Flame resistant, high visibility fabrics and methods of manufacture thereof

Abstract

A fabric for use in safety apparel is taught. The fabric comprises a first yarn comprising modacrylic run in a weft direction of said fabric and a second yarn comprising polyester run in a warp direction of said fabric. The fabric meets visibility requirements governed by CSA Z96 in Canada and by ANSI/ISEA 107 in the US and applicable international standards; and meets requirements for flame resistance governed in Canada by CAN/CGSB-155.20, CAN/CGSB 155.22, and CSA Z462; and in the US by NFPA 2112, NFPA 1971, NFPA 1975, NFPA 1977 and NFPA 70E and applicable international standards. A method of manufacturing a fabric is further taught, said method comprising the steps of running a first yarn in a weft direction, said first yarn comprising modacrylic and running a second yarn in a warp direction, said second yarn comprising polyester, wherein said method produces a fabric meeting visibility requirements and meeting requirements for flame resistance.

1 . A fabric for use in safety apparel, said fabric comprising:
 a. a first yarn comprising modacrylic run in a weft direction of said fabric; and   b. a second yarn comprising polyester run in a warp direction of said fabric,   
       wherein said fabric meets visibility requirements governed by CSA Z96 in Canada and by ANSI/ISEA 107 in the US and applicable international standards; and meets requirements for flame resistance governed in Canada by CAN/CGSB-155.20, CAN/CGSB 155.22and CSA Z462; and in the US by NFPA 2112, NFPA 1971, NFPA 1975, NFPA 1977 and NFPA 70E and applicable international standards. 
     
     
         2 . The fabric of  claim 1 , wherein said first yarn comprises a blend of modacrylic fibres with one or more conventional fibres selected from the group consisting of nylon, rayon, polyester, cotton, wool, glass, minerals or aramids, and combinations thereof. 
     
     
         3 . The fabric of  claim 2 , wherein said first yarn comprises a blend of modacrylic fibres with nylon fibres. 
     
     
         4 . The fabric of  claim 3 , wherein said first yarn comprises a blend of from 70%-100% modacrylic and from 0% to 30% nylon. 
     
     
         5 . The fabric of  claim 4 , wherein the first yarn comprises 90% modacrylic fibres and 10% nylon fibres. 
     
     
         6 . The fabric of  claim 1 , wherein said second yarn is selected from the group consisting of flame resistant polyester and non-flame resistant polyester. 
     
     
         7 . The fabric of  claim 1 , wherein said second yarn comprises a blend of polyester fibres with alternate fibres selected from the group consisting of nylon, cotton, wool, glass, mineral, aramids, rayon and combinations thereof. 
     
     
         8 . The fabric of  claim 7 , wherein said second yarn comprise a blend of from 70% to 100% polyester and from 0% to 30% alternate fibres. 
     
     
         9 . The fabric of  claim 1  wherein the fibre composition of the fabric is 67% modacrylic, 26% polyester and 7% nylon. 
     
     
         10 . The fabric of  claim 1 , wherein said fabric is affixable to one or more secondary materials. 
     
     
         11 . The fabric of  claim 10 , wherein said fabric is sewable onto said one or more secondary materials. 
     
     
         12 . The fabric of  claim 10 , wherein said one or more secondary materials are sewable onto said fabric. 
     
     
         13 . The fabric of  claim 10 , wherein said one or more secondary materials are adhereable onto said fabric. 
     
     
         14 . The fabric of  claim 10 , wherein said one or more secondary materials are laminatable onto said fabric. 
     
     
         15 . The fabric of  claim 14 , wherein said one or more secondary materials laminatable onto the fabric comprise reflective tapes, reflective fabrics and reflective films. 
     
     
         16 . The fabric of  claim 1 , wherein said fabric is used in the manufacture of high visibility, flame resistant trim on safety apparel. 
     
     
         17 . The fabric of  claim 1 , wherein said fabric weave configuration is selected from the group consisting of plain, twill, satin weave and combinations thereof. 
     
     
         18 . The fabric of  claim 1 , wherein said fabric is a knitted fabric. 
     
