Lightweight, Printable Flame Resistant Fabrics Suitable for Protective Clothing Worn in Hot and/or Humid Environments

Abstract

Flame resistant fabrics comprising a blend of modacrylic, aliphatic polyamide, and cellulosic fibers. Some embodiments are printed and/or dyed with vat dyes so as to comply with the color requirements (including the color, colorfastness, and IR requirements) set forth in the relevant sections of GL-PD-07-12 and/or MIL-PRF-EFRCE. Some embodiments further include reinforcing yarns that improve the strength of the fabrics. Still other embodiments are flame resistant fabrics for use in electrical applications that comply with some or all of the requirements of ASTM F 1506.

We claim: 
     
         1 . A flame resistant fabric comprising spun yarns comprising a fiber blend comprising a plurality of modacrylic fibers, a plurality of cellulosic fibers, and a plurality of nylon fibers, wherein the fiber blend is devoid of aramid fibers and wherein the fabric (i) has a two second or less afterflame measured pursuant to ASTM D6413 and (ii) is printable with vat dyes such that the fabric will comply with the requirements set forth in at least one of section 3.8.1, section 3.8.2, and section 3.8.3 of GL-PD-07-12. 
     
     
         2 . The flame resistant fabric of  claim 1 , wherein the fabric comprise a weight of 4-10 ounces per square yard, inclusive. 
     
     
         3 . The flame resistant fabric of  claim 1 , wherein the fabric further comprises a plurality of stretch broken yarns or filament yarns. 
     
     
         4 . The flame resistant fabric of  claim 3 , wherein the plurality of stretch broken yarns or filament yarns are provided in both a warp direction and a fill direction of the fabric so as to form a grid pattern within the fabric. 
     
     
         5 . The flame resistant fabric of  claim 3 , wherein the plurality of stretch broken yarns or filament yarns comprise nylon filament yarns. 
     
     
         6 . The flame resistant fabric of  claim 3 , wherein the fabric comprises a weight less than or equal to 6 ounces per square yard. 
     
     
         7 . The flame resistant fabric of  claim 6 , wherein the fabric comprises a tear strength of at least 14 pounds force in at least one of a warp direction and a fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         8 . The flame resistant fabric of  claim 7 , wherein the fabric comprises a tear strength of at least 16 pounds force in at least one of a warp direction and a fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         9 . The flame resistant fabric of  claim 8 , wherein the fabric comprises a tear strength of at least 19 pounds force in at least one of a warp direction and a fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         10 . The flame resistant fabric of  claim 9 , wherein the fabric comprises a tear strength of at least 21 pounds force in at least one of a warp direction and a fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         11 . The flame resistant fabric of  claim 3 , wherein the fabric comprises a weight of 4-10 ounces per square yard, inclusive, and wherein the plurality of stretch broken yarns or filament yarns comprises a weight that is 5-40% of the fabric weight. 
     
     
         12 . The flame resistant fabric of  claim 1 , wherein the fabric has a char length of six inches or less when measured pursuant to ASTM D6413. 
     
     
         13 . A flame resistant fabric comprising spun yarns comprising a fiber blend comprising a plurality of modacrylic fibers, a plurality of cellulosic fibers, and a plurality of aliphatic polyamide fibers, wherein the fiber blend is devoid of aramid fibers and wherein the fabric is printable or dyeable with vat dyes so as to comply with at least one of: GL-PD-07-12, sections 3.6.1.1, 3.6.3 (Table I), and 3.8.1; GL-PD-07-12, sections 3.6.1.2, 3.6.3 (Table I.A), and 3.8.2; GL-PD-07-12, sections 3.6.1.3, 3.6.3 (Table I.B), and 3.8.3; MIL-PRF-EFRCE, sections 3.3.2.1, 3.3.5 (Table I), and 3.3.7.1; MIL-PRF-EFRCE, sections 3.3.2.2, 3.3.5 (Table I), and 3.3.7.2; MIL-PRF-EFRCE, sections 3.3.2.3, 3.3.5 (Table I), and 3.3.7.3; MIL-PRF-EFRCE, sections 3.3.2.4, 3.3.5 (Table I), and 3.3.7.3; and MIL-PRF-EFRCE, sections 3.3.2.5, 3.3.5 (Table II), and 3.3.7.4. 
     
     
         14 . The flame resistant fabric of  claim 13 , wherein the fabric further comprises a plurality of stretch broken yarns or filament yarns. 
     
