Fabric material that is resistant to flash fires and electrical arc flashes

Abstract

Fabrics and garments are disclosed that have dual protection against flash fires and electrical arc flashes. The fabrics can be made from spun yarns containing an intimate blend of fibers. The fibers contained in each yarn can include modacrylic fibers, cellulose fibers, polyamide fibers, and inherently flame resistant fibers.

What is claimed: 
     
         1 . A garment for producing protection against flash fires and electrical arc flashes comprising;
 a fabric shaped to cover at least a portion of a wearer's body, the fabric comprising a woven fabric made from a plurality of yarns, the fabric comprising warp yarns and fill yarns, the warp yarns and fill yarns comprising a fiber blended yarn, the fiber blended yarn comprising a blend of fibers including:   modacrylic fibers in an amount from about 38% to about 49% by weight;   regenerated cellulose fibers in an amount from about 36% to about 48% by weight;   polyamide fibers in an amount from about 5% by weight to about 15% by weight;   inherently flame resistant fibers in an amount from about 5% to about 15% by weight; and   wherein the fabric displays an arc rating (ATPV) of greater than 7.5 cal/cm 2  when tested according to Test ASTM F1959/F1959M-14-e1.   
     
     
         2 . A garment as defined in  claim 1 , wherein the yarns contained within the woven fabric are made from an intimate blend of the modacrylic fibers, the regenerated cellulose fibers, the polyamide fibers, and the inherently flame resistant fibers. 
     
     
         3 . A garment as defined in  claim 1 , wherein the woven fabric has a twill weave or a rip stop weave. 
     
     
         4 . A garment as defined in  claim 1 , wherein the regenerated cellulose fibers have a tenacity of from about 28 cN/tex to about 38 cN/tex, such as from about 30 cN/tex to about 37 cN/tex, and have a water retention of less than about 70%, such as less than about 65%, such as less than about 63%. 
     
     
         5 . A garment as defined in  claim 1 , wherein the modacrylic fibers are present in the fiber blended yarn in an amount from about 40% by weight to about 44% by weight, the regenerated cellulose fibers being present in the fiber blended yarn in an amount from about 40% by weight to about 44% by weight, the polyamide fibers being present in the fiber blended yarn in an amount from about 6% to about 9% by weight, and the inherently flame resistant fibers being present in the fiber blended yarn in an amount from about 6% by weight to about 10% by weight. 
     
     
         6 . A garment as defined in  claim 1 , wherein the inherently flame resistant fibers comprise para-aramid fibers, meta-aramid fibers, or mixtures thereof. 
     
     
         7 . A garment as defined in  claim 1 , wherein the woven fabric has a basis weight of from about 6.4 osy to about 9.5 osy. 
     
     
         8 . A garment as defined in  claim 1 , wherein the fiber blended yarn comprises greater than about 85% by weight of the woven fabric. 
     
     
         9 . A garment as defined in  claim 1 , wherein the woven fabric comprises about 65 yarns per inch to about 95 yarns per inch in the warp direction and from about 50 yarns per inch to about 75 yarns per inch in the fill direction. 
     
     
         10 . A garment as defined in  claim 1 , wherein the garment comprises a shirt, overalls, trousers, or an apron. 
     
     
         11 . A garment as defined in  claim 1 , wherein the woven fabric has an arc rating (ATPV) of greater than about 8 cal/cm 2 , such as greater than about 9 cal/cm 2 , such as greater than about 9.5 cal/cm 2 . 
     
     
         12 . A garment as defined in  claim 1 , wherein the modacrylic fibers, the regenerated cellulose fibers, the polyamide fibers, and the inherently flame resistant fibers have been solution dyed. 
     
     
         13 . A garment as defined in  claim 1 , wherein the woven fabric displays a material break-open (Ebt) when tested according to Test ASTM F1959 of greater than about 10 cal/cm 2 , such as greater than about 12 cal/cm 2 , such as greater than about 13 cal/cm 2 . 
     
     
         14 . A garment as defined in  claim 1 , wherein the woven fabric displays a char length of less than about 4 inches in the warp direction and less than about 3 inches in the weft direction when tested according to Test ASTM D6143 before laundering. 
     
     
         15 . A garment as defined in  claim 1 , wherein the woven fabric displays a heat attenuation factor (HAF) when tested according to Test ASTM F1959 of greater than about 65%, such as greater than about 70%, such as greater than about 75%, such as greater than about 80%. 
     
     
         16 . A garment for producing protection against flash fires and electrical arc flashes comprising;
 a fabric shaped to cover at least a portion of a wearer's body, the fabric comprising a woven fabric made from a plurality of yarns, the fabric comprising warp yarns and fill yarns, the warp yarns and fill yarns comprising a fiber blended yarn, the fiber blended yarn comprising a blend of fibers including:   modacrylic fibers in an amount from about 38% to about 49% by weight;   regenerated cellulose fibers in an amount from about 36% to about 48% by weight;   polyamide fibers in an amount from about 5% by weight to about 15% by weight;   inherently flame resistant fibers in an amount from about 5% to about 15% by weight; and   wherein the modacrylic fibers, the regenerated cellulose fibers, the polyamide fibers, and the inherently flame resistant fibers have all been solution dyed.   
     
     
         17 . A garment as defined in  claim 16 , wherein the modacrylic fibers are present in the fiber blended yarn in an amount from about 40% by weight to about 44% by weight, the regenerated cellulose fibers being present in the fiber blended yarn in an amount from about 40% by weight to about 44% by weight, the polyamide fibers being present in the fiber blended yarn in an amount from about 6% to about 9% by weight, and the inherently flame resistant fibers being present in the fiber blended yarn in an amount from about 6% by weight to about 10% by weight. 
     
     
         18 . A garment as defined in  claim 16 , wherein the regenerated cellulose fibers have a tenacity of from about 28 cN/tex to about 38 cN/tex, such as from about 30 cN/tex to about 37 cN/tex, and have a water retention of less than about 70%, such as less than about 65%, such as less than about 63%. 
     
     
         19 . A garment as defined in  claim 16 , wherein the woven fabric displays a material break-open (Ebt) when tested according to Test ASTM F1959 of greater than about 10 cal/cm 2 , such as greater than about 12 cal/cm 2 , such as greater than about 13 cal/cm 2 . 
     
     
         20 . A fabric material for providing protection against flash fires and electrical arc flashes comprising a woven fabric made from a plurality of yarns, the fabric comprising warp yarns and fill yarns, the warp yarns and fill yarns comprising a fiber blended yarn, the fiber blended yarn comprising a blend of fibers including:
 modacrylic fibers in an amount from about 38% to about 49% by weight;   regenerated cellulose fibers in an amount from about 36% to about 48% by weight;   polyamide fibers in an amount from about 5% by weight to about 15% by weight;   inherently flame resistant fibers in an amount from about 5% to about 15% by weight; and   wherein the fabric displays an arc rating (ATPV) of greater than 7.5 cal/cm 2  when tested according to Test ASTM F1959/F1959M-14-e1.