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 - 33 . (canceled) 
     
     
         34 . A woven or knitted flame resistant fabric comprising spun yarns having a fiber blend comprising modacrylic fibers, wherein the fabric is dyed and/or printed with vat dyes such that the fabric complies with all of the color requirements set forth in at least one of (i) sections 3.4, 3.5, and 3.6 of MIL-C-83429 and (ii) sections 3.6, 3.7, and 3.8 of GL-PD-07-12. 
     
     
         35 . The fabric of  claim 34 , wherein the fiber blend further comprises cellulosic fibers. 
     
     
         36 . The fabric of  claim 35 , wherein the modacrylic fibers comprise a first percentage of the fiber blend and wherein the cellulosic fibers comprise a second percentage of the fiber blend, wherein the first percentage is greater than the second percentage. 
     
     
         37 . The fabric of  claim 35 , wherein the cellulosic fibers are synthetic cellulosic fibers. 
     
     
         38 . The fabric of  claim 37 , wherein the synthetic cellulosic fibers comprise lyocell fibers. 
     
     
         39 . The fabric of  claim 35 , wherein the cellulosic fibers are non-flame resistant. 
     
     
         40 . The fabric of  claim 35 , wherein the fiber blend further comprises nylon fibers. 
     
     
         41 . The fabric of  claim 34 , wherein the fiber blend further comprises nylon fibers. 
     
     
         42 . The fabric of  claim 41 , wherein the modacrylic fibers comprise a first percentage of the fiber blend and wherein the nylon fibers comprise a second percentage of the fiber blend, wherein the first percentage is greater than the second percentage. 
     
     
         43 . The fabric of  claim 34 , wherein the fiber blend is devoid of aramid fibers. 
     
     
         44 . The fabric of  claim 34 , wherein the fiber blend comprises 30-60% modacrylic fibers. 
     
     
         45 . The fabric of  claim 44 , wherein the fiber blend further comprises 20-60% cellulosic fibers. 
     
     
         46 . The fabric of  claim 45 , wherein the fiber blend further comprises 5-25% nylon fibers. 
     
     
         47 . The fabric of  claim 44 , wherein the fiber blend further comprises 5-25% nylon fibers. 
     
     
         48 . A garment comprising the flame resistant fabric of  claim 34 . 
     
     
         49 . A method of forming a flame resistant fabric comprising:
 a. weaving or knitting the fabric with yarns, wherein at least some of the yarns comprise a fiber blend comprising modacrylic fibers; and   b. dying or printing the fabric with vat dyes such that the fabric complies with all of the color requirements set forth in at least one of (i) sections 3.4, 3.5, and 3.6 of MIL-C-83429 and (ii) sections 3.6, 3.7, and 3.8 of GL-PD-07-12.   
     
     
         50 . The method of  claim 49 , wherein the fiber blend further comprises cellulosic fibers. 
     
     
         51 . The method of  claim 50 , wherein the fiber blend further comprises nylon fibers. 
     
     
         52 . The method of  claim 49 , wherein the fiber blend further comprises nylon fibers. 
     
     
         53 . The method of  claim 49 , wherein the fiber blend is devoid of aramid fibers.