Wearable protective denim fabrics

Abstract

Provided herein are blended fibers for use in protective clothing which confer protection against electrical arcs and/or flash fire hazards and also have a pleasing appearance, while also being comfortable to wear. The fabrics described herein can be processed to give an aesthetically desired appearance such as a washed denim look.

1 . A flame retardant denim fabric comprising
 a blended weft yarn comprising about 45% to about 60% by weight of a hydrophobic fiber; about 30% to about 50% by weight of a hydrophilic fiber; and about 5% to about 10% by weight of nylon 66, based on total weight of the blend;   a blended warp yarn comprising about 35% to about 25% by weight of a hydrophobic fiber, and about 65% to about 75% by weight of a hydrophilic fiber based on total weight of the blend;   wherein the said flame retardant denim fabric confers protection against electrical arcs, flash fire hazards, or both, and is breathable.   
     
     
         2 . The flame retardant denim fabric of  claim 1 , wherein the hydrophobic fiber is modacrylic and the hydrophilic fiber is a cellulosic fiber. 
     
     
         3 . The flame retardant denim fabric of  claim 1 , wherein a portion of the blended weft yarn further comprises an anti-static filament twisted with the blended weft yarn. 
     
     
         4 . The flame retardant denim fabric of  claim 1 , wherein the blended weft yarn comprises a first blended yarn comprising about 45% to about 60% by weight of modacrylic; about 30% to about 50% by weight of cotton; and about 5% to about 10% by weight of nylon 66, based on total weight of the blend; and a second blended weft yarn comprising about 45% to about 60% by weight of modacrylic; about 30% to about 50% by weight of cotton; about 5% to about 10% by weight of nylon 66, based on total weight of the blend, and further comprising an anti-static filament twisted with the second blended yarn. 
     
     
         5 . The flame retardant denim fabric of  claim 4 , wherein the antistatic filament count in the second blended yarn is about 35 to about 45 dtex. 
     
     
         6 . The flame retardant denim fabric of  claim 4 , wherein the anti-static filament in the flame retardant denim fabric is at a regular interval of 8 to 10 mm in the weft direction resulting in about 2.54 to about 3 antistatic filaments per inch in the weft direction. 
     
     
         7 . The flame retardant denim fabric of  claim 1 , wherein the spun yarn count is between about 8-20 Ne. 
     
     
         8 . The flame retardant denim fabric of  claim 1 , wherein the flame retardant denim fabric is finished with softeners, anti-microbial finishing agents, water proofing agents, oil or water repellents, or stain release agents, or a combination thereof. 
     
     
         9 . A flame retardant denim fabric comprising
 a blended weft yarn comprising about 45% to about 60% by weight of modacrylic; about 30% to about 50% by weight of cotton; and about 5% to about 10% by weight of nylon 66, based on total weight of the blend;   a blended warp yarn comprising about 65% to about 75% by weight of cotton and about 35% to about 25% by weight of modacrylic, based on total weight of the blend;   wherein the said flame retardant denim fabric confers protection against electrical arcs, flash fire hazards, or both, and is breathable.   
     
     
         10 . The flame retardant denim fabric of  claim 9 , wherein a portion of the blended weft yarn further comprises an anti-static filament twisted with the blended weft yarn. 
     
     
         11 . The flame retardant denim fabric of  claim 9 , wherein the blended weft yarn comprises a first blended yarn comprising about 45% to about 60% by weight of modacrylic; about 30% to about 50% by weight of cotton; and about 5% to about 10% by weight of nylon 66, based on total weight of the blend; and a second blended weft yarn comprising about 45% to about 60% by weight of modacrylic; about 30% to about 50% by weight of cotton; about 5% to about 10% by weight of nylon 66, based on total weight of the blend, and further comprising an anti-static filament twisted with the second blended yarn. 
     
     
         12 . The flame retardant denim fabric of  claim 11 , wherein the antistatic filament count in the second blended yarn is about 35 to about 45 dtex. 
     
     
         13 . The flame retardant denim fabric of  claim 11 , wherein the anti-static filament in the flame retardant denim fabric is at a regular interval of 8 to 10 mm in the weft direction resulting in about 2.54 to about 3 antistatic filaments per inch in the weft direction. 
     
     
         14 . The flame retardant denim fabric of  claim 9 , wherein the spun yarn count is between about 8-20 Ne. 
     
     
         15 . The flame retardant denim fabric of  claim 9 , wherein the flame retardant denim fabric is finished with_softeners, anti-microbial finishing agents, water proofing agents, oil or water repellents, or stain release agents, or a combination thereof. 
     
     
         16 . A process for manufacturing a denim fabric comprising
 i) preparing blends for the warp and weft yarns;   ii) spinning yarns from the blends;   iii) twisting antistatic fiber with at least a portion of the weft yarn;   (iv) dyeing and sizing the spun yarns of steps (ii) and (iii);   (v) weaving the fabric with a denim weave in an air jet loom;   (vi) desizing the denim fabric;   (vii) sanforising the denim fabric; and   (v) finishing the denim fabric.