U.S. patent number RE42,209 [Application Number 11/715,985] was granted by the patent office on 2011-03-08 for patterned, flame resistant fabrics and method for making same.
This patent grant is currently assigned to Southern Mills, Inc.. Invention is credited to Clyde C. Lunsford, Phillip H. Riggins, Michael T. Stanhope.
United States Patent |
RE42,209 |
Lunsford , et al. |
March 8, 2011 |
Patterned, flame resistant fabrics and method for making same
Abstract
The present disclosure relates to patterned, flame resistant
fabrics and methods of making them. Generally speaking, the fabrics
comprise a plurality of high tenacity, flame resistant fibers, and
a plurality of cellulosic fibers containing a flame retardant
compound, and at least one color which is printed on the fabric to
form the pattern. In a preferred embodiment, the flame resistant
fibers are para-aramid fibers and the cellulosic fibers are rayon
fibers to yield a strong, flame resistant fabric.
Inventors: |
Lunsford; Clyde C. (Sharpsburg,
GA), Riggins; Phillip H. (Greensboro, NC), Stanhope;
Michael T. (Atlanta, GA) |
Assignee: |
Southern Mills, Inc. (Union
City, GA)
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Family
ID: |
34277906 |
Appl.
No.: |
11/715,985 |
Filed: |
March 8, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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60149792 |
Aug 19, 1999 |
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Reissue of: |
09641830 |
Aug 18, 2000 |
06867154 |
Mar 15, 2005 |
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Current U.S.
Class: |
442/136; 2/7;
442/164; 428/543 |
Current CPC
Class: |
D06P
1/6426 (20130101); D06P 1/66 (20130101); D06P
3/8219 (20130101); D06P 1/65118 (20130101); D06P
3/8214 (20130101); D06P 1/6495 (20130101); Y10T
428/8305 (20150401); Y10T 442/2631 (20150401); Y10S
8/925 (20130101); Y10T 442/2869 (20150401); Y10T
442/2861 (20150401) |
Current International
Class: |
B32B
27/04 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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50-90778 |
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Jul 1975 |
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JP |
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58-87366 |
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May 1983 |
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JP |
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58-87376 |
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May 1983 |
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JP |
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Primary Examiner: Singh-Pandey; Arti
Attorney, Agent or Firm: Kilpatrick Townsend & Stockton
LLP
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent
application Ser. No. 09/062,805, filed Apr. 20, 1998, now U.S. Pat.
No. 6,132,476, and further claims the benefit of the filing date of
U.S. Provisional Patent Application Ser. No. 60/149,792, filed Aug.
19, 1999. Both of these applications are hereby incorporated by
reference into the present disclosure.
Claims
What is claimed is:
1. A patterned flame resistant fabric, comprising: a plurality of
non-producer colored high tenacity, flame resistant fibers; a
plurality of cellulosic fibers containing a flame retardant
compound, the cellulosic fibers being blended with the high
tenacity, flame resistant fibers; and at least one color that is
printed on the fabric to form said pattern.
2. The fabric of claim 1, wherein said high tenacity, flame
resistant fibers are para-aramid fibers.
3. The fabric of claim 1, wherein said cellulosic fibers are
selected from rayon, acetate, triacetate, and lyocell.
4. The fabric of claim 1, wherein said cellulosic fibers are rayon
fibers.
5. The fabric of claim 1, wherein said fabric has a percentage
composition of high tenacity, flame resistant fibers of at least
10%.
6. The fabric of claim 1, wherein said fabric has a percentage
composition of high tenacity, flame resistant fibers from
approximately 10% to 60%.
7. The fabric of claim 1, wherein said fabric has a percentage
composition of high tenacity, flame resistant fibers of
approximately 40%.
8. The fabric of claim 1, 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.
9. The fabric of claim 1, wherein said fabric contains a residual
amount of a dye-assistant selected from the group consisting of
aryl ether, benzyl alcohol, N,N-dibutyl formamide,
N-octylpyrrolidone, and mixtures thereof.
10. The fabric of claim 1, wherein the fabric comprises a plurality
of colors that are printed on the fabric to form said pattern.
11. The fabric of claim 10, wherein said pattern is a camouflage
pattern.
12. The fabric of claim 10, wherein said non-producer colored high
tenacity, flame resistant fibers and said cellulosic fibers are
dyed a base shade of color.
