Articles of Ignition Resistant Cotton Fibers

Abstract

A bi-regional fiber with a cellulosic core and a wax outer sheath is disclosed. The sheath can comprise high melting temperature wax. The fiber may be produced by processing the natural fiber at temperatures less than 70° C. The fiber can be processed in a standard manner such as, for example, a Keir process which may include bleach at approximately 100° C. with a wax subsequently added at a temperature sufficient to disperse the wax over the fiber surface. The fibers are ignition resistant as measured by industry standard tests. The wax may comprise from about 0.4 to 25 percent or greater of the fiber by weight. The wax may be natural wax, synthetic or emulsified wax or blends thereof. The bi-regional fibers can be blended with other fibers including BRCF fibers to create fire resistant fabrics including clothing, blankets and household materials.

1 . A bi-regional cotton fiber comprised of a cellulosic center and an outer surface comprised of a wax. 
     
     
         2 . The bi-regional fiber of  claim 1 , wherein the fiber is bleached. 
     
     
         3 . The bi-regional fiber of  claim 2 , wherein the fiber is bleached with chlorine, ozone, peroxide, hypochlorite or a combination thereof. 
     
     
         4 . The bi-regional fiber of  claim 1 , wherein the wax comprises at least 0.4 percent by weight of said fiber. 
     
     
         5 . The bi-regional fiber of  claim 1 , wherein the wax comprises from about 0.4 percent to about 25 percent by weight of said fiber. 
     
     
         6 . The bi-regional fiber of  claim 1 , wherein the wax comprises about 14 percent to about 16 percent by weight of said fiber. 
     
     
         7 . The bi-regional fiber of  claim 1 , wherein the wax comprises is a natural wax, a synthetic wax, an emulsified wax or a mixture thereof. 
     
     
         8 . The bi-regional fiber of  claim 7 , wherein the natural wax is a cotton wax, a jojoba wax, a soy wax, a carnauba wax, or a combination thereof. 
     
     
         9 . The bi-regional fiber of  claim 1 , wherein the wax has a melting point temperature of about 70° C. or greater. 
     
     
         10 . The bi-regional fiber of  claim 1 , wherein the wax has a melting point temperature of about 90° C. or greater. 
     
     
         11 . The bi-regional fiber of  claim 1 , which has at least 10 percent greater tensile strength as compared to natural cotton fibers. 
     
     
         12 . The bi-regional fiber of  claim 1 , which has at least 20 percent greater tensile strength as compared to natural cotton fibers. 
     
     
         13 . The bi-regional fiber of  claim 1 , further comprising applying a saponified acid or derivative thereof to the outer surface of the fiber. 
     
     
         14 . The bi-regional fiber of  claim 13 , wherein the saponified acid or derivative thereof comprises lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid or combinations thereof. 
     
     
         15 . The bi-regional fiber of  claim 1 , which is fire retardant and/or ignition resistant. 
     
     
         16 . The bi-regional fiber of  claim 15 , which meets or exceeds a vertical burn test conducted according to FAR 25.853(b). 
     
     
         17 . The bi-regional fiber of  claim 1 , which contains no harmful chemicals. 
     
     
         18 . The bi-regional fiber of  claim 17 , wherein the harmful chemicals comprise organohalogens. 
     
     
         19 . The bi-regional fiber of  claim 1 , which has reduced water absorption as compared to a natural cotton fiber. 
     
     
         20 . A material comprised of a plurality of the bi-regional fibers of  claim 1 . 
     
     
         21 . The material of  claim 20 , which is fire retardant and/or ignition resistant. 
     
     
         22 . The material of  claim 20 , which has reduced water absorption as compared to a natural cotton fiber. 
     
     
         23 . The material of  claim 20 , which has a wrinkle resistance greater than conventional cotton. 
     
     
         24 . The material of  claim 20 , further comprising additional fibers. 
     
     
         25 . The material of  claim 24 , wherein the additional fibers comprise natural fibers, synthetic fibers, carbonaceous fibers, and combinations thereof. 
     
     
         26 . The material of  claim 24 , wherein the synthetic fibers comprise polyester. 
     
     
         27 . The material of  claim 26 , wherein the synthetic fibers comprise about 50 to about 90 percent polyester and about 10 to about 50 percent bi-regional fibers. 
     
     
         28 . The material of  claim 25 , wherein the carbonaceous fibers are flexible bi-regional carbonaceous fibers. 
     
     
         29 . The material of  claim 20 , which comprises apparel for infants, toddlers, children or adults. 
     
     
         30 . The material of  claim 29 , wherein the apparel comprises shirts, socks, pants, sweaters, sweats, gators, hats, scarves, coats, undergarments, sportswear, skirts, dresses, tops, blankets, and designs and combinations thereof. 
     
     
         31 . The material of  claim 29 , wherein the apparel is suitable for wear in environments wherein conditions are greater than and/or less than body temperature. 
     
     
         32 . A method for manufacture of a fiber comprising:
 bleaching a cotton fiber; and   applying a wax to the fiber.   
     
     
         33 . The method of  claim 32 , wherein bleaching comprises treating the fiber with chlorine, ozone, peroxide, hypochlorite or a combination thereof. 
     
     
         34 . The method of  claim 32 , wherein bleaching is performed at about 40° C. or less. 
     
     
         35 . The method of  claim 32 , wherein bleaching is performed at room or ambient temperature. 
     
     
         36 . The method of  claim 32 , wherein bleaching is performed at a pH of between about 6 and about 8. 
     
     
         37 . The method of  claim 32 , wherein the fiber comprises ignition resistance without added harmful chemicals. 
     
     
         38 . The method of  claim 32 , wherein no wash step is performed after bleaching and before application of the wax. 
     
     
         39 . The method of  claim 32 , further comprising adding polyester fibers. 
     
     
         40 . The method of  claim 39 , wherein the polyester fibers were treated with a solution of a hydrolyzed partial condensation of trimethoxy methyl silane.