U.S. patent application number 10/658842 was filed with the patent office on 2004-03-11 for flame and shrinkage resistant fabric blends.
Invention is credited to Lunsford, Clyde C., Riggins, Phillip H., Stanhope, Michael T..
Application Number | 20040045103 10/658842 |
Document ID | / |
Family ID | 31996454 |
Filed Date | 2004-03-11 |
United States Patent
Application |
20040045103 |
Kind Code |
A1 |
Lunsford, Clyde C. ; et
al. |
March 11, 2004 |
Flame and shrinkage resistant fabric blends
Abstract
The present disclosure relates to flame resistant fabrics that
comprise a plurality of inherently flame resistant fibers and a
plurality of cellulosic fibers containing a flame retardant
compound. In one arrangement, the inherently flame resistant fibers
have been dyed and/or shrinkage controlled with a dye-assistant
such that the fabric contains a residual amount of a dye-assistant
selected from the group consisting of N-cyclohexylpyrrolidone,
benzyl alcohol, N,N-dibutylformamide, N,N-diethylbenzamide,
hexadecyltrimethyl ammonium salt, N,N-dimethylbenzamide,
N,N-diethyl-m-toluamide, N-octylpyrrolidone, aryl ether, an
approximately 50/50 blend of N,N-dimethylcaprylamide and
N,N-dimethylcapramide, and mixtures thereof.
Inventors: |
Lunsford, Clyde C.;
(Sharpsburg, GA) ; Riggins, Phillip H.;
(Greensboro, NC) ; Stanhope, Michael T.; (Atlanta,
GA) |
Correspondence
Address: |
THOMAS, KAYDEN, HORSTEMEYER & RISLEY, LLP
100 GALLERIA PARKWAY, NW
STE 1750
ATLANTA
GA
30339-5948
US
|
Family ID: |
31996454 |
Appl. No.: |
10/658842 |
Filed: |
September 9, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10658842 |
Sep 9, 2003 |
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09657047 |
Aug 28, 2000 |
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6626964 |
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09657047 |
Aug 28, 2000 |
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09062805 |
Apr 20, 1998 |
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6132476 |
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Current U.S.
Class: |
8/531 |
Current CPC
Class: |
Y10T 442/277 20150401;
D06P 1/6495 20130101; D06P 1/66 20130101; D06P 3/8214 20130101;
Y10T 442/2631 20150401; Y10T 442/2869 20150401; D06P 1/6426
20130101; D06P 1/65118 20130101; D06P 3/8219 20130101; Y10S 8/925
20130101; Y10T 442/2861 20150401 |
Class at
Publication: |
008/531 |
International
Class: |
D06P 003/82 |
Claims
1. A flame resistant fabric, comprising: a plurality of inherently
flame resistant fibers that were uncrystalized in fiber form; and a
plurality of cellulosic fibers containing a flame retardant
compound; wherein said inherently flame resistant fibers comprise a
material selected from the group consisting of aromatic polyamide,
polyamide imide, polyimide, and mixtures thereof; wherein said
cellulosic fibers comprise a material selected from the group
consisting of rayon, acetate, triacetate, lyocell, and mixtures
thereof.
2. The fabric of claim 1, wherein said inherently flame resistant
fibers are meta-aramid fibers.
3. The fabric of claim 1, wherein said cellulosic fibers are rayon
fibers.
4. The fabric of claim 1, wherein said fabric contains a residual
amount of dye-assistant selected from the group Consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and
mixtures thereof.
5. The fabric of claim 1, wherein said fabric contains a phosphorus
compound flame retardant in a concentration of at least
approximately 1.4% phosphorus by weight of cellulosic fiber
component.
6. The fabric of claim 1, wherein said fabric exhibits a duration
of afterflame no greater than 2.0 seconds when subjected to a
vertical flammability test conducted in accordance with FTMS 191 A
Method 5903.1 using a three second exposure.
7. The fabric of claim 1, wherein said fabric exhibits a shrinkage
percentage of no greater than approximately 7% after 20 launderings
conducted in accordance with AATCC Test Method 135-1992, Table I
(3)(V)(A)(iii).
8. The fabric of claim 1, wherein said inherently flame resistant
fibers of said fabric have been dyed a shade of color which results
in an L value between approximately 18 and the greige L value for
said fabric if said inherently flame resistant fibers were used to
form a fabric composed exclusively of said inherently flame
resistant fibers.
9. A flame resistant fabric, comprising: a plurality of inherently
flame resistant fibers; and a plurality of cellulosic fibers that
contain a flame retardant compound; wherein said fabric contains a
residual amount of a dye-assistant selected from the group
consisting of N-cyclohexylpyrrolidone, benzyl alcohol,
N,N-dibutylformamide, N,N-diethylbenzamide, hexadecyltrimethyl
ammonium salt, N,N-dimethylbenzamide, N,N-diethyl-m-toluamide,
N-octylpyrrolidone, aryl ether, an approximately 50/50 blend of
N,N-dimethylcaprylamide and N,N-dimethylcapramide, and mixtures
thereof.
10. The fabric of claim 9, wherein said dye-assistant is selected
from the group consisting of N-cyclohexylpyrrolidone, benzyl
alcohol, N,N-dibutylformamide, and mixtures thereof.
11. The fabric of claim 9, wherein said inherently flame resistant
fibers comprise a material selected from the group consisting of
aromatic polyamide, polyamide imide, polyimide, and mixtures
thereof.
12. The fabric of claim 9, wherein said inherently flame resistant
fibers are meta-aramid fibers.
13. The fabric of claim 9, wherein said cellulosic fibers comprise
rayon, acetate, triacetate, lyocell, or mixtures thereof.
14. The fabric of claim 9, wherein said cellulosic fibers are rayon
fibers.
15. The fabric of claim 9, wherein said fabric contains a
phosphorus compound flame retardant in a concentration of at least
approximately 1.4% phosphorus by weight of cellulosic fiber
component.
16. The fabric of claim 9, wherein said fabric exhibits a duration
of afterflame no greater than 2.0 seconds when subjected to a
vertical flammability test conducted in accordance with FTMS 191
Method 5903.1 using a three second exposure.
17. The fabric of claim 9, wherein said fabric exhibits a shrinkage
percentage of no greater than approximately 7% after 20 launderings
conducted in accordance with AATCC Test Method 135-1992, Table I
(3)(V)(A)(iii).
18. The fabric of claim 9, wherein said inherently flame resistant
fibers of said fabric have been dyed a shade of color which would
result in an L value between approximately 18 and the greige L
value for said fabric if said inherently flame resistant fibers
were used to form a fabric composed exclusively of said inherently
flame resistant fibers.
