Spun staple yarns made from blends of rigid-rod fibers and fibers derived from diamino diphenyl sulfone and fabrics and garments made therefrom and methods for making same
View Patent ↗This invention relates to a flame-resistant spun staple yarns and fabrics and garments comprising these yarns and methods of making the same. The yarns have 20 to 50 parts by weight of a polymeric staple fiber containing a structure derived from a monomer selected from the group consisting of 4,4′diaminodiphenyl sulfone, 3,3′diaminodiphenyl sulfone, and mixtures thereof; and 50 to 80 parts by weight of a rigid-rod staple fiber, based on 100 parts by weight of the polymeric fiber and the rigid-rod fiber in the yarn.
1. A spun yarn comprising:
20 to 50 parts by weight of a polymeric staple fiber containing a polymer or copolymer derived from a monomer selected from the group consisting of 4,4′diaminodiphenyl sulfone, 3,3′diaminodiphenyl sulfone, and mixtures thereof; and
50 to 80 parts by weight of a rigid-rod staple fiber; based on 100 parts by weight of the polymeric fiber and the rigid-rod staple fiber in the yarn.
2. The spun yarn of claim 1 wherein,
the polymeric staple fiber is present in an amount of 20 to 35 parts by weight; and
the rigid-rod staple fiber is present in an amount of 65 to 80 parts by weight, based on 100 parts by weight of the polymeric staple fiber and the rigid-rod staple fiber in the yarn.
3. The spun yarn of claim 1 having a limiting oxygen index of 21 or greater.
4. The spun yarn of claim 3 having a limiting oxygen index of 26 or greater.
5. The spun yarn of claim 1 wherein,
the rigid-rod staple fiber has a tensile modulus of 200 grams per denier (180 grams per dtex) or greater and tenacity of 5 grams per denier (4.5 grams per dtex) or more.
6. The spun yarn of claim 1 wherein,
at least 80 mole percent of the polymer or copolymer used in the polymeric staple fiber is derived from a sulfone amine monomer or a mixture of sulfone amine monomers.
7. The spun yarn of claim 1 wherein the rigid-rod staple fiber has a tenacity of 10 grams per denier (9 grams per dtex) or more.
8. The spun yarn of claim 1 wherein the polymeric polymer further contains a structure derived from the monomer selected from the group of terephthaloyl chloride, isophthaloyl chloride, and mixtures thereof.
9. The spun yarn of claim 1 where the rigid-rod staple fiber comprises poly(paraphenylene terephthalamide).
10. The spun yarn of claim 1 where the rigid-rod staple fiber is a fiber selected from the group of para-aramid, polyazole, and mixtures thereof.
11. A woven fabric comprising the yarn of claim 1 .
12. A protective garment comprising the yarn of claim 1 .
13. A flame-resistant garment comprising, in order:
an inner thermal lining, a liquid barrier; and
an outer shell fabric, the outer shell fabric comprising the woven fabric of claim 11 .
14. A method of producing a spun yarn comprising:
a) forming a fiber mixture of 20 to 50 parts by weight of a polymeric staple fiber containing a polymer or copolymer derived from a monomer selected from the group consisting of 4,4′diaminodiphenyl sulfone, 3,3′diaminodiphenyl sulfone, and mixtures thereof; and 50 to 80 parts by weight of a rigid-rod staple fiber, based on 100 parts by weight of the polymeric fiber and the rigid-rod fiber in the yarn; and
b) spinning the fiber mixture into a spun staple yarn.
15. The method of producing a spun yarn of claim 14 wherein,
the polymeric staple fiber is present in an amount of 20 to 35 parts by weight; and
the rigid-rod staple fiber is present in an amount of 65 to 80 parts by weight, based on 100 parts by weight of the polymeric staple fiber and the rigid-rod staple fiber in the yarn.
16. The method of producing a spun yarn of claim 14 wherein,
the rigid-rod staple fiber has a tensile modulus of 200 grams per denier (180 grams per dtex) or greater and a tenacity of 5 grams per denier (4.5 grams per dtex) or more.
17. The method of producing a spun yarn of claim 14 wherein,
at least 80 mole percent of the polymer or copolymer used in the polymeric staple fiber is derived from a sulfone amine monomer or a mixture of sulfone amine monomers.
18. The method of producing a spun yarn of claim 14 wherein,
the polymeric polymer further contains a structure derived from the monomer selected from the group of terephthaloyl chloride, isophthaloyl chloride, and mixtures thereof.
19. The method of producing a flame-resistant spun yarn of claim 14 wherein, the high rigid-rod staple fiber comprises poly(paraphenylene terephthalamide).
20. The method of producing a flame-resistant spun yarn of claim 14 wherein,
the high rigid-rod staple fiber is a fiber selected from the group of para-aramid, polyazole, and mixtures thereof.