U.S. patent application number 15/768142 was filed with the patent office on 2018-11-01 for lightweight, printable flame resistant fabrics suitable for protective clothing worn in hot and/or humid environments.
This patent application is currently assigned to Southern Mills, Inc.. The applicant listed for this patent is Southern Mills, Inc.. Invention is credited to Charles S. Dunn, Michael T. Stanhope, Timothy James Thorne.
Application Number | 20180313006 15/768142 |
Document ID | / |
Family ID | 58558110 |
Filed Date | 2018-11-01 |
United States Patent
Application |
20180313006 |
Kind Code |
A1 |
Stanhope; Michael T. ; et
al. |
November 1, 2018 |
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.
Inventors: |
Stanhope; Michael T.;
(Atlanta, GA) ; Thorne; Timothy James; (Atlanta,
GA) ; Dunn; Charles S.; (Griffin, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Southern Mills, Inc. |
Union City |
GA |
US |
|
|
Assignee: |
Southern Mills, Inc.
Union City
GA
|
Family ID: |
58558110 |
Appl. No.: |
15/768142 |
Filed: |
October 21, 2016 |
PCT Filed: |
October 21, 2016 |
PCT NO: |
PCT/US16/58202 |
371 Date: |
April 13, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62244337 |
Oct 21, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D10B 2201/22 20130101;
D03D 15/12 20130101; D02G 3/443 20130101; D10B 2331/021 20130101;
D10B 2201/24 20130101; D10B 2401/14 20130101; D10B 2331/02
20130101; D03D 1/0035 20130101; D10B 2321/101 20130101 |
International
Class: |
D03D 15/12 20060101
D03D015/12; D03D 1/00 20060101 D03D001/00; D02G 3/44 20060101
D02G003/44 |
Claims
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.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 62/244,337, filed on Oct. 21, 2015, entitled
"Low Cost, Printable Flame Resistant Fabric for Combat Uniforms,"
the entirety of which is hereby incorporated by this reference.
FIELD
[0002] Embodiments of the present invention relate to flame
resistant fabrics for inclusion into protective garments for
military and electrical applications.
BACKGROUND
[0003] Protective garments are designed to protect the wearer from
hazardous environmental conditions the wearer might encounter. Such
garments include those designed to be worn by military personnel,
as well as firefighters and other rescue personnel and industrial
and electrical workers.
[0004] Standards have been promulgated that govern the performance
of such garments (or constituent fabrics of such garments) to
ensure that the garments sufficiently protect the wearer in
hazardous situations.
Military
[0005] GL-PD-07-12, Rev. 8 (Purchase Description: Cloth, Flame
Resistant, Nov. 26, 2014, incorporated herein by reference) and
MIL-PRF-EFRCE (Purchase Description: Uniform, Enhanced Flame
Resistant Combat Ensemble (EFRCE) Blouse and Trouser, September
2015, incorporated herein by reference) are military purchase
descriptions that set forth the performance requirements for
fabrics used in flame resistant garments for the army (GL-PD-07-12)
and marines (MIL-PRF-EFRCE).
[0006] Both purchase descriptions (GL-PD-07-12 and MIL-PRF-EFRCE)
include color requirements for military fabrics. More specifically,
both address the color shades and camouflage patterns to which the
fabrics must be colored, depending on the environment in which the
uniforms are intended to be worn. GL-PD-07-12, section 3.6.1;
MIL-PRF-EFRCE, sections 3.3.2 and 3.3.4. GL-PD-07-12 identifies the
following three camouflage patterns: [0007] Class 1, Universal
Camouflage Pattern (UCP) (section 3.6.1.1); [0008] Class 2,
Operation Enduring Freedom Camouflage Pattern (OEF-CP) (section
3.6.1.2); and [0009] Class 3, Operational Camouflage Pattern (OCP)
(section 3.6.1.3). MIL-PRF-EFRCE identifies the following fabric
types and colors/patterns: [0010] Cloth Type I (woven Woodland,
Marine Corps Pattern (MARPAT) camouflage printed) (sections 1.2.1
and 3.3.2.1); [0011] Cloth Type II (woven Desert MARPAT camouflage
printed) (sections 1.2.1 and 3.3.2.2); [0012] Cloth Type III (woven
Navy Working Uniform (NWU) II, Desert Digital camouflage printed)
(sections 1.2.1 and 3.3.2.3); [0013] Cloth Type IV (woven NWUIII,
Woodland Digital camouflage printed) (sections 1.2.1 and 3.3.2.4);
and [0014] Cloth Type V (knit Coyote 498 solid) (sections 1.2.1 and
3.3.2.5).
[0015] Both purchase descriptions set forth colorfastness
requirements for fabrics bearing each of the different colors
shades and patterns to ensure that the fabrics retain the desired
shade of color after laundering and environmental exposures (e.g.,
light, perspiration, etc.). GL-PD-07-12, section 3.6.3 and Table I
(Class 1), Table LA (Class 2), and Table I.B (Class 3);
MIL-PRF-EFRCE, section 3.3.5 and Tables I and II.
[0016] The purchase descriptions both also contain spectral or near
infrared reflectance requirements ("IR requirements") to help
ensure that fabrics complying with such IR requirements provide
better camouflage in the infra-red wavelengths of light used by
most night-vision devices. GL-PD-07-12, section 3.8 and Table II
(Class 1), Table II.A (Class 2), and Table II.B (Class 3);
MIL-PRF-EFRCE, section 3.3.7 and Table III (Cloth Type I), Table IV
(Cloth Type II), and Table V (Cloth Type V). In other words, the
camouflage fabrics blend into the background when viewed using
night vision equipment.
Electrical
[0017] Many occupations can potentially expose an individual to
electrical arc flash and/or flames. Workers who may be exposed to
accidental electric arc flash and/or flames risk serious burn
injury unless they are properly protected. To avoid being injured
while working in such conditions, these individuals typically wear
protective garments constructed of flame resistant materials
designed to protect them from electrical arc flash and/or flames.
