Note: Descriptions are shown in the official language in which they were submitted.
FABRIC MATERIAL THAT IS RESISTANT TO FLASH FIRES AND
ELECTRICAL ARC FLASHES
BACKGROUND
[0001] Workers in many industrial settings and in various other
occupations can
be exposed to hazardous and life threating situations. For example, some
workers
operate in environments where there is a possibility that they will be exposed
to
flash fires or electrical arc flashes. For example, workers in many chemical
factories face the risk of exposure to chemical flash fires. These flash fires
can
occur quickly and without warning.
[0002] In addition to flash fires, many workers can also be exposed to
electrical
arc flashes. For example, almost every industrial or manufacturing facility
employs
electricians to make changes or modify the existing electrical system, to make
repairs and/or to change out electrical components. During these operations
and
procedures, the workers face inherent dangers in working with the electrical
lines
and the power supply.
[0003] To avoid being injured while working in the environments as
described
above, workers and other personnel should be provided protective apparel that
is
capable of protecting the worker against the hazards that they may face,
including
electrical arcs, open flames, and fires. These protective garments can take
various forms including full body suits, pants, shirts, aprons, gloves, and
the like.
Ideally, the protective garment should possess life-saving properties for
protecting
the wearer should any accidental exposure occur. For example, garments
designed to protect workers from flash fires should be made from materials
that do
not ignite when contacted with an open flame and provide a thermal barrier for
the
user. Similarly, protective garments designed to protect workers from arc
flashes
should be capable of being exposed to the arc flash without igniting or
allowing the
arc flash to propagate through the material.
[0004] In the past, various different fabrics have been proposed for
producing
garments and apparel that will protect workers from flash fires, electrical
arc
flashes, and the like. Most conventional fabrics, for instance, are very heavy
and
thick, essentially relying on having enough fabric material between the worker
and
the hazardous condition to prevent injury. Although capable of protecting
workers,
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Date Recue/Date Received 2023-07-14
these fabrics can cause other problems. For instance, the fabrics add a
significant
amount of weight to the wearer and typically do not have very good moisture
management properties. Thus, workers can become stressed and undergo
physical fatigue when wearing garments or apparel made from the fabric.
[0005] In view of the above, a need currently exists for an improved
fabric and
garments made from the fabric that can provide protection against flash fires
and/or electrical arc flashes. A need also exists for a fabric that has
improved
electrical arc flash resistance, while containing breathable materials, such
as
cellulose-based fibers. A need also exists for a fabric and garment that can
provide resistance to electrical arc flashes made from a blend of different
fibers
that can be produced having a uniform color and/or appearance.
SUMMARY
[0006] In general, the present disclosure is directed to a fabric made
from a
blend of fibers that can provide protection against flash fires and/or
electrical arc
flashes. Of particular advantage, the fabric can be made containing cellulose
fibers, such as regenerated cellulose fibers, which not only provide
protection to
the wearer but also greatly improve comfort and wearability, especially in
industrial
environments that are not temperature controlled. In one aspect, the fabric
can be
made from yarns that are the same or substantially the same in both the warp
and
fill directions providing the fabric with a great balance of physical
properties in both
directions and dimensional stability. The fabric of the present disclosure can
be
used to make all different types of garments and apparel.
[0007] In one embodiment, for instance, the present disclosure is
directed to a
garment that is resistant to flash fires and/or electrical arc flashes. The
garment
includes a fabric shaped to cover at least a portion of a wearer's body. The
fabric
comprises a woven fabric made from a plurality of yarns. The fabric comprises
warp yarns and fill yarns. The warp yarns and fill yarns comprise a fiber
blended
yarn. The fiber blended yarn comprises a blend of fibers including modacrylic
fibers in an amount of from about 38% to about 49% by weight, regenerated
cellulose fibers in an amount of from about 36% to about 48% by weight,
polyamide fibers in an amount from about 5% to about 15% by weight, and
inherently flame resistant fibers in an amount of from about 5% to about 15%
by
weight. Alternatively, the fiber blended yarn comprises a blend of fibers
including
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Date Recue/Date Received 2023-07-14
modacrylic fibers in an amount of from about 40% to about 44% by weight,
regenerated cellulose fibers in an amount from about 40% to about 44% by
weight,
polyamide fibers in an amount from about 6% to about 9% by weight, and
inherently flame resistant fibers in an amount from about 6% to about 10% by
weight.
