Flame retardant fabric composed of thermoplastic core-spun yarns

Abstract

A fabric that includes an air jet core-spun yarn including a core composed of continuous filament thermoplastic yarns and a sheath composed of cellulose staple wrapper fibers or cellulose-rich staple fibers, wherein the fabric is treated with a flame retardant compound.

What is claimed: 
     
         1 . A fabric, comprising an air jet core-spun yarn comprising a core composed of continuous filament thermoplastic yarns and a sheath composed of cellulose staple wrapper fibers, wherein the fabric is treated with a flame-retardant compound. 
     
     
         2 . The fabric according to  claim 1 , wherein the continuous filament thermoplastic core yarn comprises a flame-retardant monomer or flame-retardant additive. 
     
     
         3 . The fabric according to  claim 1 , wherein a portion of the cellulose staple wrapper fibers of the sheath are replaced by synthetic non-thermoplastic, flame resistant staple fibers. 
     
     
         4 . The fabric according to  claim 3 , wherein the synthetic non-thermoplastic, flame-retardant staple fibers may be selected from the group comprising meta- and para-aramids, polybenzimidazole, polybenzoxazole, novoloid, oxidized polyacrylonitrile, polyoxadiazole, polyacrylate, modacrylic, melamine, polyimide, or combination thereof. 
     
     
         5 . The fabric according to  claim 3 , wherein the cellulose staple wrapper fibers comprise less than 10% of an inherently flame resistant non-thermoplastic staple fiber 
     
     
         6 . The fabric according to  claim 1 , wherein the flame retardant compound is a phosphorous-based flame-retardant compound. 
     
     
         7 . The fabric according to  claim 1 , wherein the flame-retardant compound is a pentavalent tetrakis hydroxymethyl phosphonium (THP) salt compound. 
     
     
         8 . The fabric according to  claim 1 , wherein the fabric self-extinguishes when tested using test method ASTM D6413: Standard Test Method for Flame Resistance of Textiles (Vertical Test). 
     
     
         9 . A fabric, comprising an air jet core-spun yarn comprising a core composed of continuous filament thermoplastic yarns and a sheath composed of cellulose-rich staple wrapper fibers, wherein the fabric is treated with a flame-retardant compound. 
     
     
         10 . The fabric according to  claim 9 , wherein the continuous filament thermoplastic core yarn comprises a flame-retardant monomer or flame-retardant additive. 
     
     
         11 . The fabric according to  claim 9 , wherein the cellulose-rich staple wrapper fibers are composed of cellulose and synthetic non-thermoplastic, flame resistant staple fibers. 
     
     
         12 . The fabric according to  claim 11 , wherein the synthetic non-thermoplastic, flame-retardant staple fibers may be selected from the group comprising meta- and para-aramids, polybenzimidazole, polybenzoxazole, novoloid, oxidized polyacrylonitrile, polyoxadiazole, polyacrylate, modacrylic, melamine, polyimide, or combination thereof. 
     
     
         13 . The fabric according to  claim 11 , wherein the cellulose-rich staple wrapper fibers comprise less than 10% of an inherently flame resistant non-thermoplastic staple fiber. 
     
     
         14 . The fabric according to  claim 9 , wherein the flame-retardant compound is a phosphorous-based flame-retardant compound. 
     
     
         15 . The fabric according to  claim 9 , wherein the flame-retardant compound is a pentavalent tetrakis hydroxymethyl phosphonium (THP) salt compound. 
     
     
         16 . The fabric according to  claim 9 , wherein the fabric self-extinguishes when tested using test method ASTM D6413: Standard Test Method for Flame Resistance of Textiles (Vertical Test).