Such protective clothing can include various garments, for example,
coveralls, pants, and shirts. Standards have been promulgated that
govern the performance of such garments (or constituent layers or
parts of such garments) to ensure that the garments sufficiently
protect the wearer in hazardous situations. Fabrics from which some
such garments are constructed, and consequently the resulting
garments as well, are required to pass a variety of safety and/or
performance standards, including ASTM F 1506 (Standard Performance
Specification for Flame Resistant and Arc Rated Textile Materials
for Wearing Apparel for Use by Electrical Workers Exposed to
Momentary Electric Arc and Related Thermal Hazards, 2015 edition,
incorporated herein by reference).
[0018] ASTM F 1506 requires that the garments and/or individual
layers or parts thereof pass a number of different performance
tests. Table 1 of ASTM F 1506 sets forth requirements for woven
fabrics, including (among others) strength requirements (e.g.,
tensile strength, tear strength), colorfastness and laundry
shrinkage requirements, and thermal protective requirements (e.g.,
minimal char length and afterflame requirements). As indicted in
Table 1, such requirements may differ depending on the weight of
the woven fabric tested. Table 2 of F 1506 sets forth the same
property requirements for knitted fabrics.
[0019] ASTM F 1506 requires all fabrics (woven or knitted) to have
a char length of 6 inches or less and have a two second (or less)
afterflame, when measured pursuant to the testing methodology set
forth in ASTM D6413 (Standard Test Method for Flame Resistance of
Textiles, 2015 edition, incorporated herein by reference). To test
for char length and afterflame, a fabric specimen is suspended
vertically over a flame for twelve seconds. The fabric must
self-extinguish within two seconds (i.e., it must have a 2 second
or less afterflame). After the fabric self-extinguishes, a
specified amount of weight is attached to the fabric and the fabric
lifted so that the weight is suspended from the fabric. The fabric
will typically tear along the charred portion of the fabric. The
length of the tear (i.e., the char length) must be 6 inches or less
when the test is performed in both the machine/warp and
cross-machine/fill directions of the fabric. A fabric sample is
typically tested for compliance both before it has been washed (and
thus when the fabric still contains residual--and often
flammable--chemicals from finishing processes) and after a certain
number of launderings (e.g., 25 launderings for ASTM F 1506).
SUMMARY
[0020] The terms "invention," "the invention," "this invention" and
"the present invention" used in this patent are intended to refer
broadly to all of the subject matter of this patent and the patent
claims below. Statements containing these terms should not be
understood to limit the subject matter described herein or to limit
the meaning or scope of the patent claims below. Embodiments of the
invention covered by this patent are defined by the claims below,
not this summary. This summary is a high-level overview of various
aspects of the invention and introduces some of the concepts that
are further described in the Detailed Description section below.
This summary is not intended to identify key or essential features
of the claimed subject matter, nor is it intended to be used in
isolation to determine the scope of the claimed subject matter. The
subject matter should be understood by reference to the entire
specification of this patent, all drawings and each claim.
[0021] Embodiments of the invention relate to 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.
DETAILED DESCRIPTION
[0022] The subject matter of embodiments of the present invention
is described here with specificity to meet statutory requirements,
but this description is not necessarily intended to limit the scope
of the claims. The claimed subject matter may be embodied in other
ways, may include different elements or steps, and may be used in
conjunction with other existing or future technologies. This
description should not be interpreted as implying any particular
order or arrangement among or between various steps or elements
except when the order of individual steps or arrangement of
elements is explicitly described.
[0023] Some embodiments of the invention include flame resistant
fabrics suitable for use in military uniforms. Such embodiments of
the fabrics preferably comply with the relevant color requirements
(including the color, colorfastness, and IR requirements) set forth
in sections 3.6 and 3.8 of GL-PD-07-12 and sections 3.3.2, 3.3.5,
and 3.3.7 of MIL-PRF-EFRCE. Moreover, some embodiments of the
fabrics are low weight and fast drying, rendering them particularly
suitable for hot and hot/humid conditions in that such fabrics
manage moisture effectively and dry quickly.
[0024] Other embodiments of the invention include flame resistant
fabrics that comply with requirements of ASTM F 1506 and thus are
suitable for electrical worker applications.
[0025] The fabrics may be woven or knitted from a combination of
spun yarns containing a blend of different types of fibers. The
spun yarns in the fabric may all have the same fiber blend, or the
fabric may be formed with spun yarns having different fiber
blends.
[0026] At least some of the spun yarns are formed of a blend that
includes modacrylic fibers. Examples of suitable modacrylic fibers
are PROTEX.TM. fibers available from Kaneka Corporation of Osaka,
Japan, SEF.TM. available from Solutia, PyroTex.RTM. available from
PyroTex Fibers GmbH, or blends thereof. The modacrylic fibers may
constitute 30-80%, inclusive; 35-70%, inclusive; and 40-60%,
inclusive, of the fiber blend.
[0027] In addition to modacrylic fibers, the blend may also include
aliphatic polyamides to increase the fabric strength and abrasion
resistance. Nylon or flame resistant ("FR") nylon, Nylon XF, and
Nylon HT are examples of suitable aliphatic polyamides for use in
the blend. In some embodiments, aliphatic polyamide fibers (such as
nylon and/or FR nylon fibers) constitute 5-50%, inclusive; 10-45%,
inclusive; 10-35%, inclusive; 15-30%, inclusive; and 20-30%,
inclusive of the fiber blend.
[0028] The fiber blend may further include FR or non-FR cellulosic
fibers, including, but not limited to, natural and synthetic
cellulosic fibers (e.g., cotton, rayon, acetate, triacetate, and
lyocell, as well as their flame resistant counterparts FR cotton,
FR rayon, FR acetate, FR triacetate, and FR lyocell). Examples of
rayon fibers include Viscose.TM. and Modal.TM. by Lenzing,
available from Lenzing Fibers Corporation. An example of an FR
rayon material is Lenzing FR.TM., also available from Lenzing
Fibers Corporation, and VISIL.TM., available from Sateri. Examples
of lyocell fibers include TENCEL.TM., TENCEL G100.TM. and TENCEL
A100.TM., all available from Lenzing Fibers Corporation.