19. A flame resistant fabric, comprising: a plurality of inherently
flame resistant fibers that were uncrystalized in fiber a plurality
of cellulosic fibers that contain a flame retardant compound;
wherein said fabric contains a phosphorus compound flame retardant
in a concentration of at least approximately 1.4% phosphorus by
weight of cellulosic fiber component.
20. The fabric of claim 19, wherein said inherently flame resistant
fibers comprise a material selected from the group consisting of
aromatic polyamide, polyamide imide, polyimide, and mixtures
thereof.
21. The fabric of claim 19, wherein said inherently flame resistant
fibers are meta-aramid fibers.
22. The fabric of claim 19, wherein said cellulosic fibers comprise
rayon, acetate, triacetate, lyocell, or mixtures thereof.
23. The fabric of claim 19, wherein said cellulosic fibers are
rayon fibers.
24. The fabric of claim 19, wherein said fabric contains a residual
amount of dye-assistant selected from the group consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and
mixtures thereof.
25. The fabric of claim 19, wherein said fabric exhibits a duration
of conducted in accordance with FTMS 191A Method 5903.1 using a
three second exposure.
26. The fabric of claim 19, wherein said fabric exhibits a
shrinkage percentage of no greater than approximately 7% after 20
launderings conducted in accordance with AATCC Test Method
135-1992, Table I (3)(V)(A)(iii).
27. The fabric of claim 19, wherein said inherently flame resistant
fibers of said fabric have been dyed a shade of color which would
result in an L value between approximately 18 and the greige L
value for said fabric if said inherently flame resistant fibers
were used to form a fabric composed exclusively of said inherently
flame resistant fibers.
28. A flame resistant fabric, comprising: a plurality of inherently
flame resistant fibers that were uncrystalized in fiber form; and a
plurality of cellulosic fibers that contain a flame retardant
compound; wherein said fabric exhibits a duration of afterflame no
greater than 2.0 seconds when subjected to a vertical flammability
test conducted in accordance with FTMS 191A Method 5903.1 using a
three second exposure.
29. The fabric of claim 28, wherein said inherently flame resistant
fibers comprise a material selected from the group consisting of
aromatic polyamide, polyamide imide, polyimide, and mixtures
thereof.
30. The fabric of claim 28, wherein said inherently flame resistant
fibers are meta-aramid fibers.
31. The fabric of claim 28, wherein said cellulosic fibers comprise
rayon, acetate, triacetate, lyocell, or mixtures thereof.
32. The fabric of claim 28, wherein said cellulosic fibers are
rayon fibers.
33. The fabric of claim 28, wherein said fabric contains a residual
amount of dye-assistant selected from the group consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and
mixtures thereof.
34. The fabric of claim 28, wherein said fabric exhibits a
shrinkage percentage of no greater than approximately 7% after 20
launderings conducted in accordance with AATCC Test Method
135-1992, Table I (3)(V)(A)(iii).
35. The fabric of claim 28, wherein said inherently flame resistant
fibers of said fabric have been dyed a shade of color which would
result in an L value between approximately 18 and the greige L
value for said fabric if said inherently flame resistant fibers
were used to form a fabric composed exclusively of said inherently
flame resistant fibers.
36. A flame resistant fabric, comprising: a plurality of inherently
flame resistant fibers that were uncrystalized in fiber form; and a
plurality of cellulosic fibers that contain a flame retardant
compound; wherein said fabric exhibits a shrinkage percentage of no
greater than approximately 7% after 20 launderings conducted in
accordance with AATCC Test Method 135-1992, Table I
(3)(V)(A)(iii).
37. The fabric of claim 36, wherein said inherently flame resistant
fibers comprise a material selected from the group consisting of
aromatic polyamide, polyamide imide, polyimide, and mixtures
thereof.
38. The fabric of claim 36, wherein said inherently flame resistant
fibers are meta-aramid fibers.
39. The fabric of claim 36, wherein said cellulosic fibers comprise
rayon, acetate, triacetate, lyocell, or mixtures thereof.
40. The fabric of claim 36, wherein said cellulosic fibers are
rayon fibers.
41. The fabric of claim 36, wherein said fabric contains a residual
amount of dye-assistant selected from the group consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and
mixtures thereof.
42. The fabric of claim 36, wherein said inherently flame resistant
fibers of said fabric have been dyed a shade of color which would
result in an L value between approximately 18 and the greige L
value for said fabric approximately if said inherently flame
resistant fibers were used to form a fabric composed exclusively of
said inherently flame resistant fibers.
43. A flame resistant fabric, comprising: a plurality of inherently
flame resistant fibers that were uncrystalized in fiber form; and a
plurality of cellulosic fibers that contained a flame retardant
compound in fiber form.
44. The fabric of claim 43, wherein said fabric contains a residual
amount of a dye-assistant selected from the group consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide,
N-N-diethylbenzamide, hexadecyltrimethyl ammonium salt,
N,N-dimethylbenzamide, N,N-diethyl-m-toluamide, N-octylpyrrolidone,
aryl ether, an approximately 50/50 blend of N,N-dimethylcaprylamide
and N,N-dimethylcapramide, and mixtures thereof.
45. The fabric of claim 43, wherein said dye-assistant is selected
from the group consisting of N-cyclohexylpyrrolidone, benzyl
alcohol, N,N-dibutylformamide, and mixtures thereof.
46. The fabric of claim 43, wherein said inherently flame resistant
fibers comprise a material selected from the group consisting of
aromatic polyamide, polyamide imide, polyimide, and mixtures
thereof.
47. The fabric of claim 43, wherein said inherently flame resistant
fibers are meta-aramid fibers.
48. The fabric of claim 43, wherein said cellulosic fibers comprise
rayon, acetate, triacetate, lyocell, or mixtures thereof.
49. The fabric of claim 43, wherein said cellulosic fibers are
rayon fibers.
50. The fabric of claim 43, wherein said fabric contains a
phosphorus compound flame retardant in a concentration of at least
approximately 1.4% phosphorus by weight of cellulosic fiber
component.
51. The fabric of claim 43, wherein said fabric exhibits a duration
of afterflame no greater than 2.0 seconds when subjected to a
vertical flammability test conducted in accordance with FTMS 1431
Method 5903.1 using a three second exposure.
52. The fabric of claim 43, wherein said fabric exhibits a
shrinkage percentage of no greater than approximately 7% after 20
launderings conducted in accordance with AATCC Test Method
135-1992, Table I (3)(V)(A)(iii).
