Flame resistant fabrics with improved aesthetics and comfort, and method of making same

Abstract

Fabrics having improved aesthetic characteristics in addition to good FR characteristics and strength are described, as well as a method for making the fabrics. The fabrics are made by subjecting a fabric containing inherently flame resistant fibers to a fluid treatment process such that a fabric with good comfort and aesthetic characteristics is formed. In one form of the invention, the fabric comprises plied yarns, and the fluid treatment process serves to separate the plies from each other. The fabrics have a soft hand, good protective characteristics, good strength and durability, as well as good wicking and soil release characteristics.

1 . A woven flame resistant fabric comprising a plurality of multi-ply inherently flame resistant yarns, wherein at least a portion of the individual plies of said multi-ply inherently flame resistant yarns are separated from each other.  
     
     
         2 . A woven flame resistant fabric according to  claim 1 , wherein said inherently flame resistant yarns comprise fibers selected from the group consisting of meta-aramids, para-aramids, melamines, aramid fibers, fluoropolymers and copolymers thereof, chloropolymers, polybenzimidazole, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novoloids, poly(p-phenylene benzobisoazoles), poly(p-phenylene benzothiazoles), polyphenylene sulfides, flame retardant viscose rayons, polyvinyl chloride homopolymers and copolymers thereof, polyetheretherketones, polyketones, polyetherimides, polylactides, melamine fibers, and combinations thereof.  
     
     
         3 . A woven flame resistant fabric according to  claim 1 , wherein said yarns define a plurality of fiber tangles comprised of fibers that are substantially intact and undamaged extending outwardly from at least one surface of the fabric.  
     
     
         4 . A woven flame resistant fabric according to  claim 1 , wherein said fabric is woven in a construction that is selected from the group consisting of plain weave, twill weave, basket weave, oxford weave, satin weave, and jacquard weave.  
     
     
         5 . A woven flame resistant fabric according to  claim 1 , wherein said woven fabric comprises warp yarns and filling yarns, and at least a plurality of said warp yarns are spun yarns.  
     
     
         6 . A woven flame resistant fabric according to  claim 5 , wherein said at least a plurality of said filling yarns are spun yarns.  
     
     
         7 . A woven flame resistant fabric according to  claim 1 , wherein said fabric comprises at least about 65% inherently flame resistant yarns.  
     
     
         8 . A woven flame resistant fabric according to  claim 1 , wherein said fabric consists essentially of inherently flame resistant yarns.  
     
     
         9 . A woven flame resistant fabric according to  claim 1 , wherein at least a portion of the individual plies that are separated from each other comprise individual fibers that are entangled with the fibers forming another individual ply.  
     
     
         10 . A flame resistant fabric comprising a plurality of spun yarns comprising inherently flame resistant fibers, wherein said fabric has first and second surfaces, and at least one of said surfaces comprises a plurality of fiber tangles comprised of fibers that are substantially intact and undamaged extending outwardly from said at least one surface of the fabric.  
     
     
         11 . A fabric according to  claim 10 , wherein at least a plurality of said spun yarns comprise a plurality of plies, and wherein said plies are at least partially separated from each other.  
     
     
         12 . A fabric comprising at least about 65% inherently flame resistant fibers wherein said fabric has a surface that has been chemically modified to achieve an ATPV rating of about 4 or greater.  
     
     
         13 . The fabric according to  claim 12 , wherein said fabric comprises at least about 90% inherently flame resistant fibers.  
     
     
         14 . The fabric according to  claim 12 , wherein said fabric has a soil release rating of about 2.5 or greater when soiled at 0 washes and tested after one wash, according to AATCC 130-1995 Test Method.  
     
     
         15 . The fabric according to  claim 12 , wherein said fabric has a soil release rating of about 3.0 or greater when soiled at 0 washes and tested after 1 wash, according to AATCC 130-1995 Test Method.  
     
     
         16 . The fabric according to  claim 12 , wherein said fabric has a Drop Disappearance of about 2 seconds or less.  
     
     
         17 . The fabric according to  claim 12 , wherein said fabric has been chemically modified through the application of about 0.25-5% owf of ethoxylated polyamide and about 0.25-5% owf of ethoxylated polyester.  
     
     
         18 . A woven flame resistant fabric comprising at least about 65% of inherently flame resistant fibers, wherein said fabric is defined by a plurality of interwoven warp and filling yarns, and a plurality of fibers forming said warp and filling yarns are entangled with each other to an extent sufficient to achieve a Warp Fray Value of about 10% or less when tested prior to washing.  
     
     
         19 . The fabric according to  claim 18 , wherein said fabric has a warp fray of less than about 5 when tested after 125 industrial launderings.  
     
     
         20 . The fabric according to  claim 18 , wherein said fabric comprises a plurality of fiber tangles comprised of fibers that are substantially intact and undamaged extending outwardly from a surface of said fabric.  
     
     
         21 . A fabric comprising at least about 65% inherently flame resistant fabrics, wherein said fabric has a Handle-o-meter reading of about 90 grams force or less in its as-produced form.  
     
     
         22 . The fabric according to  claim 21 , wherein said fabric comprises at least about 90% inherently flame resistant fibers.  
     
     
         23 . The fabric according to  claim 21 , wherein said fabric comprises a woven fabric having a weight of about 2 oz/sq yd to about 12 oz/sq yd.  
     