[0029] In some embodiments, synthetic cellulosic fibers are
included in the fiber blend. In one embodiment, FR or non-FR
lyocell fibers are included in the blend. In some embodiments,
non-FR cellulosic fibers (such as non-FR lyocell fibers) constitute
10-60%, inclusive; 10-55%, inclusive; 10-50%, inclusive; 10-45%,
inclusive; 10-40%, inclusive; and 20-40%, inclusive, of the fiber
blend. In other embodiments, FR cellulosic fibers (such as FR
lyocell fibers) constitute 10-80%, inclusive; 15-75%, inclusive;
15-65%, inclusive; 15-50%, inclusive; 20-40%, inclusive; 10-40%,
inclusive; and 15-35%, inclusive, of the fiber blend.
[0030] In one specific, non-limiting embodiment, the fiber blend
includes a blend of modacrylic, nylon, and cellulosic fibers (e.g.,
synthetic cellulosic fibers such as lyocell fibers). For example,
in one embodiment the spun yarns are formed from a fiber blend
having approximately 30-80% modacrylic fibers, approximately 10-60%
cellulosic fibers (e.g., synthetic cellulosic), and approximately
5-50% nylon fibers. In yet another embodiment, the spun yarns are
formed from a fiber blend having approximately 35-70% modacrylic
fibers, approximately 10-50% cellulosic fibers (e.g., synthetic
cellulosic), and approximately 10-40% nylon fibers. For example, in
still another embodiment the spun yarns are formed from a fiber
blend having approximately 40-65% modacrylic fibers, approximately
10-40% cellulosic fibers (e.g., synthetic cellulosic), and
approximately 15-40% nylon fibers. The cellulosic fibers (such as
lyocell) and nylon fibers used in these blends can be FR or non-FR.
The spun yarns of these embodiments are devoid of additional
inherently flame resistant fibers, such as aramid fibers. The same
types of modacrylic fibers, cellulosic fibers, and nylon fibers
need not be used in the blend. Rather, multiple types of each may
be blended together.
[0031] The cellulosic fibers are provided in the blend to increase
the comfort and moisture management of the fabric. In some
embodiments, however, it may be desirable (but not required) to use
lower levels of cellulosic fibers to help reduce fabric drying
time. In some embodiments, the cellulosic fibers constitute less of
the fiber blend than the nylon fibers.
[0032] Given the flammable nature of non-FR nylon and non-FR
synthetic cellulosic fibers (at least as compared to FR fibers), it
may be advisable in some embodiments to ensure that the modacrylic
fibers constitute more of the fiber blend than each of the non-FR
nylon and non-FR lyocell fibers. The modacrylic fibers control and
counteract the flammability of the non-FR nylon and non-FR lyocell
fibers to prevent them from burning. It may be preferable in some
embodiments to ensure that the modacrylic fibers constitute more of
the fiber blend that the non-FR nylon and non-FR lyocell fibers
combined. In some embodiments, the fiber blend is devoid of other
FR fibers typically used in FR fabrics to impart FR properties to
the fabrics, such as, but not limited to, aramid fibers such as
meta- and para-aramid fibers.
[0033] However, in other embodiments other fibers are added to the
fiber blend of the spun yarns, including, but not limited to,
additional inherently FR fibers and/or non-inherently FR fibers (FR
or non-FR). Exemplary suitable FR and non-FR fibers include, but
are not limited to, para-aramid fibers, meta-aramid fibers,
polybenzoxazole ("PBO") fibers, polybenzimidazole ("PBI") fibers,
poly{2,6-diimidazo [4,5-40;
50-e]-pyridinylene-1,4(2,5-dihydroxy)phenylene} ("PIPD") fibers,
ultra-high molecular weight (UHMW) polyethylene fibers, UHMW
polypropylene fibers, polyvinyl alcohol fibers, polyacrylonitrile
(PAN) fibers, liquid crystal polymer fibers (e.g., aromatic
polyesters such as VECTRAN), glass fibers, polynosic rayon fibers,
carbon fibers, silk fibers, polyamide fibers, polyester fibers,
aromatic polyester fibers, TANLON.TM. fibers (available from
Shanghai Tanlon Fiber Company), wool fibers, melamine fibers (such
as BASOFIL.TM., available from Basofil Fibers), polyetherimide
fibers, polyethersulf one fibers, pre-oxidized acrylic fibers,
polyamide-imide fibers such as KERMEL.TM., polytetrafluoroethylene
fibers, polyvinyl chloride fibers, polyetheretherketone fibers,
polyetherimide fibers, polychlal fibers, polyimide fibers,
polyamide fibers, polyimideamide fibers, polyolefin fibers,
polyacrylate fibers, and any combination or blend thereof. In some
embodiments, however, embodiments of the fabrics contemplated
herein are devoid of any and/or all of these additional inherently
FR fibers and/or non-inherently FR fibers (FR or non-FR).
[0034] Examples of para-aramid fibers include KEVLAR.TM. (available
from DuPont), TECHNORA.TM. (available from Teijin Twaron BV of
Arnheim, Netherlands), and TWARON.TM. (also available from Teijin
Twaron BV). Examples of meta-aramid fibers include NOMEX.TM.
(available from DuPont), CONEX.TM. (available from Teijin), and
APYEIL.TM. (available from Unitika). An example of a polyester
fiber is DACRON.RTM. (available from Invista.TM.). An example of a
PIPD fiber includes M5 (available from Dupont). An example of
melamine fibers is BASOFIL.TM. (available from Basofil Fibers). An
example of PAN fibers is Panox.RTM. (available from the SGL Group).
Examples of UHMW polyethylene materials include Dyneema and
Spectra. An example of a liquid crystal polymer material is
VECTRAN.TM. (available from Kuraray).
[0035] Moreover, anti-static fibers, anti-microbial fibers, and/or
stretch fibers may also be added to the blend.
