Flame resistant fabric with anisotropic properties
Flame resistant fabrics are formed by warp and fill yarns having different fiber contents. The fabrics are constructed, for example, by selection of a suitable weaving pattern, such that the body side of the fabric and the face side of the fabric have different properties. The fabrics described herein can be printable and dyeable on both sides of the fabric and are suitable for use in military and industrial garments. Methods of forming flame resistant fabrics, and methods for forming garments from the fabrics, are also described.
1. A flame resistant fabric formed of warp yarns interwoven with fill yarns and comprising a body side and a face side, wherein:
(a) at least some of either of the warp yarns or the fill yarns comprise a first fiber content comprising para-aramid fibers;
(b) at least some of the other of the warp yarns or the fill yarns comprise a second fiber content different from the first fiber content;
(c) fibers of the first fiber content are predominantly exposed on the body side of the fabric;
(d) fibers of the second fiber content are predominantly exposed on the face side of the fabric;
(e) the fabric comprises at least 10% para-aramid fibers, more para-aramid fibers are located in the first fiber content than in the second fiber content, and more para-aramid fibers are located on the body side than on the face side of the fabric;
(f) the fabric is a single layer fabric;
(g) the first and second fiber contents together comprise at least two different types of flame resistant fibers, wherein at least two of the at least two different types of flame resistant fibers are selected from the group consisting of para-aramid fibers, meta-aramid fibers, flame resistant cellulosic fibers, and modacrylic fibers; and
(h) the second fiber content comprises a blend of cellulosic fibers and inherently flame resistant fibers.
2. The fabric of claim 1 , wherein the at least two different types of flame resistant fibers are selected from the group consisting of para-aramid fibers, meta-aramid fibers, flame resistant cellulosic fibers, and modacrylic fibers.
3. The fabric of claim 1 , wherein the inherently flame resistant fibers of the second fiber content comprise at least one of modacrylic fibers, meta-aramid fibers and para-aramid fibers.
4. The fabric of claim 3 , wherein the inherently flame resistant fibers of the second fiber content comprise modacrylic fibers and para-aramid fibers and wherein the cellulosic fibers of the second fiber content comprise non-flame resistant cellulosic fibers.
5. The fabric of claim 1 , wherein the second fiber content further comprises nylon fibers.
6. The fabric of claim 1 , wherein the blend of cellulosic fibers and inherently flame resistant fibers of the second fiber content comprises a blend of flame resistant cellulosic fibers and meta-aramid fibers.
7. The fabric of claim 1 , wherein the first fiber content further comprises approximately 20-80% cellulosic fibers.
8. The fabric of claim 1 , wherein the first fiber content further comprises one or more of modacrylic fibers, cellulosic fibers, and nylon fibers.
9. The fabric of claim 8 , wherein the first content further comprises modacrylic fibers and non-flame resistant cellulosic fibers.
10. The fabric of claim 1 , wherein all of either of the warp yarns or the fill yarns comprise the first fiber content.
11. The fabric of claim 10 , wherein all of the other of the warp yarns or the fill yarns comprise the second fiber content.
12. The fabric of claim 1 , wherein all of the other of the warp yarns or the fill yarns comprise the second fiber content.
13. The fabric of claim 12 , wherein all of either of the warp yarns or the fill yarns comprise the first fiber content.
14. A flame resistant knit fabric comprising (i) first yarns having a first fiber content comprising para-aramid fibers, (ii) second yarns having a second fiber content different from the first fiber content, (iii) a body side, and (iv) a face side, wherein:
(a) fibers of the first fiber content are predominantly exposed on a body side of the fabric;
(b) fibers of the second fiber content are predominantly exposed on a face side of the fabric;
(c) the fabric comprises at least 10% para-aramid fibers and more of the para-aramid fibers are located in the first fiber content than in the second fiber content;
(d) the fabric is a single layer fabric; and
(e) the first and second fiber contents together comprise at least two different types of flame resistant fibers.