13. A camouflaged-patterned flame resistant fabric, comprising: a
plurality of non-producer colored para-aramid fibers; a plurality
of cellulosic fibers containing a flame retardant compound, the
cellulosic fibers being blended with the .[.high tenacity, flame
resistant.]. .Iadd.para-aramid .Iaddend.fibers; and a plurality of
colors that are printed on the fabric to form a camouflage
pattern.
14. The fabric of claim 13, wherein said cellulosic fibers are
selected from rayon, acetate, triacetate, and lyocell.
15. The fabric of claim 13, wherein said cellulosic fibers are
rayon fibers.
16. The fabric of claim 1, wherein said fabric has a percentage
composition of high tenacity, flame resistant fibers from
approximately 10% to 60%.
17. The fabric of claim 13, wherein said fabric contains a residual
amount of a dye-assistant selected from the group consisting of
aryl ether, benzyl alcohol, N,N-dibutyl formamide,
N-octylpyrrolidone, and mixtures thereof.
18. The fabric of claim 13, wherein said non-producer colored
para-aramid fibers and said cellulosic fibers are dyed a base shade
of color.
19. A patterned flame resistant garment, comprising: fabric that
includes: a plurality of non-producer colored high tenacity, flame
resistant fibers; a plurality of cellulosic fibers containing a
flame retardant compound, the cellulosic fibers being blended with
the high tenacity, flame resistant fibers; and at least one color
that is printed on the fabric to form said pattern.
20. The garment of claim 19, wherein said high-tenacity, flame
resistant fibers are para-aramid fibers.
21. The garment of claim 19, wherein said cellulosic fibers are
selected from rayon, acetate, triacetate, and lyocell.
22. The garment of claim 19, wherein said cellulosic fibers are
rayon fibers.
23. The garment of claim 19, wherein said fabric has a percentage
composition of high tenacity, flame resistant fibers of at least
10%.
24. The garment of claim 19, wherein said fabric has a percentage
composition of high tenacity, flame resistant fibers from
approximately 10% to 60%.
25. The garment of claim 19, wherein said fabric has a percentage
composition of high tenacity, flame resistant fibers of
approximately 40%.
26. The garment of claim 19, 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.
27. The garment of claim 19, wherein said fabric contains a
residual amount of a dye-assistant selected from the group
consisting of aryl ether, benzyl alcohol, N,N-dibutyl formamide,
N-octylpyrrolidone, and mixtures thereof.
28. The garment of claim 20, wherein the garment is a component of
a battle dress uniform (BDU).
.Iadd.29. A patterned flame resistant fabric, comprising: a
plurality of high tenacity, flame resistant fibers; a plurality of
cellulosic fibers containing a flame retardant compound, the
cellulosic fibers being blended with the high tenacity, flame
resistant fibers; and at least one color that is printed on the
fabric to form said pattern..Iaddend.
.Iadd.30. The fabric of claim 29, wherein said high tenacity, flame
resistant fibers are para-aramid fibers..Iaddend.
.Iadd.31. The fabric of claim 29, wherein said cellulosic fibers
are selected from rayon, acetate, triacetate, and
lyocell..Iaddend.
.Iadd.32. The fabric of claim 29, wherein said cellulosic fibers
are rayon fibers..Iaddend.
.Iadd.33. The fabric of claim 29, wherein said fabric has a
percentage composition of high tenacity, flame resistant fibers of
at least 10%..Iaddend.
.Iadd.34. The fabric of claim 29, wherein said fabric has a
percentage composition of high tenacity, flame resistant fibers
from approximately 10% to 60%..Iaddend.
.Iadd.35. The fabric of claim 29, wherein said fabric has a
percentage composition of high tenacity, flame resistant fibers of
approximately 40%..Iaddend.
.Iadd.36. The fabric of claim 29, 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..Iaddend.
.Iadd.37. The fabric of claim 29, wherein said fabric contains a
residual amount of a dye-assistant selected from the group
consisting of aryl ether, benzyl alcohol, N,N-dibutyl formamide,
N-octylpyrrolidone, and mixtures thereof..Iaddend.
.Iadd.38. The fabric of claim 29, wherein the fabric comprises a
plurality of colors that are printed on the fabric to form said
pattern..Iaddend.
.Iadd.39. The fabric of claim 38, wherein said pattern is a
camouflage pattern..Iaddend.
.Iadd.40. The fabric of claim 38, wherein said high tenacity, flame
resistant fibers and said cellulosic fibers are dyed a base shade
of color..Iaddend.