53. The fabric of claim 43, wherein said inherently flame resistant
fibers of said fabric have been dyed a shade of color which would
result in an L value between approximately 18 and the greige L
value for said fabric if said inherently flame resistant fibers
were used to form a fabric composed exclusively of said inherently
flame resistant fibers.
54. A flame resistant fabric, comprising: a plurality of dyed,
inherently flame resistant fibers that were uncolored in fiber a
plurality of cellulosic fibers that contained a flame retardant
compound in fiber form.
55. The fabric of claim 54, wherein said fabric contains a residual
amount of a dye-assistant selected from the group consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide,
N,N-diethylbenzamide, hexadecyltrimethyl ammonium salt,
N,N-dimethylbenzamide, N,N-diethyl-m-toluamide, N-octylpyrrolidone,
aryl ether, an approximately 50/50 blend of N,N-dimethylcaprylamide
and N,N-dimethylcapramide, and mixtures thereof.
56. The fabric of claim 54, wherein said dye-assistant is selected
from the group consisting of N-cyclohexylpyrrolidone, benzyl
alcohol, N,N-dibutylformamide, and mixtures thereof.
57. The fabric of claim 54, wherein said inherently flame resistant
fibers comprise a material selected from the group consisting of
aromatic polyamide, polyamide imide, polyimide, and mixtures
thereof.
58. The fabric of claim 54, wherein said inherently flame resistant
fibers are meta-aramid fibers.
59. The fabric of claim 54, wherein said cellulosic fibers comprise
rayon, acetate, triacetate, lyocell, or mixtures thereof.
60. The fabric of claim 54, wherein said cellulosic fibers are
rayon fibers.
61. The fabric of claim 54, wherein said fabric contains a
phosphorus compound flame retardant in a concentration of at least
approximately 1.4% phosphorus by weight of cellulosic fiber
component.
62. The fabric of claim 54, wherein said fabric exhibits a duration
of afterflame no greater than 2.0 seconds when subjected to a
vertical flammability test conducted in accordance with FTMS 1431
Method 5903.1 using a three second exposure.
63. The fabric of claim 54, wherein said fabric exhibits a
shrinkage percentage of no greater than approximately 7% after 20
launderings conducted in accordance with AATCC Test Method
135-1992, Table I (3)(V)(A)(iii).
64. The fabric of claim 54, wherein said inherently flame resistant
fibers of said fabric have been dyed a shade of color which would
result in an L value between approximately 18 and the greige L
value for said fabric if said inherently flame resistant fibers
were used to form a fabric composed exclusively of said inherently
flame resistant fibers.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of U.S. patent application Ser. No.
09/657,047, filed Aug. 28, 2000, entitled "Flame and Shrinkage
Resistant Fabric Blends," which is a continuation-in-part
application of U.S. patent application Ser. No. 09/062,805, filed
Apr. 20, 1998, entitled "Flame and Shrinkage Resistant Fabric
Blends and Method for Making Same" (now U.S. Pat. No.
6,132,476).
FIELD OF THE INVENTION
[0002] The present invention relates to flame resistant fabrics.
More particularly, the present invention relates to fabric blends
containing inherently flame resistant fibers and flame resistant
cellulosic fibers that contain a flame retardant compound. These
fabrics exhibit excellent flame resistance, minimal shrinkage when
laundered, and can be produced in a full range of colors and
shades.
BACKGROUND OF THE INVENTION
[0003] Inherently flame resistant fibers are highly resistant to
heat decomposition and are therefore desirable in the manufacture
of flame resistant garments intended for environments in which
flames or extreme heat will be encountered. These desirable
properties of inherently flame resistant fibers can, however,
create difficulties during fabric production. For example, fibers
composed of aromatic polyamide, commonly known as aramid fibers,
are difficult to dye. Aramid fiber suppliers have recommended
complicated exhaust dyeing procedures with various dye-assistants,
high temperatures, and long dyeing times to effect dyeing of these
fibers. Such dyeing conditions require substantial amounts of
energy both to maintain the dyeing temperature and for the
treatment of waste dyebaths. Dye-assistants comprised of organic
agents, and commonly referred to as carriers or swelling agents,
are used to enhance dyeability. Such dye-assistants may be added to
the dyebath as a treatment prior to dyeing, or can be integrated
into the inherently flame resistant fiber during its
production.
[0004] Inherently flame resistant fibers such as aramid fibers can
be blended with fibers made of other materials. As is known in the
art, fiber blending can be used to obtain an end fabric that
combines the beneficial characteristics of each of the constituent
fibers. For instance, in the area of flame resistant fabric
manufacture, flame resistant cellulosic fibers such as flame
resistant rayon ("FR rayon") fibers can be successfully blended
with aramid fibers to obtain a flame resistant material which is
softer, more moisture absorbent, and less expensive to produce than
materials constructed only of aramid fibers.
[0005] Although improving the texture and lowering the cost of
flame resistant fabrics, blending inherently flame resistant fibers
with flame resistant cellulosics such as FR rayon can complicate
production. Specifically, cellulosics contain flame retardant
agents that, although resistant to standard cellulosic dyeing
procedures, tend to be depleted by the extreme temperatures
generally considered necessary to dye the inherently flame
resistant fibers. This depletion of flame retardant agents
significantly reduces the flame resistance of the cellulosic fibers
and therefore reduces the flame resistance of these blends.
Moreover, these conditions increase the likelihood of further
depletion of the flame retardant agents during subsequent
launderings and an even greater reduction in flame resistance.
[0006] Due to the danger of depleting the flame retardant agent or
agents contained in the cellulosic fibers of such fabric blends,
producers of cellulosic fibers often advise their customers to
avoid dyeing the inherently flame resistant fibers when blended
with flame resistant cellulosic fibers. As an alternative, these
producers suggest using producer colored inherently flame resistant
fiber where a colored, flame resistant cellulosic blend is to
desired. In producer coloring (also known as "solution dyeing"),
pigment or other coloring is typically injected into the polymer
solution before the fiber is formed. Although providing for
adequate colorization of these fibers, producer coloring presents
several disadvantages. First, producer colored fibers usually are
more expensive than non-producer colored fibers. Second, due to the
increased difficulty and cost associated with the production of
these fibers, typically only a limited variety of producer colored
fibers are available.
[0007] In addition to increasing the difficulty of dyeing the
inherently flame resistant fibers, dyeing at temperatures below
100.degree. C. renders the inherently flame resistant fibers
susceptible to substantial laundry shrinkage. Accordingly, where
the inherently flame resistant fibers are to be dyed, the dyer is
typically left with a choice between acceptable color and shrinkage
control but unacceptable flame resistance on one hand (when dyeing
above 100.degree. C.), and preserved flame resistance but high
laundering shrinkage and poor color yield on the other (when dying
below 100.degree. C.). Notably, the same shrinkage susceptibility
exists in situations where the inherently flame resistant and/or
flame resistant cellulosic fibers are not dyed.