15. A flame resistant fabric formed of warp yarns interwoven with fill yarns and comprising a body side and a face side, wherein:
(a) at least some of either of the warp yarns or the fill yarns comprise a first fiber content comprising para-aramid fibers and at least one of modacrylic or flame resistant cellulosic fibers;
(b) at least some of the other of the warp yarns or the fill yarns comprise a second fiber content different from the first fiber content;
(c) fibers of the first fiber content are predominantly exposed on the body side of the fabric;
(d) fibers of the second fiber content are predominantly exposed on the face side of the fabric;
(e) the fabric comprises at least 10% para-aramid fibers, more para-aramid fibers are located in the first fiber content than in the second fiber content, and more para-aramid fibers are located on the body side than on the face side of the fabric;
(f) the fabric is a single layer fabric;
(g) the first and second fiber contents together comprise at least three different types of flame resistant fibers, wherein at least three of the at least three different types of flame resistant fibers is selected from the group consisting of para-aramid fibers, meta-aramid fibers, flame resistant cellulosic fibers, and modacrylic fibers; and
(h) the second fiber content comprises a blend of flame resistant cellulosic fibers and meta-aramid fibers.
16. The fabric of claim 15 , wherein the at least one of modacrylic or flame resistant cellulosic fibers in the first fiber content comprises approximately 20-80% flame resistant cellulosic fibers.
17. The fabric of claim 15 , wherein all of either of the warp yarns or the fill yarns comprise the first fiber content.
18. The fabric of claim 17 , wherein all of the other of the warp yarns or the fill yarns comprise the second fiber content.
19. The fabric of claim 15 , wherein all of the other of the warp yarns or the fill yarns comprise the second fiber content.
20. The fabric of claim 19 , wherein all of either of the warp yarns or the fill yarns comprise the first fiber content.
21. The fabric claim of 1 , wherein the first and second fiber contents together comprise at least three different types of flame resistant fibers, wherein at least three of the at least three different types of flame resistant fibers are selected from the group consisting of para-aramid fibers, meta-aramid fibers, flame resistant cellulosic fibers, and modacrylic fibers.
22. The fabric claim 1 , wherein the fabric is dyed or printed.
23. The fabric of claim 22 , wherein the face side of the fabric is printed.
24. The fabric of claim 1 , wherein the cellulosic fibers of the second fiber content comprise flame resistant cellulosic fibers.
25. The fabric of claim 1 , wherein the fabric has an after-flame of less than 2 seconds and less than a 4-inch char length when tested in accordance with ASTM D 6413.
26. The fabric of claim 1 , wherein the fabric complies with NFPA2112.
27. A garment comprising the fabric of claim 1 .
28. The garment of claim 27 , wherein the garment is a military combat uniform.
29. The fabric of claim 14 , wherein the fabric is dyed or printed.
30. The fabric of claim 29 , wherein the face side of the fabric is printed.
31. The fabric of claim 14 , wherein the fabric comprises a flame resistant circular knit fabric.
32. The fabric of claim 14 , wherein the first fiber content comprises only para-aramid fibers.
33. The fabric of claim 14 , wherein at least two of the at least two different types of flame resistant fibers are selected from the group consisting of para-aramid fibers, meta-aramid fibers, flame resistant cellulosic fibers, and modacrylic fibers.
34. The fabric of claim 14 , wherein the first and second fiber contents together comprise at least three different types of flame resistant fibers.
35. The fabric of claim 34 , wherein at least three of the at least three different types of flame resistant fibers are selected from the group consisting of para-aramid fibers, meta-aramid fibers, flame resistant cellulosic fibers, and modacrylic fibers.
36. The fabric of claim 14 , wherein the second fiber content comprises at least one of modacrylic fibers, cellulosic fibers, and inherently flame resistant fibers.
37. The fabric of claim 36 , wherein the second fiber content comprises a blend of flame resistant cellulosic fibers and inherently flame resistant fibers and wherein the inherently flame resistant fibers comprise meta-aramid fibers.
38. The fabric of claim 36 , wherein the second fiber content comprises modacrylic fibers, non-flame resistant cellulosic fibers, and inherently flame resistant fibers and wherein the inherently flame resistant fibers comprise para-aramid fibers.
39. The fabric of claim 14 , wherein the first fiber content further comprises approximately 20-80% cellulosic fibers.
40. The fabric of claim 14 , wherein the first fiber content further comprises one or more of modacrylic fibers, cellulosic fibers, and nylon fibers.
41. The fabric of claim 14 , wherein the fabric has an after-flame of less than 2 seconds and less than a 4-inch char length when tested in accordance with ASTM D 6413.
42. The fabric of claim 14 , wherein the fabric complies with NFPA 2112.
43. A garment formed from the fabric of claim 14 .
44. A garment comprising the fabric of claim 15 .