[0008] In one aspect, 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. The
inherently
flame resistant fibers, for instance, can be para-aramid fibers, meta-aramid
fibers,
or mixtures thereof.
[0009] The woven fabric made in accordance with the present disclosure
can
generally have a basis weight of from about 5 osy to about 12 osy, including
all
increments of 0.1 osy therebetween. For example, the basis weight can be
greater
than about 5.5 osy, such as greater than about 6 osy, such as greater than
about
6.4 osy, such as greater than about 6.6 osy, such as greater than about 6.8
osy,
and generally less than about 11 osy, such as less than about 10 osy, such as
less
than about 9.5 osy, such as less than about 8 osy, such as less than about 7.7
osy. The fabric can made exclusively from the fiber blended yarns. In one
aspect,
the fabric comprises from about 65 yarns per inch to about 95 yarns per inch
in the
warp direction and about 50 yarns per inch to about 75 yarns per inch in the
fill
direction.
[00010] In one aspect, the fiber blended yarn as described above extends in
both the warp direction and the fill direction and comprises at least about
85% by
weight of the fabric. For instance, the fiber blended yarn can comprise
greater
than about 90% by weight of the fabric, such as greater than about 95% of the
weight of the fabric. In one aspect, the woven fabric is made entirely from
the fiber
blended yarn or includes the fiber blended yarn in combination with from about
0.5% to about 2.5% of antistatic yarns.
[00011] The woven fabric can have any suitable weave, such as a twill weave.
In one aspect, the woven fabric has a 2 x 1 twill weave. Alternatively, the
fabric
can have a rip stop weave.
[00012] The present disclosure is also directed to the fabric material as
described above used to produce the garment. When tested according to Test
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Date Recue/Date Received 2023-07-14
ASTM D6413, for instance, the fabric material can display a char length of
less
than about 4 inches in the warp direction and less than about 4 inches in the
weft
or fill direction before being laundered. When tested for arc flash protection
according to Test ASTM F1959, on the other hand, the fabric material can
display
a result of greater than about 7 cal/cm25, such as greater than about 7.5
cal/cm25,
such as greater than about 8 cal/cm25, such as greater than about 8.5
cal/cm25,
such as greater than about 9 cal/cm25, such as greater than about 9.5
cal/cm25,
such as greater than about 9.8 cal/cm25, and generally less than about 18
cal/cm2s.
[00013] In one aspect, all of the fibers contained in the warp yarns and fill
yarns
can be solution dyed yarns. For instance, the modacrylic fibers, the
regenerated
cellulose fibers, the polyamide fibers, and the inherently flame resistant
fibers can
all be solution dyed providing the garment not only with a distinctive and
uniform
color or appearance, but also with excellent color fastness.
[00014] Garments made in accordance with the present disclosure include
shirts,
overalls, trousers, aprons, and the like.
[00015] The present disclosure is also directed to a fabric material as
described
above that is used to construct the garment.
[00016] Garments and fabric materials made according to the present disclosure
have an excellent balance of properties. In one aspect, the fabric material
can be
both resistant to flash fires and electrical arc flashes.
[00017] Other features and aspects of the present disclosure are discussed in
greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[00018] A full and enabling disclosure of the present disclosure is set forth
more
particularly in the remainder of the specification, including reference to the
accompanying figures, in which:
Figure 1 is one embodiment of a garment made in accordance with the
present disclosure.
[00019] Repeat use of reference characters in the present specification and
drawings is intended to represent the same or analogous features or elements
of
the present invention.
4
Date Recue/Date Received 2023-07-14
DETAILED DESCRIPTION
[00020] It is to be understood by one of ordinary skill in the art that the
present
discussion is a description of exemplary embodiments only and is not intended
as
limiting the broader aspects of the present disclosure.
[00021] In general, the present disclosure is directed to a fabric material
and
apparel made from the fabric material that are resistant to flash fires and/or
arc
flashes. The fabric of the present disclosure generally comprises yarns made
from
a fiber blend that includes modacrylic fibers and inherently flame resistant
fibers
combined with cellulose fibers, particularly regenerated cellulose fibers, and
polyamide fibers. The fiber blend made in accordance with the present
disclosure
has been found to produce fabrics having unexpectedly improved properties with
respect to arc flash protection. In addition, fabrics made according to the
present
disclosure are comfortable to wear and breathable.
