Lightweight, arc-rated, dyeable fabrics

Abstract

Lightweight, dyeable fabrics with a balance of high thermal properties, especially arc resistance, on the one hand, and durability and comfort properties, on the other hand, are disclosed. Articles, such as garments and linen, made from the lightweight dyeable fabrics are also disclosed. The fabrics are particularly useful in garments for utility workers, industrial workers, military personnel, and firefighters, especially for use in environments requiring high visibility.

What is claimed is: 
     
         1 . A dyeable fabric, comprising:
 a fiber blend, comprising:
 about 30% by weight to about 70% by weight, based on the total weight of said fiber blend, of a plurality of hydrophobic fibers comprising at least one fiber selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (FBI), and copolymers thereof, and combinations thereof; 
 about 15% by weight to about 45% by weight, based on the total weight of said fiber blend, of a plurality of fire-resistant hydrophilic fibers comprising at least one fiber selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof; and 
 about 5% by weight to about 30% by weight, based on the total weight of the fiber blend, of a plurality of structural fibers comprising at least one fiber selected from the group consisting of aramid, melamine, nylon, elastomeric filament, and combinations thereof; 
 wherein said aramid is present at a level of greater than about 0% by weight to less than about 10% by weight, based on the total weight of said fiber blend; 
   wherein said dyeable fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm 2 ;   wherein said dyeable fabric is capable of meeting the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and   wherein said dyeable fabric has a basis weight of less than about 8.0 oz/yd 2 .   
     
     
         2 . The dyeable fabric of  claim 1 ,
 wherein said plurality of hydrophobic fibers are modacrylic.   
     
     
         3 . The dyeable fabric of  claim 1 ,
 wherein said plurality of fire-resistant hydrophilic fibers are selected from the group consisting of cellulose, wool, silk, and combinations thereof.   
     
     
         4 . The dyeable fabric of  claim 1 ,
 wherein said cellulose is selected from the group consisting of cotton, fire-resistant cotton, rayon, fire-resistant rayon, viscose, Lyocell, acetate, bast, bamboo, soy, and combinations thereof.   
     
     
         5 . The dyeable fabric of  claim 1 ,
 wherein said cellulose is fire-resistant rayon, cotton, or fire-resistant cotton.   
     
     
         6 . The dyeable fabric of  claim 1 ,
 wherein said cellulose is cotton.   
     
     
         7 . The dyeable fabric of  claim 1 ,
 wherein said plurality of structural fibers comprise:   aramid fibers;   nylon fibers; and   optionally, elastomeric filaments.   
     
     
         8 . The dyeable fabric of  claim 1 ,
 wherein said plurality of structural fibers comprise:   p-aramid fibers;   nylon fibers; and   optionally, elastomeric filaments.   
     
     
         9 . The dyeable fabric of  claim 1 ,
 wherein said plurality of hydrophobic fibers are present at a level of about 40% by weight to 60% by weight, based on the total weight of said fiber blend.   
     
     
         10 . The dyeable fabric of  claim 1 ,
 wherein said plurality of hydrophobic fibers are present at a level of about 45% by weight to 55% by weight, based on the total weight of said fiber blend.   
     
     
         11 . The dyeable fabric of  claim 1 ,
 wherein said plurality of fire-resistant hydrophilic fibers are present at a level of about 25% by weight to 45% by weight, based on the total weight of said fiber blend.   
     
     
         12 . The dyeable fabric of  claim 1 ,
 wherein said plurality of structural fibers are present at a level of about 5% by weight to 20% by weight, based on the total weight of said fiber blend.   
     
     
         13 . The dyeable fabric of  claim 1 ,
 wherein said plurality of structural fibers are present at a level of about 10% by weight to 15% by weight, based on the total weight of said fiber blend.   
     
     
         14 . The dyeable fabric of  claim 1 ,
 said aramid fibers are present at a level of about 5% by weight to less than about 10% by weight, based on the total weight of said fiber blend.   
     
     
         15 . The dyeable fabric of  claim 1 ,
 wherein said dyeable fabric is a woven fabric.   
     
     
         16 . The dyeable fabric of  claim 1 ,
 wherein said dyeable fabric is a knit fabric.   
     
     
         17 . The dyeable fabric of  claim 1 ,
 wherein said dyeable fabric is a non-woven fabric.   
     
     
         18 . The dyeable fabric of  claim 1 ,
 wherein said dyeable fabric has a basis weight of less than about 7.5 oz/yd 2 .   
     
     
         19 . The dyeable fabric of  claim 1 ,
 wherein said dyeable fabric has a basis weight of less than about 7.0 oz/yd 2 .   
     
     
         20 . The dyeable fabric of  claim 1 ,
 wherein said fiber blend is intimately blended.   
     
     
         21 . A dyed fabric, comprising:
 said dyeable fabric of  claim 1 ; and   at least one dye;   wherein said at least one dye imparts to said dyeable fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.   
     
     
         22 . The dyed fabric of  claim 21 ,
 wherein said at least one dye comprises:
 at least one basic dye for said plurality of hydrophobic fibers; 
 at least one reactive dye for said plurality of hydrophilic fibers; and 
 at least one acid dye for said plurality of structural fibers; 
 wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric; 
   wherein said dyed fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010).   
     
     
         23 . The dyed fabric of  claim 22 ,
 wherein said at least one reactive dye is present at a level of greater than about 4% by weight, based on the total weight of said fabric.   
     
     
         24 . An article, comprising:
 said dyed fabric of  claim 21 .   
     
     
         25 . The article of  claim 24 ,
 wherein said article is a garment or linen.   
     