[0008] From the above discussion, it can be appreciated that it
would be desirable to halve fabric blends comprising inherently
flame resistant fibers and flame resistant cellulosic fibers that
avoid the aforementioned problems.
SUMMARY OF THE INVENTION
[0009] The present disclosure relates to flame resistant fabrics
that comprise a plurality of inherently flame resistant fibers and
a plurality of cellulosic fibers containing a flame retardant
compound. Normally, the flame resistant fibers were uncrystalized
in fiber form and the cellulosic fibers contained a flame retardant
compound in fiber form in one arrangement, the inherently flame
resistant fibers comprise a material selected from the group
consisting of aromatic polyamide, polyamide imide, polyimide, and
mixtures thereof, while the cellulosic fibers comprise a material
selected from the group consisting of rayon, acetate, triacetate,
lyocell, and mixtures thereof.
[0010] In another arrangement, the fabric contains a residual
amount of a dye-assistant selected from the group consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide,
N,N-diethylbenzamide, hexadecyltrimethyl ammonium salt,
N,N-dimethylbenzamide, N,N-diethyl-m-toluamide, N-octylpyrrolidone,
aryl ether, an approximately 50/50 blend of N,N-dimethylcaprylamide
and N,N-dimethylcapramide, and mixtures thereof.
[0011] In a further arrangement, the fabric contains a phosphorus
compound flame retardant in a concentration of at least
approximately 1.4% phosphorus by weight of cellulosic fiber
component.
[0012] In yet another arrangement, the fabric exhibits a duration
of afterflame no greater than 2.0 seconds when subjected to a
vertical flammability test conducted in accordance with FTMS 191A
Method 5903.1 using a three second exposure.
[0013] In a further arrangement, the fabric exhibits a shrinkage
percentage of no greater than approximately 7% after 20 launderings
conducted in accordance with AATCC Test Method 135-1992, Table I
(3)(V)(A)(iii).
[0014] The features and advantages of the invention will become
apparent upon reading the following specification, when taken in
conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0015] As summarized above, the present invention provides fabric
blends of inherently flame resistant fibers and flame resistant
cellulosic fibers that contain a flame retardant compound. Although
not required, the inherently flame resistant fibers, the flame
resistant cellulosic fibers, or both typically are dyed through an
exhaust process. Where the blend is dyed, the inherently flame
resistant fibers of the fabric can be dyed a full shade of color
without significantly depleting the amount of flame retardant
compound contained in the cellulosic fibers to preserve the flame
resistance of the fabric after the dyeing process is completed and
through subsequent laundering. It is to be noted that, for the
purposes of this disclosure, the term full shade denotes
penetration of the subject fiber with dye and fixation of the dye
therein, as opposed to mere superficial staining of the fibers.
Irrespective of whether the blends are dyed, shrinkage of the
inherently flame resistant fibers is reduced such that the overall
fabric shrinkage is within levels considered acceptable by industry
standards.
[0016] Although the inherently flame resistant fibers can be
composed of any material that is inherently flame resistant, it is
preferred that these fibers are composed essentially of an aromatic
polyamide, polyamide imide, or polyimide, each of which is
considered difficult to dye. Most preferably, these fibers will be
composed essentially of an aromatic polyamide. Aromatic polyamides
are formed by reactions of aromatic diacid chlorides with aromatic
diamines to produce amide linkages in an amide solvent. Fibers made
of aromatic polyamides are generally referred to by the generic
term aramid fiber. Aramid fibers are typically available in two
distinct compositions, namely meta-type fibers composed of
poly(m-phenylene isophthalamide) commonly referred to as
meta-aramid fibers, and para-type fibers composed of
poly(p-phenyleneterephthalamide) which are commonly referred to as
para-aramid fibers. Meta-aramid fibers are currently available from
DuPont of Wilmington, Del. in several forms under the trademark
NOMEX8. For example, NOMEX T-450.RTM. is 100% meta-aramid; NOMEX
T-455.RTM. is a blend of 95% NOMEX.RTM. and 5% KEVLAR.RTM.
(para-aramid); and NOMEX IIIA.RTM. (also known as NOMEX T-462.RTM.)
is 93% NOMEX.RTM., 5% KEVLAR.RTM., and 2% carbon core nylon. In
addition, meta-aramid fibers are available under the trademarks
CONEX.RTM. and APYEIL.RTM. which are produced by Teijin and
Unitika, respectively. Para-aramid fibers are currently available
under the trademarks KEVLAR.RTM., TECHNORA.RTM., and TWARON.RTM.
from DuPont, Teijin, and Akzo respectively. In accordance with the
above description, it is to be noted that, in the present
disclosure, when a material name is followed by the term "fiber,"
the fiber described is not limited to fibers composed exclusively
of the named material.
[0017] Meta-aramid and para-aramid fibers share similar
characteristics. For instance, both have limiting oxygen indexes
(LOI's) approximately between 24 and 30 percent. However, there are
significant differences between the two compositions. Notably,
para-aramid fibers are considerably stronger than meta-aramid
fibers, having tenacity values approximately between 21-27 g/d and
a tensile strength of about 400 psi. This strength makes
para-aramid fibers particularly useful in law enforcement and
military applications. Another significant distinction between
meta-aramid and para-aramid fibers is that, although both are
difficult to dye, meta-aramid fibers appear to more readily accept
dye during the dyeing procedure. Despite being easier to dye,
meta-aramid fibers have a greater tendency to shrink when subjected
to laundering than do para-aramid fibers. Accordingly, dyed
meta-aramid blends must be produced in a manner which additionally
prevents or inhibits subsequent shrinking due to laundering.
[0018] Another group of fibers that have flame resistant properties
and that are difficult to dye are polyamide imides. Sometimes
referred to as an aromatic polyamide, polyamide imide is a high
performance thermoplastic that is the condensation polymer of
trimellitic anhydride and various diamines. Polyamide imide fibers
are currently available under the trademark KERMEL.RTM. which is
produced by Rhne-Poulenc.
[0019] A further group of fibers that have flame resistant
properties and that are difficult to dye are polyimides. Polyimide
is chemically known as poly
(4.4'-diphenylmethane-co-tolylenebenzophenonetetracarboxylicimide-
) and is made by the reaction of benzophenone tetra carboxylic
anhydride with a mixture of tolylene and diphenylmethane
diisocyanates in a polar aprotic solvent such as dimethyl-formamide
or acetamide. Polyimide fibers are currently available from Lenzing
under the trademark P-84.RTM..