[00022] In addition, the fabrics made according to the present disclosure can
have a distinctive look and aesthetic appeal. For instance, in one embodiment,
the
modacrylic fibers, the regenerated cellulose fibers, the polyamide fibers, and
the
inherently flame resistant fibers can all be solution dyed, which is also
referred to
as producer dyed fibers. The fibers used to make the yarns, for instance, can
be
solution dyed the same color, a similar color, or a complementary collection
of
colors. In this manner, once woven, the fabric has a uniform appearance. In
addition, because the fibers are solution dyed, the color of the fabric is
wear
resistant and will not fade or degrade, even when subjected to multiple
laundry
cycles.
[00023] The fiber blended fabric can be incorporated into all different types
of
protective apparel including shirts, pants, coveralls, coats, aprons, gloves,
hoods,
and the like.
[00024] In one aspect, the fabric of the present disclosure can be designed to
protect not only against electrical arc flash exposure, but also against flash
fire
exposure. For example, many workers operate in environments where possible
exposure to flash fires, such as chemical fires, and possible exposure to
electrical
arc flashes are both present. Alternatively, workers may move in between
Date Recue/Date Received 2023-07-14
manufacturing areas and thus can be exposed to both of the above hazards. The
fabric of the present disclosure can provide dual hazard protection.
[00025] Due to the fiber blend, the fabric of the present disclosure has
dramatically improved and unexpected properties when tested against resistance
to arc flashes. For instance, when tested according to Test ASTM Fl 959/F1959M-
14-e1(current year test), the fabric of the present disclosure can display an
arc
rating of greater than about 7 cal/cm2, such as greater than about 7.5
cal/cm2,
such as greater than about 8 cal/cm2, such as greater than about 8.5 cal/cm2,
such
as greater than about 9 cal/cm2, such as even greater than about 9.5 cal/cm2.
The
arc rating is generally less than about 25 cal/cm2. The fabric can also
display a
material break-open (Ebt) of greater than about 9 cal/cm2, such as greater
than
about 10 cal/cm2, such as greater than about 11 cal/cm2, such as greater than
about 12 cal/cm2, such as greater than about 13 cal/cm2, such as even greater
than about 13.5 cal/cm2. The material break-open of the fabric is generally
less
than about 30 cal/cm2. Further, the fabric can display a heat attenuation
factor
(HAF) of greater than about 70%, such as greater than about 73%, such as
greater than about 75%, such as greater than about 77%, such as greater than
about 80%, and generally less than about 98%. The above properties and
characteristics of the fabric are especially dramatic and unexpected in view
of the
amount of regenerated cellulose contained within the fiber blend. As will be
described below, in one aspect, a particular type of regenerated cellulose
fiber is
used that is believed to at least in part contribute to the dramatic results.
[00026] In addition to providing excellent protection again electrical arc
flashes
and flash fires, the fabric of the present disclosure offers many benefits and
advantages. More particularly, the fabric is made from yarns that each contain
an
intimate blend of fibers including modacrylic fibers, inherently flame
resistant
fibers, polyamide fibers, and cellulose fibers. The yarns made from the
intimate
blend have been found to be well suited for use in both the warp direction and
the
fill direction of a woven fabric. By having similar yarns in the warp and fill
directions, fabrics made according to the present disclosure have an excellent
balance of properties. For example, the fabric can have comparable physical
properties, such as strength properties, in both directions which provide the
fabric
with dimensional stability.
6
Date Recue/Date Received 2023-07-14
[00027] As described above, the fabric material of the present disclosure
contains substantial amounts of cellulose fibers, particularly regenerated
cellulose
fibers. The use of cellulose fibers can provide various advantages and
benefits,
especially in relation to fabrics that contain polymer synthetic fibers.
Cellulose
fibers, such as regenerated cellulose fibers, for instance, can increase
comfort,
and breathability. Cellulose fibers are also considered a renewable resource
that
makes the product more sustainable and better for the environment. The use of
regenerated cellulose fibers can also provide various unique advantages and
benefits. For instance, regenerated cellulose fibers can be solution dyed,
making
the fibers resistant to fading and degradation. The use of solution dyed
cellulose
fibers can greatly enhance the overall aesthetic appearance of fabrics and
garments made from the fiber blend.
