FLAME RESISTANT COMPOSITE FABRICS
A flame resistant composite fabric includes a first flame resistant fabric layer, a second flame resistant fabric layer, and a barrier layer that bonds the first flame resistant fabric layer to the second flame resistant fabric layer. The barrier layer is capable of withstanding temperature of 500° F. for at least 5 minutes without substantial change in the integrity of the flame resistant composite fabric.
1 . A flame resistant composite fabric comprising:
a first flame resistant fabric layer;
a second flame resistant fabric layer; and
a barrier layer bonding the first flame resistant fabric layer to the second flame resistant fabric layer,
wherein the barrier layer is capable of withstanding temperature of 500° F. for at least 5 minutes without substantial change in the integrity of the flame resistant composite fabric.
2 . The flame resistant composite fabric of claim 1 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of inherent flame resistant fibers, yarns, and/or fabric.
3 . The flame resistant composite fabric of claim 1 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of flame resistant treated fibers, yarns, and/or fabric.
4 . The flame resistant composite fabric of claim 1 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of flame resistant (FR) treated cotton, flame resistant treated cotton/nylon fiber blends, meta-aramid, and/or para-aramid fibers, yarns, and/or fabric.
5 . The flame resistant composite fabric of claim 1 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of modacrylic fibers, yarns, and/or fabric alone.
6 . The flame resistant composite fabric of claim 1 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of modacrylic fibers, yarns, and/or fabric in a blend with one or more of flame resistant (FR) treated cotton, flame resistant treated cotton/nylon fiber blends, meta-aramid, and/or para-aramid fibers, yarns, and/or fabric.
7 . The flame resistant composite fabric of claim 1 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of yarns comprising a flame resistant 88/12 cotton/nylon blend.
8 . The flame resistant composite fabric of claim 1 , incorporated in a fabric garment.
9 . The flame resistant composite fabric of claim 1 , wherein the barrier layer comprises one or more adhesive layers.
10 . The flame resistant composite fabric of claim 9 , wherein the one or more adhesive layers includes a chemical additive selected from brominated aromatic chemical, antimony trioxide, and blends thereof.
11 . The flame resistant composite fabric of claim 10 , wherein the brominated aromatic chemical is selected from decabromodiphenyl oxide (DBDPO) and penta bromo phenyl.
12 . The flame resistant composite fabric of claim 9 , wherein the one or more adhesive layers include a base polymer and a cross-linking agent.
13 . The flame resistant composite fabric of claim 12 , wherein the one or more adhesive layers include a thermoplastic polymer binder/adhesive and a relatively high level of cross-linking agent causing the thermoplastic polymer binder/adhesive to resemble thermosetting polymer.
14 . The flame resistant composite fabric of claim 12 , wherein the base polymer is selected from acrylic and polyurethane.
15 . The flame resistant composite fabric of claim 12 , wherein the cross-linking agent is melamine.
16 . The flame resistant composite fabric of claim 9 , wherein the one or more adhesive layers include an inherently flame resistant polymer.
17 . The flame resistant composite fabric of claim 16 , wherein the inherently flame resistant polymer is polyvinylchloride (PVC).
18 . The flame resistant composite fabric of claim 1 , wherein the barrier layer comprises a membrane layer.
19 . The flame resistant composite fabric of claim 18 , wherein the barrier layer comprises adhesive layers which bond the membrane layer to the first and second flame resistant fabric layers.
20 . The flame resistant composite fabric of claim 19 , wherein the adhesive layers include a chemical additive selected from brominated aromatic chemical, antimony trioxide, and blends thereof.
21 . The flame resistant composite fabric of claim 20 , wherein the brominated aromatic chemical is selected from decabromodiphenyl oxide (DBDPO) and penta bromo phenyl.
22 . The flame resistant composite fabric of claim 19 , wherein the adhesive layers include a base polymer and a cross-linking agent.
23 . The flame resistant composite fabric of claim 22 , wherein the base polymer is selected from acrylic and polyurethane.
24 . The flame resistant composite fabric of claim 22 , wherein the cross-linking agent is melamine.
25 . The flame resistant composite fabric of claim 19 , wherein the adhesive layers include an inherently flame resistant polymer.
26 . The flame resistant composite fabric of claim 25 , wherein the inherently flame resistant polymer is polyvinylchloride (PVC).
27 . The flame resistant composite fabric of claim 1 , wherein at least one of the first and second flame resistant fabric layers has a raised surface.
28 . The flame retardant composite fabric of claim 1 , wherein the flame retardant composite fabric has a controlled air permeability of about 0 ft 3 /ft 2 /min to about 200 ft 3 /ft 2 /min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the flame retardant composite fabric.
29 . The flame resistant composite fabric of claim 1 , wherein the first flame resistant fabric layer has an exposed, outer raised surface.