.Iadd.41. A camouflaged-patterned flame resistant fabric,
comprising: a plurality of para-aramid fibers; a plurality of
cellulosic fibers containing a flame retardant compound, the
cellulosic fibers being blended with the para-aramid fibers; and a
plurality of colors that are printed on the fabric to form a
camouflage pattern..Iaddend.
.Iadd.42. The fabric of claim 41, wherein said cellulosic fibers
are selected from rayon, acetate, triacetate, and
lyocell..Iaddend.
.Iadd.43. The fabric of claim 41, wherein said cellulosic fibers
are rayon fibers..Iaddend.
.Iadd.44. The fabric of claim 29, wherein said fabric has a
percentage composition of high tenacity, flame resistant fibers
from approximately 10% to 60%..Iaddend.
.Iadd.45. The fabric of claim 41, wherein said fabric contains a
residual amount of a dye-assistant selected from the group
consisting of aryl ether, benzyl alcohol, N,N-dibutyl formamide,
N-octylpyrrolidone, and mixtures thereof..Iaddend.
.Iadd.46. The fabric of claim 41, wherein said para-aramid fibers
and said cellulosic fibers are dyed a base shade of
color..Iaddend.
.Iadd.47. A patterned flame resistant garment, comprising: fabric
that includes: a plurality of high tenacity, flame resistant
fibers; a plurality of cellulosic fibers containing a flame
retardant compound, the cellulosic fibers being blended with the
high tenacity, flame resistant fibers; and at least one color that
is printed on the fabric to form said pattern..Iaddend.
.Iadd.48. The garment of claim 47, wherein said high-tenacity,
flame resistant fibers are para-aramid fibers..Iaddend.
.Iadd.49. The garment of claim 47, wherein said cellulosic fibers
are selected from rayon, acetate, triacetate, and
lyocell..Iaddend.
.Iadd.50. The garment of claim 47, wherein said cellulosic fibers
are rayon fibers..Iaddend.
.Iadd.51. The garment of claim 47, wherein said fabric has a
percentage composition of high tenacity, flame resistant fibers of
at least 10%..Iaddend.
.Iadd.52. The garment of claim 47, wherein said fabric has a
percentage composition of high tenacity, flame resistant fibers
from approximately 10% to 60%..Iaddend.
.Iadd.53. The garment of claim 47, wherein said fabric has a
percentage composition of high tenacity, flame resistant fibers of
approximately 40%..Iaddend.
.Iadd.54. The garment of claim 47, 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..Iaddend.
.Iadd.55. The garment of claim 47, wherein said fabric contains a
residual amount of a dye-assistant selected from the group
consisting of aryl ether, benzyl alcohol, N,N-dibutyl formamide,
N-octylpyrrolidone, and mixtures thereof..Iaddend.
.Iadd.56. The garment of claim 48, wherein the garment is a
component of a battle dress uniform (BDU)..Iaddend.
.Iadd.57. A patterned flame resistant fabric comprising: a
plurality of high tenacity, flame resistant fibers; a plurality of
cellulosic fibers comprising a flame retardant compound, the
cellulosic fibers being blended with the high tenacity, flame
resistant fibers; and at least one color that is dye printed on the
fabric to form the pattern..Iaddend.
.Iadd.58. A patterned flame resistant garment comprising the fabric
of claim 57..Iaddend.
.Iadd.59. A camouflaged-patterned flame resistant fabric
comprising: a plurality of para-aramid fibers; a plurality of
cellulosic fibers comprising a flame retardant compound, the
cellulosic fibers being blended with the para-aramid fibers; and a
plurality of colors that are dye printed on the fabric to form a
camouflage pattern..Iaddend.
Description
FIELD OF THE INVENTION
The present invention relates to patterned, flame resistant
fabrics. More particularly, the present invention relates to flame
resistant fabrics well suited for use in the construction of
camouflage battle dress uniforms. In addition, the invention
relates to methods for making such fabrics.
BACKGROUND OF THE INVENTION
Presently, U.S. infantry troops are issued camouflage patterned
garments known as battle dress uniforms (BDUs). BDUs are used both
in battle and during the execution of other tasks associated with
military service. The BDUs in current use are either provided with
a three or four color camouflage pattern that is printed directly
onto the surface of the garment fabric. The nature of the pattern
(e.g., color depth), as well as the particular physical
construction of the fabric (e.g. fiber types), are dictated by to
military specifications designated as MIL-C-44436(GL) and
MIL-C-44031D. These specifications there developed after the
creation and adoption of a material presently used by the military
for all BDUs known as "Nyco." This material comprises 50/50) blend
of nylon and cotton. Because the specifications were written based
upon the Nyco material, many of the construction characteristics
identified in MIL-C-44436(GL) and MIL-C-44031D specifically pertain
to this material.
