Lightweight, Printable Flame Resistant Fabrics Suitable for Protective Clothing Worn in Hot and/or Humid Environments

Abstract

Flame resistant fabrics comprising a blend of modacrylic, aliphatic polyamide, and cellulosic fibers. Some embodiments are printed and/or dyed with vat dyes so as to comply with the color requirements (including the color, colorfastness, and IR requirements) set forth in the relevant sections of GL-PD-07-12 and/or MIL-PRF-EFRCE. Some embodiments further include reinforcing yarns that improve the strength of the fabrics. Still other embodiments are flame resistant fabrics for use in electrical applications that comply with some or all of the requirements of ASTM F 1506.

1 . (canceled) 
     
     
         2 . A flame resistant fabric comprising:
 spun yarns comprising a fiber blend comprising 35-70% modacrylic fibers, 10-40% cellulosic fibers, and 15-40% aliphatic polyamide fibers, wherein the fabric:
 (i) has a fabric weight between 2 and 7 ounces per square yard, inclusive; 
 (ii) has a two second or less afterflame measured pursuant to ASTM D6413; and 
 (iii) is capable of being printed or dyed in compliance with at least one infrared requirement set forth in at least one of GL-PD-07-12 and MIL-PRF-EFRCE. 
   
     
     
         3 . The flame resistant fabric of  claim 2 , wherein the fiber blend is devoid of aramid fibers. 
     
     
         4 . The flame resistant fabric of  claim 2 , wherein the fabric comprises a greater percentage of aliphatic polyamide fibers than cellulosic fibers. 
     
     
         5 . The flame resistant fabric of  claim 2 , wherein the fiber blend comprises 40-70% modacrylic fibers, 10-30% cellulosic fibers, and 15-30% aliphatic polyamide fibers. 
     
     
         6 . The flame resistant fabric of  claim 5 , wherein the fiber blend comprises 50-70% modacrylic fibers, 10-25% cellulosic fibers, and 20-30% aliphatic polyamide fibers. 
     
     
         7 . The flame resistant fabric of  claim 2 , wherein the fabric weight is between 2 and 6 ounces per square yard, inclusive. 
     
     
         8 . The flame resistant fabric of  claim 2 , wherein the fabric further comprises a plurality of stretch broken yarns or filament yarns. 
     
     
         9 . The flame resistant fabric of  claim 8 , wherein the plurality of stretch broken yarns or filament yarns are provided in both a warp direction and a fill direction of the fabric so as to form a grid pattern within the fabric. 
     
     
         10 . The flame resistant fabric of  claim 8 , wherein the plurality of stretch broken yarns or filament yarns comprise aliphatic polyamide filament yarns. 
     
     
         11 . The flame resistant fabric of  claim 8 , wherein the fabric weight is between 2 and 6 ounces per square yard, inclusive. 
     
     
         12 . The flame resistant fabric of  claim 11 , wherein the fabric comprises a fabric tear strength of at least 14 pounds force in at least one of a warp direction or a fill direction of the fabric when tested pursuant to ASTM D1424. 
     
     
         13 . The flame resistant fabric of  claim 8 , wherein the fabric weight is between 2 and 6 ounces per square yard, inclusive, and wherein the plurality of stretch broken yarns or filament yarns comprises a weight that is 5-40% of the fabric weight. 
     
     
         14 . The flame resistant fabric of  claim 2 , wherein the fabric is capable of being printed or dyed so as to comply with at least one of: GL-PD-07-12, sections 3.6.1.1, 3.6.3 (Table I), and 3.8.1; GL-PD-07-12, sections 3.6.1.2, 3.6.3 (Table I.A), and 3.8.2; GL-PD-07-12, sections 3.6.1.3, 3.6.3 (Table LB), and 3.8.3; MIL-PRF-EFRCE, sections 3.3.2.1, 3.3.5 (Table I), and 3.3.7.1; MIL-PRF-EFRCE, sections 3.3.2.2, 3.3.5 (Table I), and 3.3.7.2; MIL-PRF-EFRCE, sections 3.3.2.3, 3.3.5 (Table I), and 3.3.7.3; MIL-PRF-EFRCE, sections 3.3.2.4, 3.3.5 (Table I), and 3.3.7.3; and MIL-PRF-EFRCE, sections 3.3.2.5, 3.3.5 (Table II), and 3.3.7.4. 
     
     
         15 . The flame resistant fabric of  claim 2 , wherein the fiber blend comprises a greater percentage of modacrylic fibers than either of the cellulosic fibers and the aliphatic polyamide fibers, individually. 
     
     
         16 . The flame resistant fabric of  claim 2 , wherein the fiber blend comprises a greater percentage of modacrylic fibers than the cellulosic fibers and the aliphatic polyamide fibers, cumulatively. 
     
     
         17 . The flame resistant fabric of  claim 2 , wherein the fabric has a char length of seven inches or less. 
     
     
         18 . The flame resistant fabric of  claim 2 , wherein the cellulosic fibers are non-flame resistant cellulosic fibers. 
     
     
         19 . The flame resistant fabric of  claim 2 , wherein the modacrylic fibers are the only flame resistant fibers in the fiber blend. 
     
     
         20 . A flame resistant fabric having a warp direction and a fill direction, the flame resistant fabric comprising:
 a. spun yarns provided in the warp direction and the fill direction and comprising a fiber blend comprising 50-70% modacrylic fibers, 10-25% cellulosic fibers, and 15-40% aliphatic polyamide fibers; and   b. a plurality of stretch broken yarns or filament yarns provided in at least the fill direction of the fabric,   wherein a fabric tear strength, when measured in pounds force and pursuant to ASTM D1424 (2013), of the flame resistant fabric in the fill direction is at least 50% greater than a fabric tear strength, when measured in pounds force and pursuant to ASTM D1424 (2013), in a fill direction of a comparative flame resistant fabric formed only with the spun yarns.   
     
     
         21 . A flame resistant fabric having a warp direction and a fill direction, the flame resistant fabric comprising:
 a. spun yarns provided in the warp direction and the fill direction and comprising a fiber blend comprising 50-70% modacrylic fibers, 10-25% cellulosic fibers, and 15-40% aliphatic polyamide fibers, wherein the fiber blend is devoid of aramid fibers, wherein the fiber blend comprises a greater percentage of aliphatic polyamide fibers than cellulosic fibers, and wherein the spun yarns comprise a yarn breaking strength when measured pursuant to ASTM D5034 (2013); and   b. a plurality of stretch broken yarns or filament yarns provided in the fill direction of the fabric,   wherein a fabric tear strength, when measured pursuant to ASTM D1424 (2013), of the flame resistant fabric in the fill direction is greater than a fabric tear strength, when measured pursuant to ASTM D1424 (2013), in a fill direction of a comparative flame resistant fabric formed with (1) the plurality of stretch broken yarns or filament yarns provided in the fill direction of the comparative flame resistant fabric and (2) spun yarns provided in a warp direction and the fill direction of the comparative flame resistant fabric and having (a) a yarn breaking strength, when measured pursuant to ASTM D5034 (2013), that is greater than the yarn breaking strength of the spun yarns of the flame resistant fabric and (b) a fiber blend comprising 65% FR rayon, 25% para-aramid fibers, and 10% nylon fibers.