[00028] As described above, the fabric material of the present disclosure can
contain substantial amounts of cellulose fibers, particularly regenerated
cellulose
fibers, while still displaying significant levels of protection against flash
fires and
electrical arc flashes. The fabric material of the present disclosure can
maintain
government mandated safety performance properties while providing improved
economics, quality, aesthetics and comfort relative to other fabrics made in
the
past. For example, fabrics materials and protective garments made according to
the present discourse can meet all of the requirements of the National Fire
Protection Association (NFPA) Standard 70E that relates to chemical flash fire
protection and protective apparel for electrical arc hazards.
[00029] As described above, the fabric of the present disclosure is formed
from
spun yarns that contain a particular blend of fibers. More particularly, the
blend of
fibers include modacrylic fibers, cellulose fibers, polyamide fibers, and
inherently
flame resistant fibers, such as aramid fibers. The spun yarns incorporated
into the
fabric can be single spun yarns or can be plied yarns, such as two ply yarns.
Alternatively, the fabric can contain both single spun yarns and plied yarns.
In one
aspect, the fabric contains plied yarns in at least one direction, such as in
the warp
direction, the fill direction or in both directions.
[00030] The size of the spun yarns can vary depending upon the particular
application and the desired result. For example, the size of the spun yarns
can
depend upon the desired overall fabric weight of the fabric, the type of
garment
7
Date Recue/Date Received 2023-07-14
being formed, and the like. In one aspect, when using single yarns, the yarn
size
can be 12/1, 14/1, 16/1, 18/1, 20/1, 22/1, 24/1, 26/1, 28/1, 30/1, 32/1, 34/1,
36/1,
38/1, and/or 40/1 including all intervening sizes therebetween and all ranges
therebetween. When using plied yarns, on the other hand, the size of the yarns
can be 20/2, 22/2, 24/2, 26/2, 28/2, 30/2, 34/2, 36/2, 38/2, 40/2, 44/2, 48/2,
52/2,
56/2, 60/2, 64/2, 68/2, 72/2, or 76/2 including all intervening sizes
therebetween
and all ranges therebetween. The above sizes are based on a cotton count.
[00031] The spun yarns produced according to the present disclosure containing
modacrylic fibers, cellulose fibers, polyamide fibers, and inherently flame
resistant
fibers, can extend only in the warp direction, only in the fill direction, or
can extend
in both the warp direction and the fill direction. Improved physical
properties may
be realized by having yarns made according to the present disclosure extend in
both the warp direction and the fill direction. In fact, in one embodiment,
greater
than 90% by weight, such as greater than about 95% by weight, such as 100% by
weight of the fabric can be formed from spun yarns made in accordance with the
present disclosure. The spun yarns contained in the fabric can all be
identical and
can be made from the exact same intimate blend of fibers. Alternatively,
different
spun yarns can be incorporated into the fabric that are all made with
different
ratios or amounts of the modacrylic fibers, cellulose fibers, polyamide
fibers, and
inherently flame resistant fibers.
[00032] Modacrylic fibers can be present in the spun yarns and in the fabric
generally in an amount from about 35% by weight to about 60% by weight,
including all increments of 1% by weight between. For example, the modacrylic
fibers can be present in the spun yarns in an amount greater than about 38% by
weight, such as in an amount greater than about 39% by weight, such as in an
amount greater than about 40% by weight. The modacrylic fibers are generally
contained in the spun yarns in an amount less than about 49% by weight, such
as
in an amount less than about 47% by weight, such as in an amount less than
about 45% by weight, such as in an amount less than about 44% by weight, such
as in an amount less than about 43% by weight. The modacrylic fibers
incorporated into the fabric material can serve several different functions.
For
example, modacrylic fibers can provide resistance to flash fires and electric
arc
flashes while having a relatively low density. The lower density translates
into a
8
Date Recue/Date Received 2023-07-14
protective fabric having a lighter basis weight. In addition, modacrylic
fibers have
good dimensional stability. Modacrylic fibers are also soft, strong and are
resistant
to chemicals and solvents. Thus, modacrylic fibers are particularly well
suited for
use in fabric materials that may be exposed to chemical flash fires.
[00033] In addition to modacrylic fibers, the yarns and fabric material of the
present disclosure also contain cellulose fibers. The cellulose fibers, for
instance,
improve comfort and breathability. Overall, the addition of cellulose fibers,
such as
regenerated cellulose fibers, improve quality, aesthetics and comfort.