Although most military personnel are issued BDUs, troops involved
in specialized areas of military service are often provided with
flame resistant uniforms. For example, troops that work in close
proximity to flammable liquids such as pilots, combat vehicle
crewmen, and fuel handlers are outfitted with garments composed of
meta-aramid fibers such as NOMEX.sup.R fibers, which are
manufactured by DuPont of Wilmington, Del.
Recently, the federal government has expressed interest in
providing flame resistant BDUs to military personnel. Although
personnel could be issued BDUs constructed primarily of meta-aramid
fibers to obtain the desired flame resistance, the costs of
providing each person with such a garment would be extremely large.
In addition, the tensile and tear strengths of such a fabric would
likely fall far short of the requirements of MIL-C-44436(GL) and
MIL-C-44031D. Although there are known fibers that have desirable
flame resistance properties as well as high tensile and tear
strengths, use of such fibers is generally not considered viable
for BDU construction because it is difficult to form durable
patterns on many of these fibers.
From the above, it can be appreciated that it is desirable to have
a patterned, flame resistant fabric which would be a suitable
substitute for existing BDU materials. Furthermore, it should be
desirable to have a method for making such a fabric.
SUMMARY OF THE INVENTION
The present disclosure relates to patterned, flame resistant
fabrics. Generally speaking, the fabrics comprise a plurality of
high tenacity, flame resistant fibers, and a plurality of
cellulosic fibers containing a flame retardant compound, and at
least one color which is printed on the fabric to form the pattern.
In a preferred embodiment, the flame resistant fibers are
para-aramid fibers and the cellulosic fibers are rayon fibers.
DETAILED DESCRIPTION OF THE INVENTION
The present disclosure relates to flame resistant fabrics that are
well suited for use to in the construction of military BDUs.
Although the discussion that follows focuses on BDUs and U.S.
military specifications MIL-C-44436(GL) and MIL-C44031D, it is to
be understood that the fabrics described herein could be used in
various other applications, if desired. In addition, it is to be
understood that, for purposes of the present disclosure, fibers
identified by a named material followed by the term "fiber" are not
limited to fibers composed exclusively of the named material.
As identified above, MIL-C-44436(GL) and MIL-C-44031D contain many
physical property requirements for materials used to construct
BDUs. In view of the aforementioned difficulties in designing a
flame resistant BDU, of particular concern is fabric durability as
defined by tensile (i.e. breaking) strength and tear strength.
Table I provides the class 1 requirements set by MIL-C-44436(GL),
published Jul. 13, 1992, and MIL-C-44031D, published Dec. 4, 1985,
and amended on Sep. 2, 1987, both of which are hereby incorporated
by reference into the present disclosure.
TABLE-US-00001 TABLE I Summer Weight Winter Weight Fabric Property
(MIL-C-44436(GL)) (MIL-C-44031D) Breaking strength, (pounds) min.
Warp 200 200 Filling 90 125 Tearing strength, (pounds) min. Warp
7.0 11 Filling 5.0 8
In an effort to obtain substantial compliance with these strength
requirements, the fabric of the present invention preferably
comprises a plurality of high tenacity, flame resistant fibers.
Preferred for the high tenacity, flame resistant fibers are
non-producer colored para-aramid fibers. Such fibers are currently
available under the trademarks KEVLAR.sup.R, TECHNORA.sup.R, and
TWARON.sup.R from DuPont, Teijin, and Acordis, respectively. As is
known in the art, para-aramid fibers are composed of aromatic
polyamide. Although meta-aramid fibers are also composed of
aromatic polyamide, para-aramid fibers are preferred over
meta-aramid fibers because para-aramid fibers are considerably
stronger.
To reduce manufacturing costs, improve wearer comfort, and improve
the printability of patterns onto the material, the fabric of the
present invention further preferably comprises a plurality of
cellulosic fibers. Preferred for the choice of cellulosic fibers
are rayon, acetate, triacetate, and lyocell. These cellulosics,
although softer and less expensive than the high tenacity, flame
resistant fibers, are not naturally resistant to flame. To increase
the flame resistance of these fibers, one or more flame retardants
are incorporated into the fibers during the manufacturing process.