30 . The flame resistant composite fabric of claim 1 , wherein the first flame resistant fabric layer has a weight of about 3 oz/yd 2 to about 12 oz/yd 2 .
31 . The flame resistant composite fabric of claim 1 , wherein the second flame resistant fabric layer has a weight of about 3 oz/yd 2 to about 12 oz/yd 2 .
32 . The flame resistant composite fabric of claim 1 , wherein the barrier layer has a weight of about 2 g/m 2 to about 12 g/m 2 .
33 . The flame resistant composite fabric of claim 27 , wherein the first (inner) flame resistant fabric layer defines one or more raised inner surface regions, facing towards the wearer, in the form of a pattern selected to generate a channeling effect.
34 . The flame resistant composite fabric of claim 33 , wherein the pattern selected to generate a channeling effect has the form of a grid or box.
35 . The flame resistant composite fabric of claim 1 , wherein the second (outer) flame resistant fabric layer is an outer woven layer.
36 . A flame resistant composite fabric comprising:
a first flame resistant fabric layer;
a second flame resistant fabric layer; and
a barrier layer bonding the first flame resistant fabric layer to the second flame resistant fabric layer, wherein the flame resistant composite fabric offers protection from electric arc flash hazards and/or from flash fire hazards in accordance with one or more of the following Nation Fire Protection Association standards: NFPA 70E (2009 ed.), NFPA 1975 (2009 ed.), NFPA 1977 (2005 ed.), NFPA 1951 (2007 ed.), and NFPA 2112 (2007 ed.).
37 . The flame resistant composite fabric of claim 36 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of inherent flame resistant fibers, yarns, and/or fabric.
38 . The flame resistant composite fabric of claim 36 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of flame resistant (FR) treated cotton, flame resistant treated cotton/nylon fiber blends, meta-aramid, and/or para-aramid fibers, yarns, and/or fabric.
39 . The flame resistant composite fabric of claim 36 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of modacrylic fibers, yarns, and/or fabric alone.
40 . The flame resistant composite fabric of claim 36 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of modacrylic fibers, yarns, and/or fabric in a blend with one or more of flame resistant (FR) treated cotton, flame resistant treated cotton/nylon fiber blends, meta-aramid, and/or para-aramid fibers, yarns, and/or fabric.
41 . The flame resistant composite fabric of claim 36 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of yarns comprising a flame resistant 88/12 cotton/nylon blend.
42 . The flame resistant composite fabric of claim 36 , incorporated in a fabric garment.
43 . The flame resistant composite fabric of claim 36 , wherein the barrier layer comprises one or more adhesive layers.
44 . The flame resistant composite fabric of claim 43 , wherein the one or more adhesive layers includes a chemical additive selected from brominated aromatic chemical, antimony trioxide, and blends thereof.
45 . The flame resistant composite fabric of claim 44 , wherein the brominated aromatic chemical is selected from Decabromodiphenyl oxide (DBDPO) and penta bromo phenyl.
46 . The flame resistant composite fabric of claim 43 , wherein the one or more adhesive layers include a base polymer and a cross-linking agent.
47 . The flame resistant composite fabric of claim 46 , wherein the base polymer is selected from acrylic and polyurethane.
48 . The flame resistant composite fabric of claim 46 , wherein the cross-linking agent is melamine.
49 . The flame resistant composite fabric of claim 43 , wherein the one or more adhesive layers include an inherently flame resistant polymer.
50 . The flame resistant composite fabric of claim 49 , wherein the inherently flame resistant polymer is polyvinylchloride (PVC).
51 . The flame resistant composite fabric of claim 36 , wherein the barrier layer comprises a membrane layer.
52 . The flame resistant composite fabric of claim 51 , wherein the barrier layer comprises adhesive layers which bond the membrane layer to the first and second flame resistant fabric layers.
53 . The flame resistant composite fabric of claim 52 , wherein the adhesive layers include a chemical additive selected from brominated aromatic chemical, antimony trioxide, and blends thereof.
54 . The flame resistant composite fabric of claim 53 , wherein the brominated aromatic chemical is selected from Decabromodiphenyl oxide (DBDPO) and penta bromo phenyl.
55 . The flame resistant composite fabric of claim 52 , wherein the adhesive layers include a base polymer and a cross-linking agent.
56 . The flame resistant composite fabric of claim 55 , wherein the base polymer is selected from acrylic and polyurethane.
57 . The flame resistant composite fabric of claim 55 , wherein the cross-linking agent is melamine.
58 . The flame resistant composite fabric of claim 52 , wherein the adhesive layers include an inherently flame resistant polymer.
59 . The flame resistant composite fabric of claim 58 , wherein the inherently flame resistant polymer is polyvinylchloride (PVC).
