Flame Resistant Fabrics Having Improved Resistance to Surface Abrasion or Pilling and Methods for Making Them

Abstract

Flame resistant fabrics and garments that have improved resistance to pilling and/or abrasion are disclosed. The fabrics, the fibers or yarns that make up the fabrics, or garments made from the fabrics are treated with a finish composition that is applied to the fibers, yarns, fabrics, or garments and then cured. The finish composition increases the resistance to pilling and/or abrasion of the fibers, yarns, fabrics, or garments. The finish composition includes a polymeric abrasion resistance aid, an alkylfluoropolymer, a polyethylene, and a wetting agent.

The invention claimed is: 
     
         1 . A flame resistant fabric, comprising:
 a plurality of spun yarns comprising a plurality of flame resistant fibers; and   a finish that imparts abrasion resistance to the fabric, the finish comprising a polymeric abrasion resistance aid and a hydrophobic component,   wherein the fabric, before laundering and after being laundered five times in accordance with AATCC test method 135 (2006), has an abrasion resistance of at least about 1000 cycles before a first thread break when tested in accordance with ASTM test method D3884 (2007) (H-18, 500 g on each wheel).   
     
     
         2 . The flame resistant fabric of  claim 1 , wherein the finish further comprises at least one of a durable press component and an antimicrobial component. 
     
     
         3 . The flame resistant fabric of  claim 1 , wherein the polymeric abrasion resistance aid comprises an acrylic polymer. 
     
     
         4 . The flame resistant fabric of  claim 1 , wherein the finish further comprises at least one of an alkoxylated fatty amine or derivative thereof, a melamine formaldehyde resin, an N-methylol stearamide, or combinations thereof. 
     
     
         5 . The flame resistant fabric of  claim 1 , wherein at least some of the plurality of flame resistant fibers are inherently flame resistant fibers comprising at least one of meta-aramid fibers, para-aramid fibers, polybenzimidazole fibers, polybenzoxazole fibers, melamine fibers, polyimide fibers, polyimideamide fibers, modacrylic fibers, and FR rayon fibers. 
     
     
         6 . The flame resistant fabric of  claim 1 , wherein the abrasion resistance is at least about 1500 cycles before the first thread break. 
     
     
         7 . The flame resistant fabric of  claim 6 , wherein the abrasion resistance is at least about 2500 cycles before the first thread break. 
     
     
         8 . The flame resistant fabric of  claim 1 , wherein the fabric, before laundering and after being laundered five times in accordance with AATCC test method 135 (2006), meets all flammability requirements of one or more of NFPA 1951 (2007), NFPA 1971 (2007), NFPA 1977 (2005), NFPA 2112 (2007), military specification MIL-C-83429B, or military specification GL-PD-07-12. 
     
     
         9 . The flame resistant fabric of  claim 1 , wherein the fabric, after being laundered ten times in accordance with AATCC test method 135 (2006), meets all flammability requirements of one or more of NFPA 1951 (2007), NFPA 1971 (2007), NFPA 1977 (2005), NFPA 2112 (2007), military specification MIL-C-83429B, or military specification GL-PD-07-12. 
     
     
         10 . The flame resistant fabric of  claim 1 , wherein the fabric, before laundering and after being laundered five times in accordance with AATCC test method 135 (2006), meets all water repellency requirements of one or both of NFPA 1951 (2007) or NFPA 1971 (2007). 
     
     
         11 . The flame resistant fabric of  claim 1 , wherein the fabric, after being laundered ten times in accordance with AATCC test method 135 (2006), meets all water repellency requirements of one or both of NFPA 1951 (2007) or NFPA 1971 (2007). 
     
     
         12 . The flame resistant fabric of  claim 1 , wherein the fabric, before laundering and after being laundered five times in accordance with AATCC test method 135 (2006), has water repellant properties comprising a water spray rating of at least about 70 as determined by AATCC test method 22 (2005) and a water absorption of less than or equal to about 2.0% as determined by NFPA 1971, 8.26 (2007). 
     
     
         13 . The flame resistant fabric of  claim 12 , wherein the water spray rating is about 100 as determined by AATCC test method 22 (2005) and the water absorption is less than or equal to about 1.0% as determined by NFPA 1971, 8.26 (2007). 
     
     
         14 . The flame resistant fabric of  claim 1 , wherein the fabric has a pilling performance rating of at least 4 after 60 minutes and a rating of at least 3 after 90 minutes when tested in accordance with ASTM test method D3512-05 (Reapproved 2007). 
     
     
         15 . The flame resistant fabric of  claim 14 , wherein the pilling performance rating is at least 4 after 90 minutes and at least 3 after 120 minutes. 
     
     
         16 . The flame resistant fabric of  claim 1 , wherein the fabric meets air permeability requirements in accordance with NFPA 1971 (2007). 
     
     
         17 . The flame resistant fabric of  claim 1 , wherein the fabric comprises a plain weave, a rip-stop, a twill weave, sateen weave or knitted fabric and wherein the fabric is stretch or non-stretch. 
     
     
         18 . The flame resistant fabric of  claim 1 , wherein the fabric has a weight of less than about 8.0 osy. 
     
     
         19 . A flame resistant garment comprising the flame resistant fabric of  claim 1 . 
     
     
         20 . A flame resistant fabric, comprising:
 a plurality of spun yarns comprising a plurality of flame resistant fibers; and   a finish that imparts abrasion resistance to the fabric, the finish comprising a polymeric abrasion resistance aid and at least one of a moisture management component, a durable press component, and an antimicrobial component,   wherein the fabric, before laundering and after being laundered five times in accordance with AATCC test method 135 (2006), has an abrasion resistance of at least about 1000 cycles before a first thread break when tested in accordance with ASTM test method D3884 (2007) (H-18, 500 g on each wheel).