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 single layer woven or knitted flame resistant fabric comprising a fiber blend, wherein:
 i. the fiber blend comprises a first type of inherently flame resistant fibers and a plurality of non-flame resistant synthetic cellulosic fibers;   ii. the first type of inherently flame resistant fibers comprises modacrylic fibers;   iii. the non-flame resistant synthetic cellulosic fibers comprise lyocell; and   iv. the fiber blend further comprises a second type of inherently flame resistant fibers,   
       wherein the percentage of modacrylic fibers in the fiber blend comprises a first percentage, wherein the percentage of synthetic cellulosic fibers in the fiber blend comprises a second percentage, wherein the second type of inherently flame resistant fibers comprises meta-aramid fibers comprising a third percentage of the fiber blend, wherein the third percentage is at least 30%, and wherein the fabric has a weight greater than or equal to 3 ounces per square yard (osy) and less than or equal to 7 osy. 
     
     
         35 . The flame resistant fabric of  claim 34 , wherein the second percentage is approximately 20-60%. 
     
     
         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 fabric has a weight greater than or equal to 3 osy and less than or equal to 6.5 osy. 
     
     
         38 . The flame resistant fabric of  claim 37 , wherein the fabric has a weight greater than or equal to 3 osy and less than or equal to 6.0 osy. 
     
     
         39 . The flame resistant fabric of  claim 38 , wherein the fabric has a weight greater than or equal to 3 osy and less than or equal to 5 osy. 
     
     
         40 . The flame resistant 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. 
     
     
         41 . The flame resistant fabric of  claim 40 , wherein the ratio is at least 1.10. 
     
     
         42 . The flame resistant fabric of  claim 34 , wherein the fabric is formed of yarns and all of the yarns in the fabric comprise the fiber blend. 
     
     
         43 . The flame resistant 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. 
     
     
         44 . The flame resistant fabric of  claim 43 , wherein the fabric has a before-wash char length less than or equal to 3.5 inches when tested according to ASTM Test D6413. 
     
     
         45 . The flame resistant fabric of  claim 44 , wherein the fabric has a before-wash char length less than 3.3 inches when tested according to ASTM Test D6413. 
     
     
         46 . The flame resistant fabric of  claim 45 , wherein the fabric has a before-wash char length less than or equal to 3.0 inches when tested according to ASTM Test D6413. 
     
     
         47 . The flame resistant fabric of  claim 46 , wherein the fabric has a before-wash char length less than or equal to 2.5 inches when tested according to ASTM Test D6413. 
     
     
         48 . The flame resistant fabric of  claim 34 , wherein the fabric has an afterflame less than 2 seconds when tested according to ASTM Test D6413. 
     
     
         49 . The flame resistant fabric of  claim 34 , wherein the fabric complies with at least one of ANSI 107-2004, NFPA 2112, and NFPA 70E. 
     
     
         50 . A garment comprising the flame resistant fabric of  claim 34 . 
     
     
         51 . A single layer woven or knitted flame resistant fabric comprising a fiber blend, wherein:
 a. the fiber blend comprises a first type of inherently flame resistant fibers and a plurality of non-flame resistant synthetic cellulosic fibers;   b. the first type of inherently flame resistant fibers comprises modacrylic fibers;   c. the non-flame resistant synthetic cellulosic fibers comprise lyocell; and   d. the fiber blend further comprises a second type of inherently flame resistant fibers,   e. the percentage of modacrylic fibers in the fiber blend comprises a first percentage;   f. the percentage of synthetic cellulosic fibers in the fiber blend comprises a second percentage;   g. the second type of inherently flame resistant fibers comprises meta-aramid fibers comprising a third percentage of the fiber blend;   h. the third percentage is at least 10% of the fiber blend;   i. the sum of the second and third percentages is greater than the first percentage;   j. the fabric has a weight greater than or equal to 3 osy and less than or equal to 7 osy;   k. the fabric has a before-wash char length less than or equal to 4 inches when tested according to ASTM Test D6413; and   l. the fabric has an afterflame less than 2 seconds when tested according to ASTM Test D6413.