Effective flame retardants include phosphorus compounds and
antimony compounds. Generally speaking, cellulosic fibers which
contain one or more flame retardants are given the designation "FR"
which indicates a flame resistant fiber. Accordingly, the preferred
flame resistant cellulosic fibers are FR rayon, FR acetate, FR
triacetate, and FR lyocell. Most preferably, the flame resistant
cellulosic fibers are FR rayon fibers.
Typically, the blend has a percentage composition of para-aramid
fibers of at least 10%, with the balance primarily comprising FR
rayon fibers. Preferably, the percentage composition of the
para-aramid fibers is between 10% and 60%, with approximately 40%
being most preferred. Although the current military specifications
require a 50/50 blend of nylon and cotton, the presently preferred
blend of para-aramid and FR rayon fibers is believed to be an
acceptable substitute in situations where thermal and/or flame
resistance is desired. Due to this alternative construction, it
will be appreciated that several of the physical construction
requirements (e.g., yarn weight, yarns per inch) identified in
MIL-C-44436(GL) and MIL-C-44031D might not be satisfied by fabric
constructed in accordance with the present disclosure. However,
these differences are deemed to be secondary in importance to
providing a strong, flame resistant material.
In addition to the two primary fiber components identified above,
the fabric can further comprise approximately 1% to 5% by
percentage composition of an anti-static fiber. Although the
provision of such an anti-static fiber is not considered necessary,
it .[.2( ).]. may be desirable. When used, the anti-static fiber
can comprise a fiber having a polyethylene-carbon core with a nylon
sheath such as P140 manufactured by DuPont, or F7105C manufactured
by BASF.
In keeping with MIL-C-4436(GL) and MIL-C-44031D, the fabric of the
present invention preferably is arranged as a rip-stop for summer
weight garments, and a twill weave for winter weight garments. By
way of example, the fabric can comprise a plurality of blended
yarns having warp cotton counts of 38/2 c.c. and fill cotton counts
of 30/2 c.c. or 15/1 c.c., with the fabric having approximately 96
ends per inch (e.p.i.) and approximately 54 picks per inch
(p.p.i.).
Tables II and III provide breaking strength and tearing strength
data, respectively, for a prototype summer weight fabric
constructed in accordance with the present disclosure. This fabric
comprised a 60/37/3 blend of FR rayon, KEVLAR.sup.R, and
anti-static fibers. The blend was dyed a base shade and printed
with four different colors to form the desired camouflage pattern.
Although the breaking strengths identified in Table II are not as
great as those presently required by MIC-4446(GL), these data
suggest that breaking strength values in substantial compliance
with the requirements are achievable.
TABLE-US-00002 TABLE II Breaking strength, (pounds) Warp 160
Filling 100
With regard to tearing strength, the prototype fabric exceeded the
current requirements of MIL-C-44436(GL) as indicated in Table
III.
TABLE-US-00003 TABLE III Tearing strength, (pounds) Warp 9.3
Filling 6.9
In addition to achieving substantial compliance with the strength
requirements of the military specifications, of particular concern
is satisfaction of the pattern requirements established for BDUs.
Preferably, the camouflage patterns are applied to the BDU fabric
by first dyeing the fabric a base shade and then dye printing over
the base shade with the other colors of the pattern. As mentioned
above, the difficulty in dyeing (and dye printing), high tenacity,
flame resistant fabrics complicates satisfaction of the pattern
requirements. The reasons for this difficulty are the same as those
described in relation to fabric dyeing in related U.S. patent
application Ser. No. 09/062,805, filed Apr. 20, 1998, now U.S. Pat.
No. 6,132,476. As identified in that application, the flame
retardants contained in FR cellulosics tend to be depleted by the
relatively high temperatures generally considered necessary to
affix dye within flame resistant fibers such as para-aramid fibers.
The depletion of these flame retardants significantly reduces the
flame resistance of the cellulosic fibers and therefore reduces the
flame resistance of these blends.
The inventors have discovered that, contrary to conventional
beliefs, high tenacity, flame resistant fibers such as para-aramid
fibers can be dyed and/or dye printed at temperatures below
100.degree. C. if particular dye-assistants are used during fabric
processing. Dyeing and/or dye printing at these low temperatures
avoids flame retardant depletion. It is this discovery that has led
to the determination that a pattern, such as a camouflage pattern,
can be formed on a flame resistant fabric by dyeing the high
tenacity, flame resistant fibers and cellulosic fibers a light base
shade at a temperature below 100.degree. C. and then printing the
remaining colors of the camouflage pattern onto the blend.