[0036] The spun yarns can be formed in conventional ways well known
in the industry. The spun yarns can comprise a single yarn or two
or more individual yarns that are twisted, plied, or otherwise
combined together.
[0037] The spun yarns can subsequently be used to form fabrics in a
variety of ways, all well known in the industry. The yarns can be
knitted or woven. In one embodiment, the fabric is formed as a
plain weave fabric or a twill weave (e.g. 2.times.1 twill) fabric
that comprises a plurality of body yarns. However, it will be
appreciated that other configurations could be used including, for
instance, a rip-stop weave, sateen weave, etc.
[0038] Some embodiments of the present invention incorporate into
the fabric reinforcing yarns intended to enhance the strength
properties (tensile, tear, etc.) of the fabric. The reinforcing
yarns may be spun yarns (such as, but not limited to, those
described above), continuous filament yarns, stretch broken yarns,
and combinations thereof. The reinforcing yarns may be of any size
(i.e., of any cotton count or denier). The reinforcing yarns may be
formed from a variety of different materials, including, but not
limited to, polyamides (e.g., nylon), high density polyethylene,
rayon (FR or non-FR), polyester, aramids (meta-aramid and
para-aramid), as well as the other inherently FR fibers and/or
non-inherently FR fibers (FR or non-FR) identified above. In some
embodiments, the reinforcing yarns are nylon continuous filament
yarns.
[0039] In some embodiments, the body of the fabric is formed of
spun yarns (such as those described above) and the reinforcing
yarns are provided in one or both of the machine/warp and
cross-machine/fill directions of the fabric. In some embodiments,
the reinforcing yarns are provided in both the machine/warp and
cross-machine/fill directions of the fabric so as to create a
grid-like pattern. The occurrence of the reinforcing yarns may be
the same or different in each fabric direction. The reinforcing
yarns may be provided in isolation or may be combined, coupled, or
covered (i.e., plied, ply twist, wrapped, coresheath, coverspun,
etc.) with one or more other yarns (or staple fibers).
[0040] The reinforcing yarns may be provided at any frequency
within the fabric. For example, a reinforcing yarn may be provided
every n.sup.th end or pick. The frequency at which reinforcing
yarns are used (i.e., the value of "n") can be the same or
different (1) within a direction of the fabric and/or (2) in
different directions of the fabric. In some embodiments, the value
of "n" can be anywhere between 1-60, inclusive; 1-50, inclusive;
1-40, inclusive; 1-30, inclusive; 1-20, inclusive; 1-10, inclusive;
and 1-5, inclusive, such that at least (n-1) ends or picks of body
yarns are positioned between the adjacent reinforcing yarns that
are separated by body yarns.
[0041] Moreover, it is also contemplated that two or more
reinforcing yarns may be provided directly adjacent each other
(i.e., not separated from each other by body yarns) in one or both
directions of the fabric. In other words, at least some occurrences
of reinforcing yarns in the fabric may include three reinforcing
yarns in a row, four reinforcing yarns in a row, five reinforcing
yarns in a row, etc.
[0042] The frequency of the occurrence of reinforcing yarns as well
as the number of reinforcing yarns provided at each such occurrence
may depend on the desired strength properties of the fabric as well
as the size of the reinforcing yarns. If a larger sized reinforcing
yarn is used, only one such yarn inserted every n.sup.th end and/or
pick may provide sufficient reinforcement to the fabric.
Conversely, if a smaller reinforcement yarn is used, two or more
ends or picks of such yarns may be desired where reinforcing yarns
are provided in the fabric. In some embodiments, the reinforcing
yarns comprise 5-40% of the overall fabric weight.
[0043] In some embodiments, the fabrics disclosed herein have a
weight between 2-12 ounces per square yard ("osy"), inclusive; 2-10
osy, inclusive; 2-9 osy, inclusive; 2-8 osy, inclusive; 2-7 osy,
inclusive; 2-6 osy, inclusive; 2-5 osy, inclusive; 2-4 osy,
inclusive; 3-10 osy, inclusive; 3-8 osy, inclusive; 3-6 osy,
inclusive; and 3-5 osy, inclusive. In some embodiments, the fabric
weight is 4-10 osy, inclusive, and/or is less than or equal to 6
osy.
[0044] Desired colors may be imparted in a variety of ways and with
a variety of dyes to the fabrics disclosed herein. In some
embodiments, the fabrics are printable and/or dyeable with vat dyes
to colors and/or patterns that enable the fabrics to comply with
various military requirements (including, but not limited to, the
color, colorfastness, and IR requirements set forth in sections 3.6
and 3.8 of GL-PD-07-12 and/or sections 3.3.2, 3.3.5, and 3.3.7 of
MIL-PRF-EFRCE). For example, such fabrics may be printed in
compliance with the such color requirements with vat dyes using
known printing techniques. In some embodiments, 100% of the fabric
surface is vat dye printed. However, other dyes and dyeing/printing
methodologies may be used to color the fabrics. Moreover, some
embodiments are the fabrics contemplated herein are dyed/printed in
a solid shade devoid of pattern.
[0045] Fabrics that may not be--but that are capable of being--dyed
and/or printed with vat dyes to colors and/or patterns that comply
with the color, colorfastness, and IR requirements set forth in
sections 3.6 and 3.8 of GL-PD-07-12 and/or sections 3.3.2, 3.3.5,
and 3.3.7 of MIL-PRF-EFRCE are intended to be covered by this
patent.
[0046] The different patterns specified in each purchase
description have different color requirements. The relevant
sections of each purchase description that govern the color,
colorfastness and IR requirements of a particular pattern is set
forth below in Table 1 (for GL-PD-07-12) and Table 2 (for
MIL-PRF-EFRCE). It will be obvious to one of skill in the art that
a fabric printed with a particular pattern need only satisfy the
requirements specified for that particular pattern.
