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 single-layer flame resistant fabric comprising a fiber blend comprising:
 a. a first percentage of modacrylic fibers in the fiber blend, wherein the first percentage is less than forty percent;   b. a second percentage of non-flame resistant manmade cellulosic fibers in the fiber blend; and   c. a third percentage of nylon in the fiber blend,   wherein the fabric has an afterflame less than 2 seconds when tested according to ASTM Test D6413.   
     
     
         35 . The flame resistant fabric of  claim 34 , wherein the second percentage is not greater than the first percentage. 
     
     
         36 . The flame resistant fabric of  claim 34 , wherein the sum of the second and third percentages is greater than the first percentage. 
     
     
         37 . The flame resistant fabric of  claim 34 , wherein the third percentage comprises at least 25% of the fiber blend. 
     
     
         38 . The flame resistant fabric of  claim 34 , wherein the fiber blend is devoid of aramid fibers. 
     
     
         39 . The fabric of  claim 34 , wherein the fabric has a before-wash char length less than or equal to 4 inches when tested according to ASTM Test D6413. 
     
     
         40 . The fabric of  claim 34 , wherein the fabric complies with at least one of ANSI 107-2004, NFPA 2112, and NFPA 70E. 
     
     
         41 . The fabric of  claim 34 , wherein the fabric comprises an arc thermal protection value when tested according to ASTM Test F1959 and wherein the ratio of the arc thermal protection value to the weight is at least 1.05. 
     
     
         42 . A single layer woven or knitted flame resistant fabric for garments comprising a fiber blend, wherein:
 i. the fiber blend comprises modacrylic fibers, non-flame resistant lyocell fibers, and aramid fibers;   ii. the aramid fibers constitute at least 10% of the fiber blend;   iii. the lyocell fibers constitute greater than 30% and no more than 50% of the fiber blend;   iv. the modacrylic fibers constitute at least 40% and less than 60% of the fiber blend; and   v. the fabric has a fabric weight greater than 3 ounces per square yard (osy) and less than 7.8 osy.   
     
     
         43 . The fabric of  claim 42 , wherein the aramid fibers constitute more than 10% of the fiber blend. 
     
     
         44 . The fabric of  claim 42 , wherein the fabric weight is 7.5 osy or less. 
     
     
         45 . The fabric of  claim 44 , wherein the fabric weight is 7 osy or less. 
     
     
         46 . The fabric of  claim 45 , wherein the fabric weight is 6.5 osy or less. 
     
     
         47 . The fabric of  claim 42 , wherein the fabric has a before-wash char length of less than or equal to 4 inches when tested according to ASTM Test D6413. 
     
     
         48 . The fabric of  claim 47 , wherein the fabric has a before-wash char length of less than or equal to 3.5 inches when tested according to ASTM Test D6413. 
     
     
         49 . The fabric of  claim 48 , wherein the fabric has a before-wash char length of less than or equal to 3 inches when tested according to ASTM Test D6413. 
     
     
         50 . The fabric of  claim 49 , wherein the fabric has a before-wash char length of less than or equal to 2.5 inches when tested according to ASTM Test D6413. 
     
     
         51 . A single layer woven or knitted flame resistant fabric comprising a fiber blend, wherein the fiber blend comprises modacrylic fibers and a plurality of non-flame resistant synthetic cellulosic fibers, wherein the fabric is capable of complying with ANSI 107-2004 and NFPA 2112. 
     
     
         52 . The fabric of  claim 51 , wherein the 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. 
     
     
         53 . The fabric of  claim 51 , wherein the fiber blend further comprises aramid fibers. 
     
     
         54 . The fabric of  claim 53 , wherein the aramid fibers constitute at least 10% of the fiber blend. 
     
     
         55 . The fabric of  claim 54 , wherein the aramid fibers constitute more than 10% of the fiber blend. 
     
     
         56 . The fabric of  claim 53 , wherein the aramid fibers comprise para-aramid fibers. 
     
     
         57 . The fabric of  claim 51 , wherein the fabric has a fabric weight greater than 3 ounces per square yard (osy) and less than 7.8 osy. 
     
     
         58 . The fabric of  claim 57 , wherein the fabric weight is 7.5 osy or less. 
     
     
         59 . The fabric of  claim 58 , wherein the fabric weight is 7 osy or less. 
     
     
         60 . The fabric of  claim 59 , wherein the fabric weight is 6.5 osy or less. 
     
     
         61 . The fabric of  claim 51 , wherein the fabric has a before-wash char length of less than or equal to 4 inches when tested according to ASTM Test D6413. 
     
     
         62 . The fabric of  claim 61 , wherein the fabric has a before-wash char length of less than or equal to 3.5 inches when tested according to ASTM Test D6413. 
     
     
         63 . The fabric of  claim 62 , wherein the fabric has a before-wash char length of less than or equal to 3 inches when tested according to ASTM Test D6413.