     
         19 . The fabric of  claim 17 , wherein said fabric is woven in a 8×4 warp-faced twill configuration. 
     
     
         20 . The fabric of  claim 1 , wherein said fabric is dyeable to obtain high visibility colours by conventional dyeing methods. 
     
     
         21 . The fabric of  claim 20 , wherein the fabric is dyeable to fluorescent yellow-green, fluorescent red-orange or fluorescent red hues. 
     
     
         22 . The fabric of  claim 20 , wherein the fabric is dyeable with cationic dyes. 
     
     
         23 . The fabric of  claim 1 , wherein said fabric is chemically finishable to enhance dimensional stability, reduce shrinkage, improve colour fastness and enhance feel. 
     
     
         24 . A method for manufacturing a fabric for use in safety apparel, said method comprising the steps of:
 a. running a first yarn in a weft direction, said first yarn comprising modacrylic; and   b. running a second yarn in a warp direction, said second yarn comprising polyester,   
       wherein said method produces a fabric meeting visibility requirements governed by CSA Z96 in Canada and by ANSI/ISEA 107 in the US and applicable international standards; and meeting requirements for flame resistance governed in Canada by CAN/CGSB-155.20, CAN/CGSB 155.22 and CSA Z462; and in the US by NFPA 2112, NFPA 1971, NFPA 1975, NFPA 1977 and NFPA 70E and applicable international standards. 
     
     
         25 . The method of  claim 24 , wherein said first yarn comprises a blend of modacrylic fibres with one or more conventional fibres selected from the group consisting of nylon, rayon, polyester, cotton, wool, glass, minerals or aramids, and combinations thereof. 
     
     
         26 . The method of  claim 25 , wherein said first yarn comprises a blend of modacrylic fibres with nylon fibres. 
     
     
         27 . The method of  claim 26 , wherein said first yarn comprises a blend of from 70%-100% modacrylic and from 0% to 30% nylon. 
     
     
         28 . The method of  claim 27 , wherein the first yarn comprises 90% modacrylic fibres and 10% nylon fibres. 
     
     
         29 . The method of  claim 24 , wherein said second yarn is selected from the group consisting of flame resistant polyester and non-flame resistant polyester. 
     
     
         30 . The method of  claim 24 , wherein said second yarn comprises a blend of polyester fibres with alternate fibres selected from the group consisting of nylon, cotton, wool, glass, mineral, aramids, rayon and combinations thereof. 
     
     
         31 . The method of  claim 30 , wherein said second yarn comprise a blend of from 70% to 100% polyester and from 0% to 30% alternate fibres. 
     
     
         32 . The method of  claim 24 , further comprising affixing said fabric to one or more secondary materials. 
     
     
         33 . The method of  claim 32 , wherein affixing comprises sewing said fabric onto said one or more secondary materials. 
     
     
         34 . The method of  claim 32 , wherein affixing comprises sewing said one or more secondary materials onto said fabric. 
     
     
         35 . The method of  claim 32 , wherein affixing comprises adhereing said one or more secondary materials onto said fabric. 
     
     
         36 . The method of  claim 32 , wherein affixing comprises laminating said one or more secondary materials onto said fabric. 
     
     
         37 . The method of  claim 36 , wherein said one or more secondary materials comprise reflective tapes, reflective fabrics and reflective films. 
     
     
         38 . The method of  claim 24 , further comprising manufacturing said fabric into high visibility, flame resistant trim on safety apparel. 
     
     
         39 . The method of  claim 24 , wherein running said first yarn and said second yarn comprising weaving said first yarn and sais second yarn. 
     
     
         40 . The method of  claim 24 , wherein running said first yarn and said second yarn comprising knitting said first yarn and sais second yarn. 
     
     
         41 . The method of  claim 24 , further comprising dyeing said fabric to obtain high visibility colours by conventional dyeing methods. 
     
     
         42 . The method of  claim 41 , further comprising dyeing the fabric with cationic dyes. 
     
     
         43 . The method of  claim 24 , further comprising chemically finishing said fabric to enhance dimensional stability, reduce shrinkage, improve colour fastness and enhance feel.