TABLE-US-00001 TABLE 1 (GL-PD-07-12 Requirements) GL-PD-07-12
GL-PD-07-12 Color Colorfastness GL-PD-07-12 Pattern Requirement
Requirement IR Requirement Class 1, Universal section 3.6.1.1
section 3.6.3, section 3.8.1, Camouflag Pattern Table I Table II
(UCP) Class 2, Operation section 3.6.1.2 section 3.6.3, section
3.8.2, Enduring Freedom Table I.A Table II.A Camouflage Pattern
(OEF-CP) Class 3, Operational section 3.6.1.3 section 3.6.3,
section 3.8.3, Camouflage Pattern Table I.B Table II.B (OCP)
TABLE-US-00002 TABLE 2 (MIL-PRF-EFRCE Requirements) MIL-PRF-EFRCE
MIL-PRF-EFRCE MIL-PRF-EFRCE Color Colorfastness IR Pattern
Requirement Requirement Requirement Cloth Type I section 3.3.2.1
section 3.3.5, section 3.3.7.1 (Woodland Table I MARPAT) Cloth Type
II section 3.3.2.2 section 3.3.5, section 3.3.7.2 (Desert Table I
MARPAT) Cloth Type III section 3.3.2.3 section 3.3.5, section
3.3.7.3 (NWU II) Table I Cloth Type IV section 3.3.2.4 section
3.3.5, section 3.3.7.3 (NWUIII) Table I Cloth Type V section
3.3.2.5 section 3.3.5, section 3.3.7.4 (Coyote solid) Table II
[0047] Specific, non-limiting examples of fabrics in accordance
with embodiments of the invention are described as follows: [0048]
Modacrylic Blend Ripstop: A 5.4 osy fabric formed of spun yarns
comprising 55% modacrylic fibers, 25% non-FR nylon fibers, and 20%
non-FR lyocell fibers. The fabric is a plain weave with a ripstop
provided every 20.sup.th and 21.sup.st end and every 11.sup.th and
12.sup.th pick. [0049] High Strength Modacrylic Blend Ripstop: A
5.6 osy fabric formed of spun yarns comprising 55% modacrylic
fibers, 25% non-FR nylon fibers, and 20% non-FR lyocell fibers. The
fabric is a plain weave ripstop whereby two reinforcing yarns, each
formed of a 100 denier nylon continuous filament yarn plied with a
20 singles spun yarn (the same as used in the rest of the fabric),
are provided every 20.sup.th and 21.sup.st end and every 11.sup.th
and 12.sup.th pick. [0050] High Strength Modacrylic Blend Twill: A
5.6 osy fabric formed of spun yarns comprising 55% modacrylic
fibers, 25% non-FR nylon fibers, and 20% non-FR lyocell fibers. The
fabric is a twill weave with two reinforcing yarns, each formed of
a 100 denier nylon continuous filament yarn plied with a 20 singles
spun yarn (the same as used in the rest of the fabric), provided
every 20.sup.th an 21.sup.st end and every 11.sup.th and 12.sup.th
pick.
[0051] Table 3 sets forth performance data for printed versions of
the Modacrylic Blend Ripstop, High Strength Modacrylic Blend
Ripstop, and High Strength Modacrylic Blend Twill and compares that
data against the applicable requirements of GL-PD-07-12,
MIL-PRF-EFRCE, and ASTM F 1506.
TABLE-US-00003 TABLE 3 GL PD 07 12 MIL-PRF- Purchase EFRCE ASTM F
Description, Purchase 1506-10a Modacrylic High Strength High
Strength Section 3.9, Description, Standard Blend Modacrylic
Modacrylic Table III, Section Performance Characteristic Ripstop
Blend Ripstop Blend Twill Type III 3.3.1, Table 1 Specification
Test Method Fiber Blend (% Fiber) Modacrylic 55 55 55 -- -- --
AATCC 20 Nylon (non-FR) 25 25 25 -- -- -- Lyocell (non-FR) 20 20 20
-- -- -- Yarns in grid 20/1's spun 100 d filament 100 d filament
N/A N/A N/A N/A yarn nylon plied with nylon plied with 20/1's spun
yarn 20/1's spun yarn Warp grid yarns ends 20 & 21 ends 20
& 21 ends 20 & 21 N/A N/A N/A N/A (weave as one) (weave as
one) (weave separate) Fill grid yarns picks 11 & 12 picks 11
&12 picks 11 & 12 N/A N/A N/A N/A (weave as one) (weave as
one) (weave as one) Construction 85 .times. 56 81 .times. 53 77
.times. 55 60 .times. 50 (min) N/A N/A ASTM D 3775 (w .times. f)
Weight (oz/yd.sup.2) 5.4 5.6 5.6 6.0-7.0 6.4-7.1 3.0-5.9 ASTM D
3776 Elmendorf Tear Strength (lbf, w .times. f) Dry 7.7 .times. 6.2
17.2 .times. 18.6 22.4 .times. 23.5 12.0 .times. 10.0 (min) 12
.times. 16 (min) 2.5 (min) ASTM 1424 Wet 8.7 .times. 6.1 18.7
.times. 22.9 21.9 .times. 22.4 8.0 .times. 6.0 (min) 12 .times. 16
(min) N/A Tensile Strength (lbf, w .times. f) Dry 106 .times. 73
111 .times. 72 157 .times. 102 110 .times. 100 (min) 165 .times.
150 (min) 30 (min) ASTM D 5034 Wet 95 .times. 68 101 .times. 68 145
.times. 92 N/A 140 .times. 125 (min) N/A Flame Resistance Before
Laundering (w .times. f) After Flame (sec) 0 .times. 0 0 .times. 0
0 .times. 0 2.0 .times. 2.0 (max) 2.0 .times. 2.0 (max) 2.0 .times.
2.0 (max) ASTM D 6413 Char Length (in) 5.6 .times. 5.5 6.4 .times.
6.1 6.0 .times. 5.7 4.5 .times. 4.5 (max) 5.0 .times. 5.0 (max) 6.0
.times. 6.0 (max) Melt/Drip None None None None None N/A Laundered
25.times. (w .times. f) After Flame (Sec) 0 .times. 0 0 .times. 0 0
.times. 0 2.0 .times. 2.0 (max) 2.0 .times. 2.0 (max) 2.0 .times.