60 . The flame retardant composite fabric of claim 36 , wherein the flame retardant composite fabric has a controlled air permeability of about 0 ft 3 /ft 2 /min to about 200 ft 3 /ft 2 /min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the flame retardant composite fabric.
61 . The flame resistant composite fabric of claim 36 , wherein at least one of the first and second flame resistant fabric layers has a raised surface.
62 . The flame resistant composite fabric of claim 36 , wherein the first flame resistant fabric layer has an exposed, outer raised surface.
63 . The flame resistant composite fabric of claim 36 , wherein the first flame resistant fabric layer has a weight of about 3 oz/yd 2 to about 12 oz/yd 2 .
64 . The flame resistant composite fabric of claim 36 , wherein the second flame resistant fabric layer has a weight of about 3 oz/yd 2 to about 12 oz/yd 2 .
65 . The flame resistant composite fabric of claim 36 , wherein the barrier layer has a weight of about 2 g/m 2 to about 12 g/m 2 .
66 . The flame resistant composite fabric of claim 61 , wherein the first (inner) flame resistant fabric layer defines one or more raised inner surface regions, facing towards the wearer, in the form of a pattern selected to generate a channeling effect.
67 . The flame resistant composite fabric of claim 66 , wherein the pattern selected to generate a channeling effect has the form of a grid or box.
68 . The flame resistant composite fabric of claim 36 , wherein the second (outer) flame resistant fabric layer is an outer woven layer.
69 . A flame resistant composite fabric comprising:
a first flame resistant fabric layer;
a second flame resistant fabric layer; and
a barrier layer bonding the first flame resistant fabric layer to the second flame resistant fabric layer, wherein the barrier layer comprises an adhesive including a flame retardant additive system comprising a brominated aromatic chemical.
70 . The flame resistant composite fabric of claim 69 , wherein the brominated aromatic chemical is selected from decabromodiphenyl oxide (DBDPO) and penta bromo phenyl.
71 . The flame resistant composite fabric of claim 69 , wherein the flame retardant additive system comprises a blend of the brominated aromatic chemical and antimony trioxide.
72 . The flame resistant composite fabric of claim 69 , wherein the adhesive is a polyurethane based adhesive.
73 . The flame resistant composite fabric of claim 69 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of inherent flame resistant fibers, yarns, and/or fabric.
74 . The flame resistant composite fabric of claim 69 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of flame resistant treated fibers, yarns, and/or fabric.
75 . The flame resistant composite fabric of claim 69 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of flame resistant (FR) treated cotton, flame resistant treated cotton/nylon fiber blends, meta-aramid, and/or para-aramid fibers, yarns, and/or fabric.
76 . The flame resistant composite fabric of claim 69 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of modacrylic fibers, yarns, and/or fabric.
77 . The flame resistant composite fabric of claim 69 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of modacrylic fibers, yarns, and/or fabric in a blend with one or more of flame resistant (FR) treated cotton, flame resistant treated cotton/nylon fiber blends, meta-aramid, and/or para-aramid fibers, yarns, and/or fabric.
78 . The flame resistant composite fabric of claim 69 , wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of yarns comprising a flame resistant 88/12 cotton/nylon blend.
79 . The flame resistant composite fabric of claim 69 , incorporated in a fabric garment.
80 . The flame resistant composite fabric of claim 69 , wherein the barrier layer comprises a membrane layer.
81 . The flame resistant composite fabric of claim 80 , wherein the adhesive bonds the membrane layer to the first and second flame resistant fabric layers.
82 . The flame retardant composite fabric of claim 69 , wherein the flame retardant composite fabric has a controlled air permeability of about 0 ft 3 /ft 2 /min to about 200 ft 3 /ft 2 /min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the flame retardant composite fabric.
83 . The flame resistant composite fabric of claim 69 , wherein at least one of the first and second flame resistant fabric layers has a raised surface.
84 . The flame resistant composite fabric of claim 69 , wherein the first flame resistant fabric layer has an exposed, outer raised surface.
85 . The flame resistant composite fabric of claim 69 , wherein the first flame resistant fabric layer has a weight of about 3 oz/yd 2 to about 12 oz/yd 2 .
86 . The flame resistant composite fabric of claim 69 , wherein the second flame resistant fabric layer has a weight of about 3 oz/yd 2 to about 12 oz/yd 2 .
87 . The flame resistant composite fabric of claim 69 , wherein the barrier layer has a weight of about 2 g/m 2 to about 12 g/m 2 .
88 . The flame resistant composite fabric of claim 83 , wherein the first (inner) flame resistant fabric layer defines one or more raised inner surface regions, facing towards the wearer, in the form of a pattern selected to generate a channeling effect.
89 . The flame resistant composite fabric of claim 88 , wherein the pattern selected to generate a channeling effect has the form of a grid or box.
90 . The flame resistant composite fabric of claim 69 , wherein the second (outer) flame resistant fabric layer is an outer woven layer.