Flame and heat resistant yarns and fabrics

Abstract

The present invention relates to flame and heat resistant yarns comprising polyacrylate fibers, and to flame retardant textile materials formed from such yarns. The flame and heat resistant yarns include a series of polyacrylate fibers blended with a series of companion fibers, which can include other flame resistant fibers. The polyacrylate fibers provide enhanced char strength to the yarns, while the companion fibers can be selected to provide increased tensile strength and other desired properties to the flame and heat resistant yarns. The flame and heat resistant yarns can be used to form fabrics or textile materials for use in a variety of applications, which fabrics exhibit a reduced fabric char length when subject to vertical flammability testing, and meet flammability requirements for any or all of National Fire Protection Association Standards NFPA 1971, NFPA 1975, NFPA 2112, NFPA 1951, NFPA 1977, and/or NFPA 70E; or which further meet or exceed the flame resistance requirements achieving an SFI Foundation performance rating of 3.2A/1 to SFI 3.2A/40, and/or Code of Federal Regulations 16 CFR 1633.

What is claimed: 
     
         1 . A flame and heat resistant yarn, comprising:
 a first series of fibers, comprising polyacrylate fiber; and   a second series of fibers having a greater tensile strength than the polyacrylate fibers of the first series of fibers;   wherein the first and second series of fibers are blended together to form the flame and heat resistant yarn, and wherein the polyacrylate fibers comprise a percentage of a total fiber weight of the flame and heat resistant yarn sufficient to provide a flame and heat resistant fabric formed from the flame and heat resistant yarn with a char length less than or equal to 4 inches when tested in accordance with ASTM D6413 Standard and with a fabric char length that which meets or exceeds any or all of NFPA 1971, NFPA 1975, NFPA 2112, NFPA 1951, NFPA 1977, and/or NFPA 70E Standards.   
     
     
         2 . The flame and heat resistant yarn of  claim 1 , wherein the second series of fibers comprises at least one fiber selected from the group comprising lyocell or viscose rayon, cotton, wool, polyesters, polyarnides, polyphenylene sulfide, polyetherimide, flame retardant lyocell, flame retardant viscose rayon, flame retardant wool, flame retardant cotton, flame retardant polyesters, flame retardant polyarnides, acrylic, modacrylic, polyolefins, metal, glass, ceramic and/or other inorganic fibers. 
     
     
         3 . The flame and heat resistant yarn of  claim 2  further comprising an additional series of non-thermoplastic fibers selected from the group comprising: para-aramids, meta-aramids, phenolic, melamine, liquid crystal polymer, polyvinylchloride, polytetrafluoroethylene, oxidized polyacrylonitrile, polybenzimidazole, polybenzoxazole, and/or polysulfonamide. 
     
     
         4 . The flame and heat resistant yarn of  claim 1 , wherein the second series of fibers comprises at least one fiber selected from the group comprising para-aramids, meta-aramids, phenolic, melamine, liquid crystal polymer, polyvinylchloride, polytetrafluoroethylene, polybenzimidazole, polybenzoxazole, oxidized polyacrylonitrile, and/or polysulfonamide. 
     
     
         5 . The flame and heat resistant yarn of  claim 1 , wherein the polyacrylate fibers comprise about 2% to about 95% by weight of the yarn. 
     
     
         6 . The flame and heat resistant yarn of  claim 1 , wherein the polyacrylate fibers comprise about 5% to about 85% by weight of the yarn. 
     
     
         7 . The yarn of  claim 1 , wherein the polyacrylate fibers are dyed. 
     
     
         8 . The flame and heat resistant yarn of  claim 1 , wherein the flame and heat resistant yarn is plied, cabled, core spun or twisted with one or more other yarns. 
     
     
         9 . The flame and heat resistant yarn of  claim 8 , wherein the other yarns comprise metal, glass, and/or other inorganic yarns. 
     
     
         10 . A woven or knit fabric formed from the yarn of  claim 1 . 
     
     
         11 . The fabric of  claim 10 , wherein the polyacrylate fibers of the yarn are dyed. 
     
     
         12 . The fabric of  claim 10 , wherein the fabric comprises the yarn of  claim 1  is woven or knitted with one or more other yarns having a different composition. 
     
     
         13 . A non-woven textile material formed from the yarn of  claim 1 . 
     
     
         14 . An article of manufacture formed from the yarn of  claim 1 , wherein the article of manufacture comprises shirts, pants, jackets, coveralls, hats, undergarments, and/or gloves. 
     
     
         15 . An article of manufacture formed from the yarn of  claim 1 , wherein the article of manufacture comprises a fire blocking fabric for mattresses and/or seating. 
     
     
         16 . The article of manufacture of  claim 13 , wherein the article meets or exceeds the performance of requirements promulgated in Code of Federal Regulations 16 CFR 1633. 
     
     
         17 . An article of manufacture formed from the yarn of  claim 1 , wherein the article of manufacture comprises bed sheets, blankets, upholstered furniture, tapestries, wall coverings, curtains, carpeting, flooring materials, insulating materials, pillows, quilts, comforters and/or luggage. 
     
     
         18 . An article of manufacture formed from the yarn of  claim 1 , wherein the article of manufacture comprises a thermal insulation, carpeting, wall coverings, curtains, or seating for aircraft, trains, ships, buses, and/or automobiles. 
     
     
         19 . A flame resistant fabric formed from the yarn of  claim 1  which meets or exceeds the requirements for a SFI Foundation performance rating of 3.2A/1 to SFI 3.2A/40.