2.0 (max) AATCC 135, Char Length (in) 5.5 .times. 5.8 5.3 .times.
6.3 5.7 .times. 6.4 4.5 .times. 4.5 (max) 5.0 .times. 5.0 (max) 6.0
.times. 6.0 (max) 3,V, Aiii Melt/Drip None None None None None N/A
Arc Test Results (single layer): Afterflame Time Less than 5 Less
than 5 Less than 5 N/A N/A 5 (max) ASTM F 1959 (sec) Laundry
Shrinkage (% change, w .times. f) Laundered 5.times. 0.8 .times.
0.7 1.4 .times. 0.8 1.4 .times. 1.4 4.0 .times. 4.0 (max) 5.0
.times. 5.0 (max) 3.0 .times. 3.0 (max) GL-PD-07-12: (AATCC 135,
(AATCC 135, (AATCC 135, (AATCC 135, (AATCC 96 (AATCC 135, AATCC
135, 3, V, Aiii) 3, V, Aiii) 3, V, Aiii) 3, V, Aiii) Vic, Dry A) 3,
IV, Aiii) 3, V, Aiii MIL-PRF- EFRCE: AATCC 96 Vic, Dry A ASTM F
1506- 10a: AATCC 135, 3, IV, Aiii Air Permeability 44.8 76.3 85.1
25.0 (min) 20.0 (min) N/A ASTM D 737 (ft..sup.3/min./ft..sup.2)
Colorfastness: Laundering shade Complies Complies Complies N/A N/A
Class 3 (min) AATCC 612A, change 1.times. AATCC 132 Dry-cleaning
Complies Complies Complies N/A N/A Class 3 (min) shade change
All of the testing methodologies referenced throughout this
document are hereby incorporated by reference.
[0052] With respect to GL-PD-07-12 and MIL-PRF-EFRCE, the
Modacrylic Blend Ripstop, High Strength Modacrylic Blend Ripstop,
and High Strength Modacrylic Blend Twill surpass almost every
required fabric property set forth in the purchase descriptions.
For example, these fabrics exceed the tear strength requirements
despite being of lighter weights than specified in the purchase
descriptions.
[0053] Tear strength is a measure of the amount of force required
to propagate in a fabric a tear after its initiation. The tear
strength of fabrics is measured pursuant to ASTM D1424-09 (Standard
Test Method for Tearing Strength of Fabrics by Falling-Pendulum
(Elmendorf-Type) Apparatus (2013 edition), incorporated by
reference), and the results are reported in pounds force (lbf).
[0054] Pursuant to ASTM D1424-09, a slit of a specified size is cut
into a fabric sample of a specified size. A clamp positioned on the
fabric sample on each side of the slit to support the fabric
sample. A weighted pendulum is released and swings down to apply a
force to the fabric sample. The amount of force required to
propagate the existing tear in the fabric is measured and that
amount of force represents the tear strength of the fabric.
[0055] The tear strength of fabrics according to embodiments of the
invention can be enhanced by inclusion of the reinforcing yarns
(such as, e.g., stretch broken and/or filaments yarns, as discussed
above) in the fabric. This can be seen, for example, by comparing
the tear strength of the Modacrylic Blend Ripstop (devoid of nylon
filament yarns) against the stronger High Strength Modacrylic Blend
Ripstop and High Strength Modacrylic Blend Twill, which each
include nylon filament reinforcing yarns (see Table 3 above).
[0056] Some embodiments of the fabrics (particularly, but not
necessarily, those having reinforcing yarns) have tear strengths
greater or equal to 14 pounds force in one or both of the warp and
fill directions. Some embodiments of the fabrics (particularly, but
not necessarily, those having reinforcing yarns) have tear
strengths greater or equal to 14 pounds force in one or both of the
warp and fill directions while being of relatively low weight (6
osy or less). Some embodiments of the fabrics (particularly, but
not necessarily, those having reinforcing yarns) have tear
strengths greater or equal to 16 pounds force in one or both of the
warp and fill directions. Some embodiments of the fabrics
(particularly, but not necessarily, those having reinforcing yarns)
have tear strengths greater or equal to 16 pounds force in one or
both of the warp and fill directions while being of relatively low
weight (6 osy or less). Some embodiments of the fabrics
(particularly, but not necessarily, those having reinforcing yarns)
have tear strengths greater or equal to 19 pounds force in one or
both of the warp and fill directions. Some embodiments of the
fabrics (particularly, but not necessarily, those having
reinforcing yarns) have tear strengths greater or equal to 19
pounds force in one or both of the warp and fill directions while
being of relatively low weight (6 osy or less). Some embodiments of
the fabrics (particularly, but not necessarily, those having
reinforcing yarns) have tear strengths greater or equal to 21
pounds force in one or both of the warp and fill directions. Some
embodiments of the fabrics (particularly, but not necessarily,
those having reinforcing yarns) have tear strengths greater or
equal to 21 pounds force in one or both of the warp and fill
directions while being of relatively low weight (6 osy or
less).
[0057] In some embodiments, inclusion of reinforcing yarns (such
as, e.g., stretch broken and/or filaments yarns, as discussed
above) in the fabric increases the tear strength of the fabric (in
either or both of the warp direction and fill direction) by at
least 50%; at least 60%; at least 70%; at least 80%; at least 90%;
at least 100%; at least 105%; at least 120%; at least 140%; and/or
at least 170%. Such improvement in tear strength can be seen by
comparing the tear strength of the fabric formed only with spun
body yarns against the tear strength of an otherwise identical
fabric that is formed with the same spun body yarns but with
reinforcing yarns as well. Such improvement in tear strength can
been see, for example, by comparing the tear strength results of
the Modacrylic Blend Ripstop against the High Strength Modacrylic
Blend Ripstop in Table 3.