Processing in this manner, a strong, flame resistant BDU can be
produced which substantially satisfies the pattern requirements of
the military specifications identified above.
The preferred dye-assistants for dyeing the high tenacity, flame
resistant fibers of the blend 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, Haco-mid M-8/10 (an approximately
50/50 blend of N,N-dimethylcaprylamide and N,N-dimethylcapramide),
and mixtures thereof. Most preferably, however, the dye-assistant
is selected from the group consisting of aryl ether, benzyl
alcohol, N,N-dibutyl formamide, N-octylpyrrolidone, and mixtures
thereof.
To accomplish dyeing of the high tenacity, flame resistant fibers
of the blend, a dye-assistant, a dye, and other additives if
desired, typically are applied to the fabric using a one-step
batch-type process. By way of example, basic, acid, or disperse
dyes can be used to dye the high tenacity, flame resistant fibers.
In one embodiment, 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 an apertured venturi contained within the
vessel. The fabric first is scoured and then is dyed with the aid
of the selected dye-assistant. The temperature of the dyebath
normally is increased gradually from room temperature to a peak
temperature below approximately 100.degree. C. Preferably, the peak
temperature is approximately 85.degree. C. Upon reaching the
predetermined peak temperature, the dyebath temperature is
maintained to allow dye to penetrate the fibers.
In another embodiment, the fabric is beam dyed in conventional
manner. Although jet and beam dyeing are preferred, it is to be
understood that other known atmospheric dyeing methods may be
equally advantageous. Irrespective of the particular dyeing method
used, there is no need to pressurize the dyebath to prevent boiling
since the dyeing temperature does not reach or exceed 100.degree.
C. Therefore, all dyeing can be conducted at atmospheric pressure.
Optionally, the flame resistant cellulosic fibers can be dyed in
similar manner. This dyeing can be conducted prior to,
simultaneously with, or subsequent to dyeing of the high tenacity,
flame resistant fibers. In that the cellulosic fibers normally
readily accept dye, no dye-assistant is needed to dye the fibers.
By way of example, direct or reactive dyes can be used to dye the
cellulosic fibers.
Once the fabric has been dyed to the desired depth of shade
(typically a light green or khaki for camouflage), if at all, the
fibric is printed with conventional methods. By way of example,
this printing can be accomplished with rotary screen printing
apparatus. As will be appreciated by persons having ordinary skill
in the art, printing can be achieved with dyes, pigments, or a
combination of both. Where the fabric is to be dye printed, the
aforementioned dye-assistants are useful in permitting the dye to
penetrate the high tenacity, flame resistant fibers. In one
embodiment, this dye-assistant can be added to the print paste.
Alternatively, dye printing can be facilitated with dye-assistant
contained within the fibers that has not been removed (e.g., if the
fabric is not rinsed before printing). By way of example, basic,
acid, or disperse dyes can be used to dye print the high tenacity,
flame resistant fibers.
Where both the high tenacity, flame resistant fibers and the
cellulosic fibers are to be dye printed, printing of the two fiber
types can be accomplished simultaneously. Where dye printing of the
individual high tenacity, flame resistant fibers is not desired or
deemed necessary, dye-assistant is not needed. In such a case, the
dye-based print paste may only penetrate the flame resistant
cellulosic fibers. Suitable dyes for these fibers include direct,
reactive, and vat dyes. Of these, vat dyes may be preferable in
military applications due to their infrared spectral reflectance
properties.
When the fabric is to be pigment printed only, dye-assistant is
unnecessary in that the pigment is applied to the fabric as a
surface coating instead of a fiber penetrating dye. Although such
pigment printing is feasible, it is presently prohibited by the
military specifications identified herein and therefore not
presently preferred. As mentioned above however, because these
specifications may change over time, an at least partially pigment
printed fabric is presently contemplated.
Once printed, the fabric then can be finished in a conventional
manner. This finishing process can include the application of
wicking agents, water repellents, stiffening agents, softeners, and
the like. Through these techniques, it is believed that full shades
of color are achievable which substantially comply with the
military BDU specifications.
While preferred embodiments of the invention have been disclosed in
detail in the foregoing description and drawings, it will be
understood by those skilled in the art that variations and
modifications thereof can be made without departing from the scope
of the invention as set forth in the following claims.
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