     
         15 . The flame resistant fabric of  claim 14 , wherein the plurality of stretch broken yarns or filament yarns are provided in both a warp direction and a fill direction of the fabric so as to form a grid pattern within the fabric. 
     
     
         16 . The flame resistant fabric of  claim 14 , wherein the plurality of stretch broken yarns or filament yarns comprise nylon filament yarns. 
     
     
         17 . The flame resistant fabric of  claim 13 , wherein the fabric comprises a weight less than or equal to 6 ounces per square yard. 
     
     
         18 . The flame resistant fabric of  claim 13 , where the plurality of modacrylic fibers comprises a first percentage of the fiber blend, the plurality of cellulosic fibers comprises a second percentage of the fiber blend, and the plurality of aliphatic polyamide fibers comprises a third percentage of the fiber blend, wherein the first percentage is greater than each of the second percentage and the third percentage. 
     
     
         19 . The flame resistant fabric of  claim 18 , wherein the first percentage is greater than a sum of the second percentage and the third percentage. 
     
     
         20 . The flame resistant fabric of  claim 18 , wherein the third percentage is greater than the second percentage. 
     
     
         21 . The flame resistant fabric of  claim 13 , wherein the fabric has a char length of seven inches or less and a two second or less afterflame when measured pursuant to ASTM D6413. 
     
     
         22 . The flame resistant fabric of  claim 13 , wherein the fiber blend comprises approximately 30-80% modacrylic fibers, approximately 10-60% cellulosic fibers, and approximately 5-50% aliphatic polyamide fibers. 
     
     
         23 . The flame resistant fabric of  claim 22 , wherein the fiber blend comprises approximately 35-70% modacrylic fibers, approximately 10-50% cellulosic fibers, and approximately 10-40% aliphatic polyamide fibers. 
     
     
         24 . The flame resistant fabric of  claim 23 , wherein the fiber blend comprises approximately 40-65% modacrylic fibers, approximately 10-40% cellulosic fibers, and approximately 15-40% aliphatic polyamide fibers. 
     
     
         25 . A flame resistant fabric comprising:
 a. spun yarns comprising a fiber blend comprising a plurality of modacrylic fibers, a plurality of cellulosic fibers, and a plurality of aliphatic polyamide fibers; and   b. a plurality of stretch broken yarns or filament yarns provided in at least one of a warp direction and a fill direction of the fabric, wherein the fabric is printable or dyeable with vat dyes so as to comply with at least one of: GL-PD-07-12, sections 3.6.1.1, 3.6.3 (Table I), and 3.8.1; GL-PD-07-12, sections 3.6.1.2, 3.6.3 (Table I.A), and 3.8.2; GL-PD-07-12, sections 3.6.1.3, 3.6.3 (Table I.B), and 3.8.3; MIL-PRF-EFRCE, sections 3.3.2.1, 3.3.5 (Table I), and 3.3.7.1; MIL-PRF-EFRCE, sections 3.3.2.2, 3.3.5 (Table I), and 3.3.7.2; MIL-PRF-EFRCE, sections 3.3.2.3, 3.3.5 (Table I), and 3.3.7.3; MIL-PRF-EFRCE, sections 3.3.2.4, 3.3.5 (Table I), and 3.3.7.3; and MIL-PRF-EFRCE, sections 3.3.2.5, 3.3.5 (Table II), and 3.3.7.4.   
     
     
         26 . The flame resistant fabric of  claim 25 , wherein the plurality of stretch broken yarns or filament yarns are provided in both the warp direction and the fill direction of the fabric so as to form a grid pattern within the fabric. 
     
     
         27 . The flame resistant fabric of  claim 25 , wherein the plurality of stretch broken yarns or filament yarns comprise nylon filament yarns. 
     
     
         28 . The flame resistant fabric of  claim 25 , wherein the fabric comprises a weight less than or equal to 6 ounces per square yard. 
     
     
         29 . The flame resistant fabric of  claim 28 , wherein the fabric comprises a tear strength of at least 14 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         30 . The flame resistant fabric of  claim 29 , wherein the fabric comprises a tear strength of at least 16 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         31 . The flame resistant fabric of  claim 30 , wherein the fabric comprises a tear strength of at least 19 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         32 . The flame resistant fabric of  claim 31 , wherein the fabric comprises a tear strength of at least 21 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         33 . The flame resistant fabric of  claim 25 , wherein the fabric has a char length of seven inches or less and a two second or less afterflame when measured pursuant to ASTM D6413. 
     