[0020] Irrespective of the type of inherently flame resistant
fibers used, the inherently flame resistant fibers normally are
uncrystalized in fiber form prior to dyeing or other processing. As
known in the art, "crystalinity" refers to the formation of
highly-ordered substances, i.e., crystals, within the fiber. In
such crystals, the atoms of the fiber material are ordered in
regular chain structures which are packed into an ordered, regular
three-dimensional crystal lattice. Generally speaking, crystallized
fibers do not readily accept dye. Therefore, dyeing is usually
carried out only on uncrystalized fibers. These fibers normally are
crystallized, however, by the high temperatures conventionally used
to dye such fibers. This crystallization is helpful both in dye
retention and in resistance to shrinkage.
[0021] In the present invention, one or more of the above
identified inherently flame resistant fibers is blended with one or
more types of cellulosic fiber. Preferred for the choice of
cellulosic fibers are rayon, acetate, triacetate, and lyocell.
These cellulosics, although softer and less expensive than the
inherently flame resistant fibers, are not naturally resistant to
flame. To increase the flame resistance of these fibers, they
typically are treated in fiber form with one or more flame
retardants such as phosphorus compounds like SANDOLAST 9000.RTM.,
currently available from Clarion, antimony compounds, and the like.
Generally speaking, cellulosic fibers which contain one or more
flame retardants are given the designation "FR". Accordingly, the
preferred flame resistant cellulosic fibers are FR rayon, FR
acetate, FR triacetate, and FR lyocell.
[0022] Of the many blends conceivable with the above described
listing of preferred fibers, most preferred is a blend of NOMEX
IIIA.RTM. and FR rayon having a percentage composition of NOMEX
IIIA.RTM. of at least 20% and a nercentage comnposition of FR rayon
of at least 10%. Typically, the fabric will comprise a 50/50,
65/35, or a 35/65 blend of NOMEX IIIA.RTM. and FR rayon.
[0023] The fabric of the present invention can be dyed and/or
shrinkage controlled using customary dyeing equipment. Typically, a
dye, a dye-assistant, and a flame retardant for the inherently
flame resistant fibers, are combined to form a mixture, (e.g., a
dyebath, solution, dispersion, or the like). Although the term
"dye-assistant" is used herein, it is to be understood that this
material is used even where the inherently flame resistant and/or
flame resistant cellulosic fibers are not to be dyed. The fabric is
then contacted with this mixture, typically by immersion, and the
mixture heated. In accordance with the present invention, a fibrous
textile material, e.g., fiber, web, yam, thread, sliver, woven
fabric, knitted fabric, non-woven fabric, or the like, is placed in
the bath with the additives using conventional equipment such as
dye jets or other appropriate equipment.
[0024] The preferred dye-assistants of the present invention are
selected from the group consisting of N-cyclohexylpyrrolidone,
benzyl alcohol, N,N-dibutylformamide, N,N-diethylbenzamide,
hexadecyltrimethyl ammonium salt, N,N-dimethylbenzamide,
N,N-diethyl-m-toluamide, N-octylpyrrolidone, aryl ether, Halcomid
M-8/10 (an approximately 50/50 blend of N,N-dimethylcaprylamide and
N,N-dimethylcapramide), and mixtures thereof. Where the highest
degree of shrinkage prevention is desired, the dye-assistant most
preferably is selected from the group consisting of
N-cyclohexylpyrrolidone, benzyl alcohol, N,N-dibutylformamide, and
mixtures thereof.
[0025] As an alternative to adding dye-assistant to the bath, the
dye-assistant can instead be imbibed into the fibers themselves
during production. Exemplary of the types of fibers that could be
used in this manner are those disclosed by Vance et al. in U.S.
Pat. No. 4,688,234, and Hodge et al. in U.S. Pat. No. 5,074,889,
both of which are hereby incorporated by reference. As disclosed by
Vance et al., typically a surfactant such as
hexadecyltrimethylammonium salt or isopropylammonium
dodecylbenzenesulfonate is added to the fiber at a level of
approximately 5% to 15% by weight. When the fibers are imbibed with
dye-assistant, dyeing is conducted in the same manner as described
above except that no additional dye-assistant need be added to the
dyebath.
[0026] In addition to the dye-assistants, a flame retardant
compound can also be included; in the dyebath, applied as an after
dyeing surface treatment, or otherwise incorporated in the fiber to
enhance flame resistance or to counteract any deleterious effects
of the dye assistant contained within the inherently flame
resistant fibers. Preferred flame retardants are ANTIBLAZE 80.RTM.
("AB80.RTM.") and ANTIBLAZE 10.RTM. ("AB100.RTM.") which are both,
currently available from Albright & Rhodia.
[0027] Dyes that can be used advantageously with the present
carriers for the dyeing of the inherently flame resistant fibers
can include anionic, cationic, disperse dyes, and mixtures thereof.
Of these dyes, particularly preferred are cationic dyes. With
regard to the dyeing of the cellulosic fibers, preferred are
direct, reactive, vat, and sulfur.
[0028] As described above, dyeing blends of inherently flame
resistant fibers and flame resistant cellulosic fibers has,
heretofore, been inadvisable because the dyeing conditions normally
used adversely affect one or both types of the fibers. In
particular, the high temperatures conventionally deemed necessary
to attain adequate dyeing and shrinkage control of the inherently
flame resistant fibers deplete the flame retardant contained in the
cellulosic fibers. Notably, this depletion generally is not
remedied by the inclusion of additional flame retardant in the
dyebath under conventional conditions. Furthermore, these
conventional dyeing conditions cause increased subsequent depletion
of flame retardant when the fabric blends are laundered. Under the
method of the instant invention, however, effective dyeing of the
inherently flame resistant fibers can be attained at temperatures
below approximately 100.degree. C., without a substantial loss of
cellulosic flame retardant and without losing shrinkage control.
Notably, shrinkage control can be provided even where the
inherently flame resistant fibers are not dyed. Typically,
temperatures approximately between 70.degree. C. and 100.degree. C.
are used with approximately 85.degree. C. being most preferred. It
will be appreciated, however from the data provided below, that
temperatures as low as 60.degree. C. and even 50.degree. C. can be
used to dye the blends. However, in that the dyeing process is less
efficient and shrinkage prevention more difficult at these lower
temperatures, usually temperatures between the stated 70.degree.
C.-100.degree. C. range are used.