[00034] In one embodiment, a particular type of regenerated cellulose fiber is
incorporated into the fiber blend. The regenerated cellulose fibers, for
instance,
can have a tenacity of from about 28 cl\l/tex to about 39 cl\l/tex, including
all
increments of 1 cl\l/tex therebetween. For instance, the tenacity of the
fibers can
be greater than about 28 cl\l/tex, such as greater than about 29 cl\l/tex,
such as
greater than about 30 cl\l/tex, such as greater than about 31 cl\l/tex, such
as
greater than about 32 cl\l/tex. The tenacity is generally less than about 38
cl\l/tex,
such as less than about 37 cl\l/tex, such as less than about 36 cl\l/tex.
[00035] The regenerated cellulose fibers can have an elongation of generally
less than about 20%. For instance, the elongation can be less than about 18%,
such as less than about 17%, and generally greater than about 8%, such as
greater than about 10%, such as greater than about 12%. The regenerated
cellulose fibers can also be selected so as to have a relatively low water
retention
ability. For instance, the water retention ability of the fibers can be less
than about
70%, such as less than about 65%, such as less than about 63%, such as less
than about 61%, and generally greater than about 40%, such as greater than
about 52%.
[00036] The regenerated cellulose fibers can also have a relatively low
crystallinity. For instance, the crystallinity of the fibers can be less than
about
39%, such as less than about 37%, such as less than about 35%, such as less
than about 33%, such as less than about 30%, such as less than about 28%, such
as less than about 26%. The crystallinity is generally greater than about 10%,
such as greater than about 15%. The regenerated cellulose fibers can have a
size
of generally greater than about 0.5 dtex, such as greater than about 0.8 dtex,
such
as greater than about 1 dtex, such as greater than about 1.2 dtex, such as
greater
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Date Recue/Date Received 2023-07-14
than about 1.5 dtex. The size of the fibers is generally less than about 10
dtex,
such as less than about 8 dtex, such as less than about 5 dtex, such as less
than
about 3 dtex, such as less than about 2.5 dtex, such as less than about 2
dtex.
[00037] In accordance with the present disclosure, significant amounts of
cellulose fibers are incorporated into the fabric material and blended with
other
fibers that results in a fabric material that meets government safety
standards with
respect to flash fires and electrical arc flashes. In general, the cellulose
fibers can
be present in the spun yarns and in the fabric material generally in an amount
of
from about 30% by weight to about 60% by weight or from about 36% to about
48% by weight, including all increments of 1% by weight therebetween. For
example, natural cellulose fibers can be present in the spun yarns in an
amount
greater than about 36% by weight, such as in an amount greater than about 37%
by weight, such as in an amount greater than about 38% by weight, such as in
an
amount greater than about 39% by weight, such as in an amount greater than
about 40% by weight, and generally in an amount less than about 49% by weight,
such as in an amount less than about 48% by weight, such as in an amount less
than about 47% by weight, such as in an amount less than about 45% by weight,
such as in an amount less than about 44% by weight.
[00038] The fiber blend of the present disclosure also contains polyamide
fibers.
The polyamide fibers can be made from polyamide 6, polyamide 6,6 or mixtures
thereof. The polyamide fibers are present in the fiber blend in order to
provide the
fabric with greater strength and abrasion resistance. The polyamide fibers can
be
present in the fabric generally in an amount from about 3% to about 25% by
weight, including all increments of 1% by weight therebetween. In one aspect,
the
polyamide fibers are present in the fiber blend and in the fabric in an amount
greater than about 5% by weight, such as in an amount greater than about 6% by
weight, such as in an amount greater than about 7% by weight, and generally in
an
amount less than about 15% by weight, such as in an amount less than about 12%
by weight, such as in an amount less than about 9% by weight.
[00039] The modacrylic fibers, cellulose fibers, and polyamide fibers are also
combined with inherently flame resistant fibers in producing the spun yarns.
The
inherently flame resistant fibers can include, for instance, aramid fibers
such as
para-aramid fibers and/or meta-aramid fibers. Other inherently flame resistant
Date Recue/Date Received 2023-07-14
fibers include polybenzimidazole (PBI) fibers or poly(p-phenylene-2,6-
bezobisoxazole) (PBO) fibers and the like. In one embodiment, for instance,
the
fabric material only contains aramid fibers such as para-aramid fibers alone
or in
combination with meta-aramid fibers. In still another embodiment, the fabric
material contains only meta-aramid fibers. In still another embodiment, the
fabric
material contains aramid fibers in combination with PBI fibers. The inherently
flame resistant fibers can be present in the spun yarns and in the fabric
material
generally in an amount from about 3% by weight to about 30% by weight, such as
in an amount of from about 5% by weight to about 25% by weight including all
increments of 1% therebetween. For example, the inherently flame resistant
fibers
can be present in the spun yarns in an amount greater than about 5% by weight,
such as in an amount greater than about 6% by weight, such as in an amount
greater than about 7% by weight, and generally in an amount less than about
15%
by weight, such as in an amount less than about 14% by weight, such as in an
amount less than about 13% by weight, such as in an amount less than about 12%
by weight, such as in an amount less than about 10% by weight.