     
         24 . A woven fabric comprising at least about 65% inherently flame resistant fibers, wherein said fabric has a chemically modified surface and a bending modulus of about 0.6 or less when tested in a warp direction and in an as-produced form.  
     
     
         25 . The woven fabric according to  claim 24 , wherein said fabric comprises at least about 90% inherently flame resistant fibers.  
     
     
         26 . The woven fabric according to  claim 24 , wherein said fabric has a weight of about 2 to about 12 oz/sq yd.  
     
     
         27 . The woven fabric according to  claim 24 , wherein said fabric has been chemically modified through the application of an ethoxylated polyamide and an ethoxylated polyester.  
     
     
         28 . A woven fabric having a weight of about 4 to about 8 oz/sq yd, said fabric comprising at least about 90% inherently flame resistant fibers, wherein said fabric has a Drape Coefficient of about 60 or less.  
     
     
         29 . The woven fabric according to  claim 28 , wherein said fabric has a Drape Coefficient of about 40 or less.  
     
     
         30 . A woven fabric comprising at least about 65% inherently flame resistant fibers and a weight of about 4 to about 8 oz/sq yd, wherein said fabric has an ATPV rating of about 6 calories/cm 2  or greater.  
     
     
         31 . A woven fabric according to  claim 30 , wherein said fabric has been chemically treated to achieve a Vertical Wicking of about 5 inches or greater when tested in its as-produced form.  
     
     
         32 . A fabric comprising at least about 65% inherently flame resistant fibers and having a weight of about 4 to about 8 oz/sq yd, an ATPV of about 4 or greater and a DMIN of about 0.22 or less in its as-produced form.  
     
     
         33 . The fabric according to  claim 32 , wherein said fabric has a DMIN of about 0.21 or less in its as-produced form.  
     
     
         34 . The fabric according to  claim 32 , wherein said fabric comprises at least about 90% inherently flame resistant fibers.  
     
     
         35 . A fabric having a weight of about 4 to about 8 oz/sq yd and comprising at least about 90% of inherently flame resistant fibers, wherein said fabric has a WC of about 0.35 or greater.  
     
     
         36 . The fabric according to  claim 35 , wherein said fabric has a plurality of fiber tangles comprised of fibers that are substantially intact and undamaged extending outwardly from at least one surface of the fabric.  
     
     
         37 . A fabric comprising at least about 65% inherently flame resistant fibers, wherein said fabric has treatment of ethoxylated polyamide in an amount of about 0.25-5% owf and an ethoxylated polyester in an amount of about 0.25-5% owf.  
     
     
         38 . The fabric according to  claim 37 , wherein said fabric has a soil release rating of about 2.5 or greater when soiled at 0 washes and tested after one wash in accordance with AATCC 130-1995 (corn oil).  
     
     
         39 . The fabric according to  claim 37 , wherein said fabric is a woven fabric about 2 to about 12 oz/sq yd in weight, and said fabric has a soil release rating of about 3 or greater when soiled at 0 washes and tested after one wash in accordance with AATCC 130-1995 (corn oil.)  
     
     
         40 . A fabric comprising at least about 65% inherently flame resistant fibers and a chemical wicking treatment, wherein said fabric has a Drop Disappearance of about 2 seconds or less when tested in an unwashed condition.  
     
     
         41 . The fabric according to  claim 40 , wherein said fabric has a Drop Disappearance of about 1 second or less.  
     
     
         42 . The fabric according to  claim 40 , wherein said fabric has a Drop Disappearance of about 2 seconds or less after 50 washes  
     
     
         43 . The fabric according to  claim 40 , wherein said fabric has a Drop Disappearance of about 3 seconds or less after 125 washes.  
     
     
         44 . A fabric having a weight of about 2 to about 12 oz/sq yd and at least about 65% inherently flame resistant fibers, wherein a plurality of said fibers are entangled with each other, such that said fabric has an air permeability of about 70 cfm or greater when tested according to AATCC Test Method 737-1996, and an ATPV of about 6 or greater.  
     
     
         45 . A fabric having a weight of about 4 to about 8 oz/sq yd, said fabric comprising at least about 90% inherently FR fibers, wherein said fabric has a soil release rating of about 2.5 or greater for corn oil when tested according to AATCC Test Method 130-1995 in an unwashed condition, and a vertical wicking of about 5 inches or greater.  
     
     
         46 . A fabric according to  claim 45 , wherein said fabric has a soil release rating of about 3.5 or greater for corn oil when tested according to AATCC Test Method 130-95 when soilded at 48 washes and tested after 49 washes.  
     
     
         47 . A fabric according to  claim 45 , wherein said fabric comprises inherently flame resistant fibers selected from the group consisting of meta-aramids, para-aramids, melamines, aramid fibers, fluoropolymers and copolymers thereof, chloropolymers, polybenzimidazole, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novoloids, poly(p-phenylene benzobisoazoles), poly(p-phenylene benzothiazoles), polyphenylene sulfides, flame retardant viscose rayons, polyvinyl chloride homopolymers and copolymers thereof, polyetheretherketones, polyketones, polyetherimides, polylactides, melamine fibers, and combinations thereof.  
     
     
         48 - 51 . (canceled)  
     
     
         52 . A fabric made by the process of claim  48 .  
     
     
         53 - 54 . (canceled)