[0029] To conduct dyeing and/or shrinkage control of the inherently
flame resistant fibers of the blends, a dye-assistant, other
additives e.g., a dye) if desired, are preferably applied to the
fibers of the fabric using a one-step batch-type process, although
split treatment with dye-assistants applied separately from dye is
feasible, and in some applications might be desirable. Typically, a
roll of fabric is loaded into a jet dyer such as a pressure jet
dyeing vessel in which the fabric can be circulated through a
apertured venturi contained within the vessel. Once loaded into the
vessel, the ends of the fabric are sewn together to form a
continuous loop. The fabric can optionally be scoured if desired by
passing it through an aqueous solution that passes through the
apertures in the venturi and impinges the fabric. After scouring
has been completed, the jet is again charged with water, the
selected dye-assistant, dye (if the fabric is to be dyed), and any
other auxiliary additives that are desired. Alternatively, where
dye-assistant has been imbibed into the fibers, no additional
dye-assistant is added to the bath since an adequate amount of
dye-assistant is typically already contained within the fibers
themselves. In such circumstances, the same steps apply with the
exception of the step of adding dye-assistant to the bath.
[0030] The temperature of the bath is gradually increased from room
temperature to a peak temperature approximately between 70.degree.
C. and 100.degree. C. Upon reaching the predetermined peak
temperature, the bath is maintained at this peak temperature for
about 30 to 90 minutes to allow any dye present to fully penetrate
the fibers, and to crystallize the fibers. Although the
temperatures used are much lower than those normally relied upon
for crystallization, acceptable crystallization is achieved through
use of the preferred dye-assistants identified herein. It will be
appreciated that since the temperature does not reach 100.degree.
C., there is no need to increase the pressure of the dyebath beyond
atmospheric pressure to prevent boiling. Therefore, all processing
can be conducted at constant ambient atmospheric pressure, although
a closed vessel and increased pressure may be used to reduce
foaming or control odors.
[0031] After the expiration of approximately between 30 to 90
minutes at the peak temperature, the bath is cooled until the
fabric has reached a temperature at which it can be handled. At
this time, the dyebath is discarded and the fabric is again scoured
to remove excess dye-assistant or other chemicals contained in the
inherently flame resistant fibers. After all processing has been
completed, the fabric then can be finished in the conventional
manner. This finishing process can include the application of
wicking agents; water repellents, stiffening agents softeners, and
the like. At this stage, the finished fabric normally contains
residual dye-assistant in a concentration of approximately 0.5% to
10% owf, depending on the dye-assistant used and total processing.
Typically, it is preferred to keep the levels of residual
dye-assistants in the lower portion of the range, approximately
between 0.5% and 5.0% owf.
[0032] Illustrative of the beneficial results attainable when
processing at low temperatures as compared with dyeing at high
temperatures, Table I provides phosphorous compound retention data
for identical samples of a 75/25 blend of NOMEX T-462.RTM. and FR
rayon that were separately dyed at 250.degree. F.
(.about.121.degree. C.) and 185.degree. F. (85.degree. C.). As
evidenced by these test data, much larger amounts of phosphorus
compound are retained when processing at 185.degree. F. as opposed
to 250.degree. F., especially after repeated industrial launderings
conducted in accordance with NFPA 1975, 1994 ed., s. 4-2.4 as
described in the publication entitled Standard of Station/Work
Uniforms for Fire Fighters, 1994 edition, which is hereby
incorporated by reference.
1TABLE I PHOSPHORUS RETENTION Phosphorus Concentration* Peak Dye
After Launderings Dye-Assistant Temperature 0 25 50 75 100 benzyl
alcohol 250.degree. F. (.about.121.degree. C.) 0.66 0.59 0.51 0.35
0.36 aryl ether 250.degree. F. (.about.121.degree. C.) 0.54 0.47
0.29 0.44 0.25 none (water) 250.degree. F. (.about.121.degree. C.)
0.76 0.63 0.52 0.43 0.34 aryl ether 185.degree. F. (85.degree. C.)
0.77 0.70 0.64 0.65 0.61 N-cyclohexyl- 185.degree. F. (85.degree.
C.) 0.74 0.66 0.65 0.62 0.61 pyrrolidone none (water) 185.degree.
F. (85.degree. C.) 0.77 0.70 0.70 0.67 0.67 *phosphorus
concentration was determined by inductively coupled plasma-atomic
mission spectroscopy hydrochloric acid digestion of samples.
[0033] As shown in Table II, phosphorus retention is maintained
when dyeing according to the present invention even at temperatures
approaching 100.degree. C. In group A, identical samples of a 65/35
T-462.RTM. blend of NOMEX and FR rayon were union dyed at
210.degree. F. (.about.99.degree. C.) for 60 minutes using
N-cyclohexylpyrrolidone as a dye-assistant. In group B, the samples
were union dyed under the same conditions but for 90 minutes at a
peak temperature of 210.degree. F. In samples 1-4 of each group, 3
g/l of AB80.RTM. were added to the dyebath. All samples were also
laundered 100 times in accordance with NFPA 1975, 1994 ed., s.
4-2.4. As is evident from these data, phosphorous concentrations
stayed above 0.5% when dyed for either 60 or 90 minutes regardless
of whether AB80.RTM. was added to the dyebath or not.
2TABLE II PHOSPHORUS RETENTION (Peak Dyeing Temp. = 210.degree. F.
(.about.99.degree. C.)) Amt. of Sample No. Dye-Assitant Used (g/l)
Phosphorus Concentration (%) Group A: 60 min. peak dye time 1 30
0.82 2 35 0.82 3 40 0.74 4 45 0.81 5 30 0.55 6 35 0.58 7 40 0.55 8
45 0.54 Group B: 90 min. peak dye time 1 30 0.77 2 35 0.80 3 40
0.84 4 45 0.78 5 30 0.65 6 35 0.68 7 40 0.60 8 45 0.60
[0034] Testing has shown that blends of inherently flame resistant
fibers and flame resistant cellulosic fibers normally have a
phosphorus concentration of at least approximately 0.5% owf to
remain adequately flame resistant in accordance with FTMS 191A
Method 5903.1 as described in the publication entitled FTMS Textile
Test Methods, 1978 edition, which is hereby incorporated by
reference. According to Method 5903.1, a three inch by twelve inch
fabric specimen is placed in a holder and is suspended vertically
over a 11/2 inch high methane gas flame. During the test, the
material is placed in contact with the flame at the flame's
mid-point for a period of twelve seconds. After expiration of the
twelve seconds, the flame is extinguished and the material observed
to, inter alia, determine how long it will continue to burn. This
duration of burning after extinguishment of the methane flame is
referred to as "afterflame." Presently deemed acceptable under
military and NFPA standards are afterflame durations of 2.0 seconds
and less.