[00040] As described above, the fabric material of the present disclosure can
be
made exclusively from the spun yarns as described above. In one aspect,
antistatic fibers and/or yarns can also be incorporated into the fabric. The
antistatic fibers or yarns, for instance, can be contained in the fabric
material
generally in an amount less than about 3% by weight, such as in an amount less
than about 2% by weight, and generally in an amount greater than about 0.5% by
weight. The antistatic fibers can contain carbon.
[00041] In one aspect, the spun yarns made according to the present disclosure
include an intimate fiber blend containing modacrylic fibers in an amount of
from
about 38% to about 49% by weight, cellulose fibers in an amount of from about
36% to about 48% by weight, polyamide fibers in an amount from about 5% to
about 15% by weight, and inherently flame resistant fibers, particularly meta-
aramid fibers alone or in combination with para-aramid fibers, in an amount of
from
about 5% by weight to about 15% by weight.
[00042] In another aspect, the spun yarns made according to the present
disclosure include an intimate fiber blend containing modacrylic fibers in an
amount of from about 40% to about 44% by weight, cellulose fibers in an amount
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Date Recue/Date Received 2023-07-14
of from about 40% to about 44% by weight, polyamide fibers in an amount from
about 6% to about 9% by weight, and inherently flame resistant fibers,
particularly
meta-aramid fibers alone or in combination with para-aramid fibers, in an
amount
of from about 6% by weight to about 10% by weight.
[00043] The size and length of the fibers contained in the fiber blend can be
the
same or can differ depending upon the type of material used to produce the
fiber.
In general, the each type of fiber can have a fiber length of greater than
about 25
mm, such as greater than about 30 mm, such as greater than about 35 mm, such
as greater than about 40 mm, such as greater than about 45 mm, such as greater
than about 50 mm, and less than about 80 mm, such as less than about 70 mm,
such as less than about 60 mm, such as less than about 55 mm, such as less
than
about 50 mm, such as less than about 40 mm.
[00044] In one aspect, spun yarns made in accordance with the present
disclosure can account for about 50% to about 100% of the warp yarns used to
produce the fabric, such as from about 70% to about 100%, such as from about
70% to about 98%, such as from about 80% to about 90%. Similarly, the spun
yarns made in accordance with the present disclosure can account for from
about
50% to about 100% of the fill yarns, such as from about 60% to about 100% of
the
fill yarns, such as from about 70% to about 100% of the fill yarns, such as
from
about 70% to about 98% of the fill yarns.
[00045] When producing a woven fabric in accordance with the present
disclosure, the fabric can have any suitable weave. For instance, the fabric
can
have a plain weave, a twill weave, or a rip stop weave. In one embodiment, the
fabric can also be made with a herringbone weave. Twill weaves that can be
used
include 1 by 2 twill weaves, 1 by 3 twill weaves, 1 by 4 twill weaves, 2 by 1
twill
weaves, and the like. Alternatively, the fabric can have a rip stop weave.
[00046] The yarn density of fabrics made according to the present disclosure
can vary depending upon the size and type of yarns used, the desired basis
weight
of the fabric, and other various factors.
[00047] In one aspect, the fabric can have greater than about 50 ends per
inch,
such as greater than about 65 ends per inch, such as greater than about 70
ends
per inch, such as greater than about 75 ends per inch and generally less than
about 100 end per inch, such as less than about 95 ends per inch, such as less
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Date Recue/Date Received 2023-07-14
than about 90 ends per inch. The fabric can have generally greater than about
30
picks per inch, such as greater than about 50 picks per inch, such as greater
than
about 55 picks per inch, such as greater than about 60 picks per inch, such as
greater than about 65 picks per inch, and generally less than about 90 picks
per
inch, such as less than about 75 picks per inch, such as less than about 70
picks
per inch, such as less than about 65 picks per inch.
