Fire-resistant fabric

Abstract

A washable fire-resistant fabric and a method for making a washable fire-resistant fabric comprises a lightweight pliant non-woven batt blended from two types of fire-resistant organic fibers which are non-irritating to human skin. A method for stitch bonding a pliant batt of intertwined fire-resistant fibers to form a fabric which is durable and resistant to unraveling is also provided. The fabric has fire-resistant properties wherein the fabric prevents the ignition of articles made therefrom when exposed to high heat or flame sources and further insulates a wearer of the clothing from high heat or flame sources to prevent serious burns.

1 . A fire-resistant fabric comprising: 
 a non-woven batt comprising a melamine fire-resistant organic fiber, a modacrylic non-combustible organic fiber, and about 0% to about 10% by weight of other fire-resistant fibers; and    wherein the ratio of the melamine fire-resistant organic fiber to the modacrylic non-combustible organic fiber is from about 80/20 to about 40/60.    
   
   
       2 . The fabric according to  claim 1 , wherein the other fire-resistant fibers are chosen from the group consisting of an aramid fiber, a cotton fiber, a rayon fiber, and mixtures thereof.  
   
   
       3 . The fabric according to  claim 2 , wherein the non-woven batt comprises from about 0% to about 8% by weight of the other fire-resistant fibers.  
   
   
       4 . The fabric according to  claim 2 , wherein the non-woven batt comprises from about 0% to about 5% by weight of the other fire-resistant fibers.  
   
   
       5 . The fabric according to  claim 3 , wherein the ratio of the melamine fire-resistant fiber to the modacrylic non-combustible fiber is from about 70/30 to about 60/40 and the other fire-resistant fibers comprises from about 0% to about 8% aramid fiber.  
   
   
       6 . The fabric according to  claim 2 , wherein the ratio of the melamine fire-resistant fiber to the modacrylic non-combustible fiber is from about 60/40, and is substantially free of an aramid fiber.  
   
   
       7 . The fabric according to  claim 1 , wherein the non-woven batt is stitch bonded.  
   
   
       8 . The fabric according to  claim 7 , wherein the stitch bonding comprises a thread chosen from the group consisting of a polyester thread, a chemically treated polyester thread, and a yarn made from fire-resistant fibers.  
   
   
       9 . The fabric according to  claim 8 , wherein the stitch bonding comprises a plurality of a row of chain stitches and a row of tricot stitches, wherein the row of chain stitches is parallel to and proximately associated with the row of tricot stitches.  
   
   
       10 . The fabric according to  claim 9 , wherein the row of chain stitches and the row of tricot stitches are spaced at approximately 1/7 inch intervals.  
   
   
       11 . The fabric according to  claim 9 , wherein the row of chain stitches is parallel and physically connected to the row of tricot stitches.  
   
   
       12 . The fabric according to  claim 5 , wherein the non-woven batt comprises a thickness of about ⅛ to about 7/16 inch thick and a weight of approximately four to ten ounces per square yard.  
   
   
       13 . The fabric according to  claim 12 , wherein the non-woven batt comprises a thickness of about 3/16 inch and a weight of approximately six to seven ounces per square yard.  
   
   
       14 . A fire-resistant fabric comprising: 
 a non-woven batt comprising a melamine fire-resistant organic fiber and a modacrylic fire-resistant organic fiber, and about 0% to about 10% of other organic fibers chosen from the group consisting of an aramid fiber, a cotton fiber, a rayon fiber, and a mixture thereof; and    wherein the ratio of the melamine fire-resistant organic fiber to the modacrylic non-combustible organic fiber is from about 70/30 to about 60/40.    
   
   
       15 . The fabric according to  claim 14 , wherein the non-woven batt comprises from about 0% to about 8% by weight of an aramid fiber.  
   
   
       16 . The fabric according to  claim 15 , wherein the non-woven batt is substantially free of an aramid fiber.  
   
   
       17 . The fabric according to  claim 14 , wherein the ratio of the melamine fire-resistant organic fiber to the modacrylic fire-resistant organic fiber is about 65/35, and the other organic fibers comprises about 8% of an aramid fiber.  
   
   
       18 . The fabric according to  claim 14 , wherein the non-woven batt is stitch bonded.  
   
   
       19 . The fabric according to  claim 18 , wherein the stitch bonding comprises a plurality of a row of chain stitches and a row of tricot stitches, wherein the row of chain stitches is parallel to and proximately associated with the row of tricot stitches.  
   
   
       20 . The fabric according to  claim 19 , wherein the row of chain stitches and the row of tricot stitches are spaced at approximately 1/7 inch intervals.  
   
   
       21 . The fabric according to  claim 19 , wherein the row of chain stitches is parallel and physically connected to the row of tricot stitches.  
   
   
       22 . The fabric according to  claim 14 , wherein the non-woven batt comprises a thickness of about ⅛ to about 7/16 inch thick and a weight of approximately four to ten ounces per square yard.  
   
   
       23 . The fabric according to  claim 22 , wherein the non-woven batt comprises a thickness of about 3/16 inch and a weight of approximately six to seven ounces per square yard.  
   
   
       24 . A fire-resistant fabric comprising: 
 a non-woven batt comprising a melamine fire-resistant organic fiber, a modacrylic non-combustible organic fiber, and about 8% by weight of an aramid fiber;    wherein the ratio of the melamine fire-resistant organic fiber to the modacrylic non-combustible organic fiber is from about 70/30 to about 60/40;    wherein the non-woven batt is stitch bonded to form the fire-resistant fabric; and wherein the stitch bonding comprises a plurality of a row of chain stitches and a row of tricot stitches and the row of chain stitches is parallel and physically connected to the row of tricot stitches.