[0035] Tables III and IV provided below illustrate the criticality
of the 0.5% owf measure of phosphorus retention on afterflame
control. The data in Table III was obtained by dyeing identical
samples of 75/25 blends of NOMEX.RTM. and FR rayon with the various
listed dye-assistants at 250.degree. F. (note that "CHP" stands for
N-cyclohexylpyrrolidone and "BPP" stands for emulsified
butyl/propylphthalimide). After dyeing, the samples were
industrially laundered 0, 25, 75, or 100 times in accordance with
NFPA 1975, 1994 ed., s. 4-2.4, and then exposed to flame in
accordance with test method FTlSM 5903.1 for three seconds instead
of twelve. Although only providing a three second exposure to
flame, it is believed that the three second flame exposure is a
more critical indicator of fabric performance than the twelve
second exposure of FTMS 5903.1. In particular, the twelve second
duration provides greater opportunity of flame extinguishment (see
Table IV). Additionally, the twelve second flame exposure period
does not reflect the fabric's resistance to flash fires which
typically inflict damage primarily within the first three to four
seconds. Under the three second exposure test, afterflames greater
than 0.8 seconds provide cause for concern in that afterflames that
exceed 0.8 seconds indicate an increased likelihood of injury to
the fabric wearer. As is evident from the data of Table II,
afterflames greater than 0.8 seconds are consistently avoided when
the phosphorus concentrations of the fabric is at least
approximately 0.5% owf.
3TABLE III AFTERFLAME RELATIVE TO PHOSPHORUS RETENTION (Three
Second Exposure) No. of Phosphorus Dye-Assistant Launderings
Concentration (%) Afterflame (sec) none (water) 0 0.76 0.1 aryl
ether 0 0.54 0.8 acetophenone 0 0.59 0.5 CHP 0 0.69 0.5 benzyl
alcohol 0 0.66 0.4 BPP 0 0.78 0.4 none (water) 25 0.63 0.4 aryl
ether 25 0.47 0.5 acetophenone 25 0.42 0.4 CHP 25 0.49 0.5 benzyl
alcohol 25 0.59 0.4 BPP 25 0.35 0.4 none (water) 50 0.52 0.4 aryl
ether 50 0.29 3.5 acetophenone 50 0.35 0.6 CHP 50 0.38 0.6 benzyl
alcohol 50 0.51 0.4 BPP 50 0.42 1.1 none (water) 75 0.43 0.6 aryl
ether 75 0.44 0.6 acetophenone 75 0.30 29.8 CHP 75 0.39 0.6 benzyl
alcohol 75 0.35 1.0 BPP 75 0.44 0.9 none (water) 100 0.34 0.7 aryl
ether 100 0.25 4.0 acetophenone 100 0.25 24.1 CHP 100 0.37 1.1
benzyl alcohol 100 0.36 0.8 BPP 100 0.30 2.6
[0036] Table IV provides afterflame data of the same fabric and
dye-assistants tested in Table III, but after twelve seconds of
exposure to flame in accordance with FTMS 5903.1.
4TABLE IV AFTERFLAME RELATIVE TO PHOSPHORUS RETENTION (Twelve
Second Exposure) No. of Phosphorus Dye-Assistant Launderings
Concentration (%) Afterflame (sec) none (water) 0 0.76 N/A aryl
ether 0 0.54 0.0 acetophenone 0 0.59 0.0 CHP 0 0.69 0.0 benzyl
alcohol 0 0.68 0.0 BPP 0 0.78 0.0 none (water) 25 0.63 0.0 aryl
ether 25 0.47 0.2 acetophenone 25 0.42 0.0 CHP 25 0.49 0.0 benzyl
alcohol 25 0.59 0.0 BPP 25 0.35 0.0 none (water) 50 0.52 0.0 aryl
ether 50 0.29 0.0 acetophenone 50 0.35 0.0 CHP 50 0.38 0.0 benzyl
alcohol 50 0.51 0.0 BPP 50 0.42 0.0 none (water) 75 0.43 0.0 aryl
ether 75 0.44 0.0 acetophenone 75 0.30 16.1 CHP 75 0.39 0.0 benzyl
alcohol 75 0.35 0.0 BPP 75 0.44 0.0 none (water) 100 0.34 0.0 aryl
ether 100 0.25 0.0 acetophenone 100 0.25 13.9 CHP 100 0.37 0.0
benzyl alcohol 100 0.36 0.0 BPP 100 0.30 0.0
[0037] Taking into account fabric composition, it has been
determined that a phosphorus compound concentration of
approximately 0.5% owf translates into a phosphorus concentration
of at least approximately 1.4% phosphorus by weight of cellulosic
fiber component. In that it is desired to have a fabric which is
adequately flame resistant even after extensive laundering, where
phosphorus compound is used as the flame retardant contained in the
cellulosic fibers it is preferred that the resultant blends have a
phosphorus concentration of at least approximately 1.4% phosphorus
by weight of cellulosic fiber component after 100 launderings
conducted in accordance with NFPA 1975, 1994 ed., s. 4-2.4.
[0038] The dye-assistant used must promote dyeing and/or control
shrinkage of the inherently flame resistant fibers at relatively
low temperatures. With regard to dyeing, testing was conducted with
NOMEX.RTM./FR rayon blends at low temperature to determine the
degree of shade depth attainable when dyeing with a variety of
alternative dye-assistants. Using several identical samples of a
65/35 blend of NOMEX IIIA.RTM. and FR rayon fibers and a laboratory
launderometer dye apparatus, ten separate dyeing trials were made,
each with a different dye-assistant (see Table V). In each trial,
the launderometer tube was loaded at a 10:1 liquor ratio with the
dyebath containing 2.8% basic blue dye C.I. #41 owf and 40 g/l of
the particular dye-assistant being tested (water was used as a
control in the last trial). Dyeing was conducted at 85.degree. C.
for 60 minutes. Shade depth was measured terms of the lightness or
L value of the standardized L,a,b scale. In accordance to this
scale, the smaller the value of the L parameter, the deeper the
shade, and therefore the greater the extent of dyeing achieved. As
indicated in Table V, each of N-cyclohexylpyrrolidone, benzyl
alcohol, N,N-dibutylformamide, N,N-diethyl-m-toluamide, aryl ether,
N-octylpyrrolidone, and N,N-dimethylbenzamide provided a deep shade
of dyeing.
5TABLE V SHADE DEPTH (Peak Dyeing Temp. = 85.degree. C.)