     
         34 . The flame resistant fabric of  claim 25 , wherein the fiber blend is devoid of aramid fibers. 
     
     
         35 . A flame resistant fabric comprising:
 a. spun yarns comprising a fiber blend comprising a plurality of modacrylic fibers, a plurality of cellulosic fibers, and a plurality of aliphatic polyamide fibers; and   b. a plurality of stretch broken yarns or filament yarns provided in at least one of a warp direction and a fill direction of the fabric,   wherein the fabric has a weight of less than or equal to six ounces per square yards and a tear strength of at least 14 pounds force in at least one of the warp direction and the fill direction of the fabric when measured pursuant to ASTM D1424.   
     
     
         36 . The flame resistant fabric of  claim 35 , wherein the plurality of stretch broken yarns or filament yarns are provided in both the warp direction and the fill direction of the fabric so as to form a grid pattern within the fabric. 
     
     
         37 . The flame resistant fabric of  claim 35 , wherein the fabric comprises a tear strength of at least 16 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         38 . The flame resistant fabric of  claim 37 , wherein the fabric comprises a tear strength of at least 19 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         39 . The flame resistant fabric of  claim 38 , wherein the fabric comprises a tear strength of at least 21 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         40 . The flame resistant fabric of  claim 35 , wherein the fabric has a char length of seven inches or less and a two second or less afterflame when measured pursuant to ASTM D6413. 
     
     
         41 . The flame resistant fabric of  claim 35 , wherein the fiber blend is devoid of aramid fibers. 
     
     
         42 . A flame resistant fabric comprising:
 a. spun yarns comprising a fiber blend comprising a plurality of modacrylic fibers, a plurality of cellulosic fibers, and a plurality of aliphatic polyamide fibers; and   b. a plurality of stretch broken yarns or filament yarns provided in at least one of a warp direction and a fill direction of the fabric,   wherein the fabric complies with ASTM F 1506.   
     
     
         43 . The flame resistant fabric of  claim 42 , wherein the plurality of stretch broken yarns or filament yarns are provided in both a warp direction and a fill direction of the fabric so as to form a grid pattern within the fabric. 
     
     
         44 . The flame resistant fabric of  claim 42 , wherein the fabric comprises a weight less than or equal to 6 ounces per square yard. 
     
     
         45 . The flame resistant fabric of  claim 44 , wherein the fabric comprises a tear strength of at least 14 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         46 . The flame resistant fabric of  claim 42 , wherein the fiber blend comprises approximately 30-80% modacrylic fibers, approximately 10-60% cellulosic fibers, and approximately 5-50% aliphatic polyamide fibers. 
     
     
         47 . The flame resistant fabric of  claim 42 , wherein the fiber blend is devoid of aramid fibers. 
     
     
         48 . A flame resistant fabric comprising spun yarns comprising a fiber blend comprising a plurality of modacrylic fibers, a plurality of cellulosic fibers, and a plurality of aliphatic polyamide fibers, wherein the fiber blend is devoid of aramid fibers and wherein the fabric is printed or dyed with vat dyes to impart on the fabric a camouflage pattern specified in GL-PD-07-12 or MIL-PRF-EFRCE. 
     
     
         49 . The flame resistant fabric of  claim 48 , wherein the fabric complies with the infrared requirements specified in GL-PD-07-12 or MIL-PRF-EFRCE for the camouflage pattern. 
     
     
         50 . The flame resistant fabric of  claim 48 , wherein the fabric further comprises a plurality of stretch broken yarns or filament yarns. 
     
     
         51 . The flame resistant fabric of  claim 50 , wherein the plurality of stretch broken yarns or filament yarns are provided in both a warp direction and a fill direction of the fabric so as to form a grid pattern within the fabric. 
     
     
         52 . The flame resistant fabric of  claim 50 , wherein the plurality of stretch broken yarns or filament yarns comprise nylon filament yarns. 
     
     
         53 . The flame resistant fabric of  claim 50 , wherein the fabric comprises a weight less than or equal to 6 ounces per square yard. 
     
     
         54 . The flame resistant fabric of  claim 53 , wherein the fabric comprises a tear strength of at least 14 pounds force in at least one of the warp direction and the fill direction of the fabric when tested pursuant to ASTM D1424.