[00048] In general, the fabric can have a basis weight of from about 4 osy to
about 14 osy, including all increments of 0.1 osy therebetween. In one
embodiment, the fabric can have a basis weight of greater than about 5.5 osy,
such as greater than about 6 osy, such as greater than about 6.4 osy, such as
greater than about 6.6 osy, such as greater than about 6.8 osy. The basis
weight
of the fabric can be generally less than about 12 osy, such as less than about
10
osy, such as less than about 9 osy, such as less than about 8.5 osy, such as
less
than about 8 osy, such as less than about 7.8 osy, such as less than about 7.6
osy, such as less than about 7.4 osy.
[00049] The fabrics constructed in accordance with the present disclosure can
be used to construct numerous different types of products for use in various
applications. In one embodiment, for instance, the fabrics can be used to
produce
apparel or garments for providing protection against hazards, such as flash
fires or
electric arc flashes. Due to the combination of comfort, durability and
protection,
fabrics of the present disclosure are particularly well suited for producing
protective
apparel to be worn by workers in various environments, such as in industrial
environments and manufacturing facilities. Garments or apparel made in
accordance with the present disclosure can include shirts, pants, bib
overalls, one-
piece bodysuits, socks and other leg wear, gloves, scarves, hats, hoods,
aprons,
and the like.
[00050] For instance, referring to FIG. 1, one example of a coverall 10 made
in
accordance with the present disclosure is shown. The coverall 10 includes
pants
or leg coverings 12 and sleeves 14 all integrated into a single garment. The
garments can include various pockets but also include flaps 16 for covering
the
pockets.
[00051] It should be understood that the coveralls 10 as shown in FIG. 1 is
merely one embodiment of a garment made in accordance with the present
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Date Recue/Date Received 2023-07-14
disclosure. In other embodiments, the garment can include separate pants or
trousers that are worn with a shirt all made from the same fabric of the
present
disclosure.
[00052] The fabric of the present disclosure and/or apparel or garments made
from the fabric can be dyed any desired color. For example, in one aspect,
fabrics
made according to the present disclosure can be piece dyed when producing
garments. During piece dying, the woven fabric is fed through a dying process.
Of
particular advantage, fabrics can be piece dyed according to the present
disclosure and have a uniform and consistent shade of color even though the
fabric contains different types of fibers.
[00053] Alternatively, the yarns can first be dyed and then woven to form the
fabric. For instance, fabrics can be made according to the present disclosure
containing yarns that have been packaged dyed, which includes doped dyed
yarns.
[00054] In still another aspect, the fibers incorporated into the fabric of
the
present disclosure can first be dyed prior to forming the yarns. For example,
in
one embodiment, the modacrylic fibers, the cellulose fibers, the polyamide
fibers,
and the inherently flame resistant fibers can all be solution dyed. Using a
fiber
blend in which all of the fibers have been solution dyed can provide various
advantages and benefits. Solution dyed fibers refer to fibers that are
extruded
from a molten polymer or made from a regenerated cellulose and formed into
filaments in which a coloring agent, such as a pigment, is mixed with the
polymer
or dope prior to extrusion. Solution dyed fibers are fibers that have perfect
or
nearly perfect color retention even after exposure to sunlight, being worn
multiple
times, or subjected to multiple laundry cycles.
[00055] In one embodiment, the spun yarns can include fibers that have been
solution dyed and the woven fabric can be later piece dyed.
[00056] In one aspect, the fabric or garment can be dyed to shades that have
high visibility in accordance with The American National Standard for High-
Visibility Safety Apparel (ANSI/ISEA 107-2020). For example, the fabric can
display a background color of fluorescent yellow-green, fluorescent orange-red
or
fluorescent red in accordance with the ANSI 107 standard. The colors can also
be
14
Date Recue/Date Received 2023-07-14
wash resistant and maintain the ANSI 107 standard after 5 laundry cycles or
after
laundry cycles.
[00057] Fabrics made according to the present disclosure can have numerous
beneficial properties and characteristics that provide protection against
hazards,
such as flash fires and/or electrical arc flashes, but also provide comfort to
the
wearer. Fabrics made according to the present disclosure, for instant, can be
durable, be resistant to pilling and be abrasion resistant. Of particular
advantage,
fabrics made according to the present disclosure also have excellent
dimensional
stability and retain their mechanical properties even when wet.