Dye-Assistant Shade Depth (L) N-cyclohexylpyrrolidone 27.84
N,N-diethyl-m-toluamide 28.30 *aryl ether 27.93 N-octylpyrrolidone
27.80 N,N-dibutylformamide 28.22 butylbenzesulfonamide 36.20 benzyl
alcohol 26.98 N,N-dimethylbenzamide 29.06 sodium xylene sulfonate
36.75 water 33.85 *Aryl ether dye-assistants are commercially
available from Miles, Hickson Dan Chem, or Stockhausen as
proprietary products.
[0039] As identified above, acceptable dyeing can be achieved with
temperatures below 85.degree. C. Tables VI, VII, and VIII
illustrate the depths of shade attainable with dyeing at 50.degree.
C., 60.degree. C., and 70.degree. C., respectively. In each trial,
identical samples of 100% NOMEX IIIA.RTM. were dyed no more than 40
g/l of the selected dye-assistant present.
6TABLE VI SHADE DEPTH (Peak Dyeing Temp. = 50.degree. C.)
Dye-Assistant Shade Depth (L) N-cyclohexylpyrrolidone 41.55 benzyl
alcohol 29.38 N,N-dibutylformamide 40.92 N,N-diethyl-m-toluamide
39.04 N,N-diethylbenzamide 38.20 acetophenone 39.89
[0040]
7TABLE VII SHADE DEPTH (Peak Dyeing Temp. = 60.degree. C.)
Dye-Assistant Shade Depth (L) N-cyclohexylpyrrolidone 34.68 benzyl
alcohol 27.80 N,N-dibutylformamide 35.84 N,N-diethyl-m-toluamide
38.69 N,N-diethylbenzamide 33.83 acetophenone 31.32
[0041]
8TABLE VIII SHADE DEPTH (Peak Dyeing Temp. = 70.degree. C.)
Dye-Assistant Shade Depth (L) N-cyclohexylpyrrolidone 22.62 benzyl
alcohol 20.35 N,N-dibutylformamide 25.42 N,N-diethyl-m-toluamide
33.45 N,N-diethylbenzamide 23.42 acetophenone 21.09
[0042] In addition to permitting deep coloration of the inherently
flame resistant fibers, the method of the present invention reduces
the shrinkage of the inherently flame resistant fibers and
therefore fabric blends containing such fibers. Table IX provides
shrinkage data for 65/35 blends of NOMEX IIIA.RTM. and FR rayon
fibers dyed with 40 g/l of various carriers at 85.degree. C. for 60
minutes. Each fabric sample was then subjected to 5, 10, and 20
AATCC Test Method 135-1992, Table I (3)(V)(A)(iii) launderings as
described in the publication entitled American Association of
Textile Chemists and Colorists, 1992 edition, which is hereby
incorporated by reference. As is evident from Table IX, the least
amount of shrinkage occurred when the dye-assistant used was
N-cyclohexylpyrrolidone, benzyl alcohol, and N,N-dibutylformamide
with the warp direction of the fabric only shrinking 3.8%, 5.7%,
and 6.6% after 20 launderings.
9TABLE IX FABRIC SHRINKAGE (Peak Dyeing Temp. = 85.degree. C.) Fill
Shrinkage (%) Warp Shrinkage (%) Dye-Assistant 5x 10x 20x 5x 10x
20x N-cyclohexylpyrrolidone 1.5 2.1 2.1 3.0 3.5 3.8
N,N-diethyl-m-toluamide 4.1 6.1 7.1 5.1 7.8 9.7 aryl ether 4.6 7.1
10.2 5.1 9.1 12.6 N,N-octylpyrrolidone 4.1 5.6 7.7 5.1 7.5 10.2
N,N-dibutylformamide 2.1 3.1 3.1 3.0 4.9 5.7 Butylbenzesulfonamide
6.2 7.7 11.8 7.5 11.2 18.7 benzyl alcohol 1.0 3.1 4.7 2.7 4.9 6.6
N,N-dimethylbenzamide 4.1 7.1 9.6 6.5 9.7 12.4 sodium xylene
sulfonate 5.6 8.6 12.7 7.4 11.9 16.1 Water 5.6 8.2 12.2 7.2 11.7
15.9
[0043] Table X provides shrinkage data for identical samples of
100% NOMEX IIIA.RTM. fabric at 70.degree. C. for 60 minutes. After
being dyed, each sample was laundered 5, 10, and 20 times in
accordance with AATCC Test Method 135-1992, Table I(3)(V)(A)(iii).
As shown in this table, significant shrinkage control is obtainable
at temperatures as low as 70.degree. C.
10TABLE X FABRIC SHRINKAGE (Peak Dyeing Temp. = 70.degree. C.) Fill
Shrinkage (%) Warp Shrinkage (%) Dye-Assistant 5x 10x 20x 5x 10x
20x N-cyclohexylpyrrolidone 3.4 5.2 8.2 5.9 7.3 11.4 (30 g/l)
N-cyclohexylpyrrolidone 4.1 5.2 9.3 5.2 7.5 12.4 (40 g/l) benzyl
alcohol 3.3 4.9 8.0 4.9 6.7 11.1 (30 g/l) benzyl alcohol 4.1 5.2
8.2 4.1 6.4 10.3 (40 g/l) N,N-dibutylformamide 5.7 7.7 12.9 7.2
10.1 16.0 (40 g/l)
[0044] Although the shrinkage data provided above in Tables IX and
X pertain specifically to shrinkage after dyeing the inherently
flame resistant fibers, it is to be noted that the shrinkage of the
inherently flame resistant fibers of these fabric blends can be
controlled without actually dyeing the fibers. For instance, if a
blend having just the cellulosic fibers dyed (or no fibers dyed)
were desired, the dyeing process described above would be followed
with the exception that dye for the inherently flame resistant
fibers would not be included in the bath or other medium.
Similarly, just the inherently flame resistant fibers of the blend
could be dyed according to the present method, if desired.
[0045] The results of Tables I-X illustrate that blends of
inherently flame resistant fibers such as aromatic polyamides,
polyamide imides, and polyimides, and cellulosic fibers such as
rayon, acetate, triacetate, and lyocell that contain a flame
retardant compound can be effectively dyed such that the inherently
flame resistant fibers are dyed a full shade of color (including
deep shades, if desired), and the amount of flame retardant
compound contained in the cellulosic fibers substantially
maintained such that there is not a significant loss of flame
resistance in the end fabric. Moreover, these results show that
where inherently flame resistant fibers are susceptible to
laundering shrinkage, dyeing and/or shrinkage inhibiting according
to the present invention significantly reduces such shrinkage.
[0046] In the specification and examples, there have been disclosed
preferred embodiments of the invention, although specific terms are
employed, they are used in a generic and descriptive sense only and
not for the purpose of limitation, the scope of the invention being
defined by the following claims.
* * * * *