[0058] The tear strength of the greige fabrics identified in Table
4 were tested. More specifically, four woven fabrics were formed,
each with one of the body yarn types identified in Table 4. In
other words, the first fabric was formed with body yarns having a
65/25/10 FR rayon/para-aramid/nylon fiber blend. The second fabric
was formed with body yarns having a 93/5/2
meta-aramid/para-aramid/anti-static fiber blend. The third fabric
was formed with body yarns having a 48/37/15
modacrylic/lyocell/para-aramid fiber blend. The fourth fabric was
formed with body yarns having a 55/25/20 modacrylic/nylon/lyocell
fiber blend and represents an embodiment of a fabric made pursuant
to the present invention.
[0059] The fabrics were woven both without reinforcing yarns (i.e.,
the fabrics only included body yarns) and with identical
reinforcing yarns. The break or tensile strength of the body yarns
and reinforcing yarns was measured (pursuant to ASTM D5034
(Standard Test Method for Breaking Strength and Elongation of
Textile Fabrics (Grab Test) (2013 edition)), and the results were
reported in pounds force. Moreover, the tear strength of the
fabrics in the fill direction, both with and without reinforcing
yarns, was also measured (pursuant to ASTM D1424). The results are
graphically represented in Graph 1.
TABLE-US-00004 TABLE 4 Non- Body Reinforcing Reinforced Reinforced
% Filling Yarn Yarn Fabric Fabric Tear Strength Breaking Breaking
Filling Tear Filling Tear Increase with Strength Strength Strength
Strength Reinforcement Body Yarn/Fabric Fiber Blend (lbf) (lbf)
(lbf) (lbf) Yarns 65/25/10 FR rayon/para-aramid/nylon 1.9 2.2 9.4
10.9 16.0 93/5/2 meta-aramid/para-aramid/anti-static 1.8 2.2 12.8
12.2 -4.7 48/37/15 modacrylic/lyocell/para-aramid 1.33 2.2 11.9
17.5 47.1 55/25/20 modacrylic/nylon/lyocell 1.15 2.2 9.3 14.6
57.0
[0060] The data demonstrates that the reinforcing yarns were
significantly more effective when included in a fabric having
weaker body yarns. For example, the first fabric has body yarns
that are significantly stronger than those of the fourth fabric.
Not surprising, inclusion of the same reinforcing yarns in each of
these fabrics increased the overall tear strength of each fabric.
However, what is surprising is the efficacy of such reinforcing
yarns in fabrics made from weaker yarns. Inclusion of the
reinforcing yarns in the fabric with the strongest body yarns (the
first fabric) only resulted in a 16% improvement in fabric tear
strength. However, inclusion of the same reinforcing yarns in the
fabric with the weakest body yarns (the fourth fabric) led to a 57%
increase in fabric tear strength. Not only that, the tear strength
of the reinforced fabric formed with the weaker yarns actually
surpassed the tear strength of the reinforced fabric formed with
the strongest yarns.
[0061] Embodiments of the fabrics disclosed herein are printable
and/or dyeable with vat dyes so as to comply with at least one of
the following: [0062] GL-PD-07-12, sections 3.6.1.1, 3.6.3 (Table
I), and 3.8.1; [0063] GL-PD-07-12, sections 3.6.1.2, 3.6.3 (Table
I.A), and 3.8.2; [0064] GL-PD-07-12, sections 3.6.1.3, 3.6.3 (Table
I.B), and 3.8.3; [0065] MIL-PRF-EFRCE, sections 3.3.2.1, 3.3.5
(Table I), and 3.3.7.1; [0066] MIL-PRF-EFRCE, sections 3.3.2.2,
3.3.5 (Table I), and 3.3.7.2; [0067] MIL-PRF-EFRCE, sections
3.3.2.3, 3.3.5 (Table I), and 3.3.7.3; [0068] MIL-PRF-EFRCE,
sections 3.3.2.4, 3.3.5 (Table I), and 3.3.7.3; and [0069]
MIL-PRF-EFRCE, sections 3.3.2.5, 3.3.5 (Table II), and 3.3.7.4.
[0070] By way only of example, High Strength Modacrylic Blend Twill
fabric was vat dye printed with the Class 3, Operational Camouflage
Pattern (OCP) pattern specified in GL-PD-07-12, section 3.6.1.3.
The colorfastness and near IR reflectance of the fabric was tested
and compared against the applicable GL-PD-07-12 requirements for
the OCP pattern. Table 5 compares the colorfastness of the High
Strength Modacrylic Blend Twill fabric with the OCP pattern against
the colorfastness requirements for that pattern (GL-PD-07-12,
section 3.6.3 and Table I.B). Table 6 compares the spectral or near
IR reflectance of the High Strength Modacrylic Blend Twill fabric
with the OCP pattern against the spectral reflectance requirements
for that pattern (GL-PD-07-12, section 3.8.3 and Table II.B). The
High Strength Modacrylic Blend Twill fabric with the OCP pattern
passed all of the applicable colorfastness and near IR reflectance
requirements for that pattern.