[00058] Regarding protection against various hazards, the fabric material of
the
present disclosure can display excellent flame protection. For example, when
tested according to Test ASTM D6413 (flame performance), fabric materials
according to the present disclosure display a char length before laundering of
less
than about 4.5 inches, such as less than about 4 inches, such as less than
about
3.5 inches in the warp direction. The fabric material may display a char
length of
less than about 3.5 inches, such as less than about 3.3 inches, such as less
than
about 3 inches in the fill direction. When tested according to the vertical
burn after
flame, the fabric can display an after flame of 0 seconds in both the warp and
fill
directions.
[00059] The fabric of the present disclosure can also display excellent
physical
properties. For instance, the fabric can display a tensile strength in the
warp
direction of greater than about 125 lbs., such as greater than about 130 lbs.
In the
fill direction, the tensile strength can be greater than about 80 lbs, such as
greater
than about 85 lbs., such as greater than about 90 lbs. The fabric can have a
tear
strength in the warp direction of greater than about 5.5 lbs., such as greater
than
about 6 lbs., such as greater than about 6.3 lbs. In the fill direction, the
tear
strength can be greater than about 4.5 lbs., such as greater than about 5
lbs., such
as greater than about 5.3 lbs.
[00060] The present disclosure may be better understood with reference to the
following example.
Example No. 1
[00061] The following example demonstrates some of the advantages and
benefits of fabrics made according to the present disclosure.
Date Recue/Date Received 2023-07-14
[00062] A fabric was made in accordance with the present disclosure. The
fabric
was made exclusively from spun yarns formed from an intimate fiber blend. The
fiber blend contained 42% by weight modacrylic fibers, 42% by weight
regenerated
cellulose fibers, 8% by weight nylon fibers, and 8% by weight aramid fibers.
The
yarns had a size of 30/2 base. The fabric had a twill weave. The fabric had a
basis weight of 7 osy. All of the fibers contained in the fabric were solution
dyed to
produce a navy color. The regenerated cellulose fibers had a tenacity of from
33
to 34 cN/tex, an elongation of from 12 to 14%, and a water retention ability
of 60%.
The fabric contained 76 yarns per inch in the warp direction and 59 yarns per
inch
in the fill direction.
[00063] The fabric was tested for various properties and the following results
were obtained:
Test Results
Tensile strength (lbs) 131 x 95
Tear strength (lbs) 6.5 x 5.5
Air permeability (cfm) 34
Home laundry shrinkage (%) 2.1 x 3.4
Vertical burn char (inch) 3.4 x 2.8
Vertical burn after flame (s) 0 x 0
[00064] The fabric as described above was also tested according to Test ASTM
F1959/F1959M-14-el. The fabric was tested for arc rating, material break-open,
and heat attenuation factor. The test curve was 8 kA. The arc gap was 30 cm
and
the distance to fabric was 30 cm. The number of samples analyzed was 30. The
incident energy range was 8 to 17 cal/cm2.
[00065] The following results were obtained and compared to a fabric disclosed
in Australian Patent Application No. AU 2012208990. The AU '990 fabric
contained 50% by weight FR modacrylic fibers, 35% by weight TENCEL cellulosic
fibers, 10% by weight nylon fibers, and 5% by weight para-amid fibers. The
following results were obtained:
Fabric made
Fabric according
Test according to the
to AU 2012208990
present
16
Date Recue/Date Received 2023-07-14
disclosure
Arc rating, ATPV (cal/cm2) 10 6.5
Material break-open, Ebt (cal/cm2) 14 -
Heat attenuation factor, HAF (%) 82 -
[00066] As shown above, the fabric made according to the present disclosure
performed dramatically and unexpectedly better than the fabric disclosed in AU
2012208990. In addition, the fabric made according to the present disclosure
was
made exclusively from solution dyed fibers that provided the fabric with not
only a
distinctive and uniform color, but also with a color that would not degrade or
fade.
[00067] These and other modifications and variations to the present invention
may be practiced by those of ordinary skill in the art, without departing from
the
spirit and scope of the present invention, which is more particularly set
forth in the
appended claims. In addition, it should be understood that aspects of the
various
embodiments may be interchanged both in whole or in part. Furthermore, those
of
ordinary skill in the art will appreciate that the foregoing description is by
way of
example only and is not intended to limit the invention so further described
in such
appended claims.
17
Date Recue/Date Received 2023-07-14
