers containing antimony;  
 about 10 wt.% to about 50 wt.% cotton fibers;  
 up to about 25 wt.% nylon fibers; and  
 greater than about 3 wt.% and less than 10 wt.% para-aramid fibers;  
   spinning the blend of staple fibers into yarn; and    knitting or weaving the yarn to form fabric.    
   
   
       12 . The method of  claim 11 , further comprising the steps of: 
 dyeing the modacrylic fibers with basic dye; and    dyeing the cotton fibers with fiber reactive or direct dye.    
   
   
       13 . The method of  claim 12 , wherein the dyeing steps are carried out at a dye bath temperature not exceeding about 230° F.  
   
   
       14 . The method of  claim 12 , wherein the blend of staple fibers includes nylon fibers, and further comprising the step of dyeing the nylon fibers with acid or disperse dye.  
   
   
       15 . The method of  claim 14 , wherein the fibers are first dyed with the basic dye, then the fibers are dyed with the fiber reactive or direct dye, and finally the fibers are dyed with the acid or disperse dye.  
   
   
       16 . The method of  claim 12 , further comprising using a dye fixative to fix the dyes.  
   
   
       17 . The method of  claim 11 , further comprising the step of applying a resin to the fabric for shrinkage control.  
   
   
       18 . The method of  claim 11 , wherein the fabric is woven in a twill pattern.  
   
   
       19 . The method of  claim 11 , wherein the spinning step comprises ring spinning the blend of staple fibers into yarn.  
   
   
       20 . The method of  claim 11 , wherein the spinning step comprises air jet spinning the blend of staple fibers into yarn.  
   
   
       21 . The method of  claim 11 , further comprising the step of calendering the fabric to reduce air permeability of the fabric.  
   
   
       22 . A blend of staple comprising: 
 about 40 wt.% to about 65 wt.% modacrylic fibers containing antimony;    about 10 wt.% to about 50 wt.% cotton fibers;    up to about 25 wt.% nylon fibers; and    greater than about 3 wt.% and less than 10 wt.% para-aramid fibers.    
   
   
       23 . The blend of fibers of  claim 22 , wherein the modacrylic fibers contain at least about 7 wt.% antimony based on the weight of the modacrylic.  
   
   
       24 . The blend of fibers of  claim 22 , wherein the blend comprises: 
 about 45 wt.% to about 55 wt.% modacrylic fibers;    about 20 wt.% to about 30 wt.% cotton fibers;    about 15 wt.% to about 20 wt.% nylon fibers; and    about 5 wt.% to about 9 wt.% para-aramid fibers.    
   
   
       25 . The blend of fibers of  claim 22 , wherein the blend comprises: 
 about 50 wt.% to about 55 wt.% modacrylic fibers;    about 20 wt.% to about 25 wt.% cotton fibers;    about 15 wt.% to about 20 wt % nylon fibers; and    about 5 wt.% to about 7 wt.% para-aramid fibers.    
   
   
       26 . A yarn formed from a blend of fibers comprising: 
 about 40 wt.% to about 65 wt.% modacrylic fibers containing antimony;    about 10 wt.% to about 50 wt.% cotton fibers;    up to about 25 wt.% nylon fibers; and    greater than about 3 wt.% and less than 10 wt.% para-aramid fibers.    
   
   
       27 . The yarn of  claim 26 , wherein the yarn is ring-spun.  
   
   
       28 . The yarn of  claim 26 , wherein the yarn is air jet-spun.  
   
   
       29 . The yarn of  claim 26 , wherein the yarn is open-end spun.  
   
   
       30 . A flame-resistant fabric, the fabric being formed with yarn comprising a blend of fibers, the blend comprising: 
 about 40 wt.% to about 65 wt.% FR acrylic fibers;    about 10 wt.% to about 50 wt.% FR cotton fibers;    up to about 25 wt.% nylon fibers; and    greater than about 3 wt.% and less than 10 wt.% para-aramid fibers.