TABLE-US-00005 TABLE 5 (Colorfastness) GL-PD-07-12 Purchase
Description, Class 3 High Operational Strength Camouflage
Modacrylic Pattern (OCP), Blend Section 3.6, Test Colorfastness to:
Twill Table I.B Method Pattern OCP OCP Light 40 hrs (rating) AATCC
16 Dark Cream 599 3 3 (min) Tan 525 3 3 (min) Light Sage 560 3 3
(min) Olive 527 3-4 3 (min) Dark Green 528 3-4 3-4 (min) Brown 529
3-4 3-4 (min) Bark Brown 561 4 3-4 (min) Crocking Dry (rating) Dark
Cream 599 5 4 (min) AATCC 8 Tan 525 5 4 (min) Light Sage 560 5 4
(min) Olive 527 5 4 (min) Dark Green 528 5 3 (min) Brown 529 4.5 3
(min) Bark Brown 561 4.5 3 (min) Wet (rating) Dark Cream 599 4.5
3.5 (min) Tan 525 4.5 3.5 (min) Light Sage 560 4.5 3.5 (min) Olive
527 4 3.5 (min) Dark Green 528 4 2 (min) Brown 529 3 2 (min) Bark
Brown 561 2 2 (min) Laundering Shade Change (rating) AATCC 61 3A,
1.times. Dark Cream 599 4-5 3 (min) Tan 525 4-5 3 (min) Light Sage
560 4-5 3 (min) Olive 527 4-5 3 (min) Dark Green 528 5 2-3 (min)
Brown 529 4-5 2-3 (min) Bark Brown 561 4-5 2-3 (min) Staining -
Cotton (rating) Dark Cream 599 5 3 (min) Tan 525 5 3 (min) Light
Sage 560 4-5 3 (min) Olive 527 5 3 (min) Dark Green 528 5 2-3 (min)
Brown 529 4-5 2-3 (min) Bark Brown 561 4-5 2-3 (min) Staining -
Nylon (rating) Dark Cream 599 4 3 (min) Tan 525 4 3 (min) Light
Sage 560 3-4 3 (min) Olive 527 4-5 3 (min) Dark Green 528 5 2-3
(min) Brown 529 3-4 2-3 (min) Bark Brown 561 3-4 2-3 (min) Staining
- Overall (rating) Dark Cream 599 4-5 3 (min) Tan 525 4-5 3 (min)
Light Sage 560 4 3 (min) Olive 527 4-5 3 (min) Dark Green 528 4-5
2-3 (min) Brown 529 4 2-3 (min) Bark Brown 561 4-5 2-3 (min)
Perspiration Color Change (rating) AATCC 15 Dark Cream 599 5 3-4
(min) Tan 525 5 3-4 (min) Light Sage 560 5 3-4 (min) Olive 527 5
3-4 (min) Dark Green 528 5 3-4 (min) Brown 529 5 3-4 (min) Bark
Brown 561 5 3-4 (min) Staining (rating) Dark Cream 599 5 3-4 (min)
Tan 525 5 3-4 (min) Light Sage 560 5 3-4 (min) Olive 527 5 3-4
(min) Dark Green 528 5 3-4 (min) Brown 529 5 3-4 (min) Bark Brown
561 5 3-4 (min)
TABLE-US-00006 TABLE 6 (Spectral/IR Reflectance) (3) Light Sage 560
(1) Dark Cream 559 (4) Olive 527 (6) Dark Green 528 Wavelength (2)
Tan 525 (5) Brown 529 (7) Bark Brown 561 (nm) MIN Actual MAX MIN
Actual MAX MIN Actual MAX 600 22 (1) 38; (2) 31 44 12 (3) 25; (4)
23; (5) 15 30 3 (6) 13; (7) 8 11 620 24 (1) 39; (2) 32 45 12 (3)
25; (4) 24; (5) 16 30 3 (6) 12; (7) 9 12 640 24 (1) 42; (2) 36 45
12 (3) 26; (4) 25; (5) 18 32 4 (6) 13; (7) 9 13 660 25 (1) 45; (2)
40 45 12 (3) 28; (4) 26; (5) 19 32 4 (6) 13; (7) 11 14 680 28 (1)
47; (2) 43 45 14 (3) 29; (4) 27; (5) 20 34 4 (6) 14; (7) 14 17 700
28 (1) 48; (2) 44 48 14 (3) 30; (4) 28; (5) 22 36 6 (6) 15; (7) 17
23 720 30 (1) 50; (2) 46 52 16 (3) 30; (4) 30; (5) 25 39 6 (6) 18;
(7) 20 23 740 32 (1) 51; (2) 47 55 18 (3) 31; (4) 31; (5) 28 41 10
(6) 21; (7) 22 25 760 36 (1) 53; (2) 49 56 20 (3) 33; (4) 32; (5)
32 43 14 (6) 25; (7) 25 30 780 38 (1) 54; (2) 51 57 22 (3) 34; (4)
34; (5) 34 45 18 (6) 28; (7) 27 35 800 40 (1) 56; (2) 53 57 22 (3)
36; (4) 36; (5) 37 45 21 (6) 31; (7) 28 40 820 44 (1) 57; (2) 54 58
24 (3) 38; (4) 38; (5) 38 46 24 (6) 33; (7) 30 42 840 46 (1) 60;
(2) 58 59 26 (3) 41; (4) 40; (5) 41 47 26 (6) 35; (7) 32 43 860 48
(1) 62; (2) 60 60 28 (3) 43; (4) 43; (5) 44 48 28 (6) 38; (7) 35
45
[0071] Fabrics according to some embodiments of the invention are
self-extinguishing, exhibit no melt or drip when exposed to a flame
or thermal event, and/or have an afterflame of less than or equal
to two seconds when tested in accordance with ASTM D6413. While the
char lengths of the tested fabrics failed to comply with the
requirements of GL-PD-07-12 and MIL-PRF-EFRCE, fabrics according to
some embodiments of the invention have a char length of 6 inches or
less and of 7 inches or less, when tested pursuant to ASTM
D6413.
[0072] As evident in Table 3, some embodiments fully comply with
the requirements of ASTM F 1506, including exhibiting a char length
of 6 inches or less when tested in accordance with ASTM D6413. It
is expected that increasing the weight of the fabrics tested would
increase the likelihood the fabric complying fully with the
requirements of ASTM F 1506.
[0073] Embodiments of the flame resistant fabrics disclosed herein
can be used to construct the entirety of, or various portions of, a
variety of protective garments for use in military applications
and/or electrical applications, including, but not limited to,
combat uniforms, coveralls, jumpsuits, shirts, jackets, vests, and
trousers. Low weight versions (e.g., 6 osy or less) of fabrics
disclosed herein may be particularly suitable for inclusion in
uniforms for use in hot and hot/humid environments, such as
deserts, jungles, and other tropical environments.
[0074] Different arrangements of the components described above, as
well as components and steps not shown or described are possible.
Similarly, some features and subcombinations are useful and may be
employed without reference to other features and subcombinations.
Embodiments of the invention have been described for illustrative
and not restrictive purposes, and alternative embodiments will
become apparent to readers of this patent. Accordingly, the present
invention is not limited to the embodiments described above or
depicted in the drawings, and various embodiments and modifications
can be made without departing from the scope of the invention.
* * * * *