     
         26 . A dyed woven fabric, comprising:
 a fiber blend, comprising:
 about 50% by weight, based on the total weight of said fiber blend, of modacrylic fibers; 
 about 35% by weight, based on the total weight of said fiber blend, of cotton fibers; 
 about 10% by weight, based on the total weight of said fiber blend, of a plurality of fibers selected from the group consisting of nylon fibers, elastomeric filaments, and combinations thereof; and 
 about 5% by weight, based on the total weight of said fiber blend, of p-aramid fibers; 
   at least one dye;   wherein said at least one dye imparts to said woven fabric a color selected from the group consisting of fluorescent yellow-green, fluorescent orange-red, fluorescent red, and combinations thereof.   wherein said dyed woven fabric has an arc rating as measured by NFPA® 70E (2012) of at least about 8 cal/cm 2 ;   wherein said dyed woven fabric meets the chromaticity and minimum total luminance factor requirements set forth in ANSI 107 (2010); and   wherein said dyed woven fabric has a basis weight of less than about 8.0 oz/yd 2 .   
     
     
         27 . The dyed woven fabric of  claim 26 ,
 wherein said at least one dye comprises:
 at least one basic dye for said plurality of hydrophobic fibers; 
 at least one reactive dye for said plurality of hydrophilic fibers; and 
 at least one acid dye for said plurality of structural fibers; 
 wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric. 
   
     
     
         28 . The dyed woven fabric of  claim 27 ,
 wherein said at least one reactive dye is present at a level of greater than about 4% by weight, based on the total weight of said fabric.   
     
     
         29 . The dyed woven fabric of  claim 27 ,
 wherein said dyed woven fabric has a basis weight of less than about 7.5 oz/yd 2 .   
     
     
         30 . The dyed woven fabric of  claim 27 ,
 wherein said dyed woven fabric has a basis weight of less than about 7.0 oz/yd 2 .   
     
     
         31 . The dyed woven fabric of  claim 27 ,
 wherein said fiber blend is intimately blended.   
     
     
         32 . An article, comprising:
 the dyed woven fabric of  claim 27 .   
     
     
         33 . The article of  claim 32 ,
 wherein the article is a garment or linen.   
     
     
         34 . A method of preparing a high-visibility fabric, comprising:
 preparing a yarn from a fiber blend;
 wherein said fiber blend comprises: 
 about 30% by weight to about 70% by weight, based on the total weight of said fiber blend, of a plurality of hydrophobic fibers comprising at least one fiber selected from the group consisting of modacrylic, fluoropolymer, polybenzimidazole (FBI), and copolymers thereof, and combinations thereof; 
 about 15% by weight to about 45% by weight, based on the total weight of said fiber blend, of a plurality of fire-resistant hydrophilic fibers comprising at least one fiber selected from the group consisting of cellulose, cellulose derivatives, wool, and copolymers thereof, and combinations thereof; and 
 about 5% by weight to about 30% by weight, based on the total weight of said fiber blend, of a plurality of structural fibers comprising at least one fiber selected from the group consisting of aramid, melamine, nylon, elastomeric filaments, and combinations thereof; 
 wherein said aramid is present at a level of greater than about 0% by weight to less than about 10% by weight, based on the total weight of said fiber blend; 
   converting said yarn into a fabric substrate;   wherein said fabric substrate is woven, knitted, nonwoven, or a combination thereof; and   dyeing said fabric substrate to prepare said high-visibility fabric;   wherein said high-visibility fabric is colored fluorescent yellow-green, fluorescent orange-red, fluorescent red, or a combination thereof.   
     
     
         35 . The method of  claim 34 ,
 wherein said dyeing, comprises:   (a) contacting said hydrophobic fibers with at least one basic dye;   (b) contacting said hydrophilic fibers with at least one reactive dye;
 wherein said at least one reactive dye is present at a level of greater than about 1% by weight, based on the total weight of said fabric substrate; and 
   (c) contacting said structural fibers with a composition comprising:   (i) at least one acid dye; and   (ii) optionally, at least one dye assist.   
     
     
         36 . The method of  claim 35 ,
 wherein said step (b) and step (c) are carried out substantially simultaneously; and   wherein said at least one dye assist is present.   
     
     
         37 . The method of  claim 34 ,
 wherein said dyeing, comprises:   (a1)) contacting said hydrophobic fibers with at least one basic dye;   (a2) optionally, reduction cleaning said hydrophobic fibers after said step (a1);   (b1) contacting said hydrophilic fibers with at least one reactive dye;
 wherein said at least one reactive dye is present at a level of greater than about 4% by weight, based on the total weight of said fabric substrate; 
   (b2) optionally, contacting said hydrophilic fibers with an after treatment after said step (b1);
 wherein said after treatment comprises a process selected from the group consisting of: soaping, fixing, and combinations thereof; and 
   (c) contacting said structural fibers with at least one acid dye.   
     
     
         38 . The method of  claim 34 ,
 wherein said at least one reactive dye is present at a level of greater than about 1% by weight to about 5% by weight, based on the total weight of said fabric substrate.   
     
     
         39 . The method of  claim 34 , further comprising:
 pre-treating said fabric substrate, prior to said dyeing;   wherein said pre-treating comprises at least one process selected from the group consisting of desizing, scouring, bleaching, and combinations thereof.   
     
     
         40 . The method of  claim 34 , further comprising:
 post-treating said high-visibility fabric;   wherein said post-treating comprises at least one process selected from the group consisting of resin finishing, controlled compressive shrinkage processing, overfeed shrinkage control during drying, shrinkage control processing via open width compactor, and combinations thereof.