Flame resistant fabrics and garments made from same

Abstract

Unique blends of fibers that incorporate synthetic cellulosic fibers to render fabrics made with such blends more durable than fabrics made with natural cellulosic fibers such as cotton. While more durable than cotton, the synthetic cellulosic fibers used in the blends are still inexpensive and comfortable to the wearer. Thus, the benefits of cotton (affordability and comfort) are still attained while a drawback of cotton—low durability—is avoided. In one embodiment, the fiber blend includes FR modacrylic fibers and synthetic cellulosic fibers, preferably, but not necessarily non-FR lyocell fibers such as TENCEL™ and TENCEL A100™. Other fibers may be added to the blend, including, but not limited to, additional types of inherently FR fibers, anti-static fibers, anti-microbial fibers, stretch fibers, and/or high tenacity fibers. The fiber blends disclosed herein may be used to form various types of FR fabrics. Desired colors may be imparted in a variety of ways and with a variety of dyes to the fabrics disclosed herein. Fabrics having the fibers blends disclosed herein can be used to construct the entirety of, or various portions of, a variety of protective garments for protecting the wearer against electrical arc flash and flames, including, but not limited to, coveralls, jumpsuits, shirts, jackets, vests, and trousers.

1 . A flame resistant fabric comprising a fiber blend, wherein the fiber blend comprises a first type of inherently flame resistant fibers and a plurality of synthetic cellulosic fibers, wherein the first type of inherently flame resistant fibers comprises FR modacrylic fibers.  
     
     
         2 . The fabric of  claim 1 , wherein the synthetic cellulosic fibers comprise lyocell.  
     
     
         3 . The fabric of  claim 2 , wherein the synthetic cellulosic fibers comprise TENCEL™.  
     
     
         4 . The fabric of  claim 2 , wherein the synthetic cellulosic fibers comprise TENCEL A100™.  
     
     
         5 . The fabric of  claim 1 , wherein the synthetic cellulosic fibers are not flame resistant.  
     
     
         6 . The fabric of  claim 1 , wherein the FR modacrylic fibers comprise PROTEX™ fibers.  
     
     
         7 . The fabric of  claim 1 , wherein the FR modacrylic fibers comprise a first percentage of the fiber blend and the synthetic cellulosic fibers comprise a second percentage of the fiber blend, wherein the first percentage is greater than the second percentage.  
     
     
         8 . The fabric of  claim 1 , wherein the fiber blend further comprises a second type of inherently flame resistant fibers.  
     
     
         9 . The fabric of  claim 8 , wherein the second type of inherently flame resistant fibers comprises at least one of para-aramid fibers, meta-aramid fibers, polybenzimidazole fibers, polybenzoxazole fibers, melamine fibers, carbon fibers, pre-oxidized acrylic fibers, polyacrylonitrile fibers, TANLON™ fibers, or polyamide-imide fibers.  
     
     
         10 . The fabric of  claim 8 , wherein the fiber blend comprises approximately 30-60% of the first type of inherently flame resistant fibers, approximately 20-60% synthetic cellulosic fibers, and approximately 5-30% of the second type of inherently flame resistant fibers.  
     
     
         11 . The fabric of  claim 10 , wherein the synthetic cellulosic fibers comprise TENCEL A100™.  
     
     
         12 . The fabric of  claim 8 , wherein the fiber blend further comprises a plurality of high tenacity fibers.  
     
     
         13 . The fabric of  claim 12 , wherein the plurality of high tenacity fibers comprises at least one of nylon fibers or polyester fibers.  
     
     
         14 . The fabric of  claim 1 , wherein the fabric is woven.  
     
     
         15 . The fabric of  claim 1 , wherein the fabric is nonwoven.  
     
     
         16 . The fabric of  claim 1 , wherein the fabric is knitted.  
     
     
         17 . The fabric of  claim 1 , wherein the fabric comprises a knitted mesh fabric.  
     
     
         18 . The fabric of  claim 1 , wherein at least some of the fibers in the fabric are dyed.  
     
     
         19 . The fabric of  claim 18 , wherein at least some of the FR modacrylic fibers are dyed with at least one of a basic dye or a disperse dye.  
     
     
         20 . The fabric of  claim 18 , wherein at least some of the synthetic cellulosic fibers are dyed with at least one of a fiber reactive dye, direct dye, or vat dye.  
     
     
         21 . The fabric of  claim 18 , wherein the fabric complies with ANSI 107-2004.  
     
     
         22 . The fabric of  claim 18 , wherein the fabric complies with MIL-C-83429.  
     
     
         23 . The fabric of  claim 1 , wherein at least a portion of the fabric is printed.  
     
     
         24 . The fabric of  claim 23 , wherein the fabric complies with MIL-C-83429.  
     
     
         25 . The fabric of  claim 24 , wherein the fabric is printed using at least one vat dye.  
     
     
         26 . A garment comprising the fabric of  claim 1 .  
     
     
         27 . The garment of  claim 26 , wherein the garment is a shirt comprising a body portion, wherein at least a portion of the body portion comprises the fabric.  
     
     
         28 . The garment of  claim 27 , wherein the fabric further comprises a second type of inherently flame resistant fibers.  
     
     
         29 . The garment of  claim 27 , wherein the fabric comprises a knitted mesh fabric.  
     
     
         30 . A flame resistant fabric comprising a fiber blend, wherein the fiber blend comprises approximately 30-60% of a first type of inherently flame resistant fibers, approximately 20-60% synthetic cellulosic fibers, and approximately 5-30% of a second type of inherently flame resistant fibers, wherein the first type of inherently flame resistant fibers comprise FR modacrylic fibers and wherein the synthetic cellulosic fibers comprise TENCEL A100™.  
     
     
         31 . The fabric of  claim 30 , wherein the second type of inherently flame resistant fibers comprise at least one of para-aramid fibers, meta-aramid fibers, polybenzimidazole fibers, polybenzoxazole fibers, melamine fibers, carbon fibers, pre-oxidized acrylic fibers, polyacrylonitrile fibers, TANLON™ fibers, or polyamide-imide fibers.  
     
     
         32 . The fabric of  claim 30 , wherein the fiber blend comprises approximately 40-50% FR modacrylic fibers, approximately 30-40% TENCEL A100™ fibers, and approximately 10-15% aramid fibers.  
     
     
         33 . The fabric of  claim 30 , wherein the fiber blend further comprises nylon fibers.