Flame retardant fabrics and methods for manufacturing the same

1. A flame retardant knit fabric produced by a process comprising:

applying a melamine-based compound to a fabric comprising nylon wherein applying comprises placing the fabric in a vat of a melamine-based aqueous solution;

applying a tetrakis (hydroxymethyl) phosphonium (“THP”)-based compound to the fabric; and

fixing the melamine-based compound and THP-based compound as a flame retardant in the fabric.

2. The fabric of claim 1 , wherein after applying the melamine-based compound to the fabric, the method further comprises pressing the fabric through a pair of spaced rollers.

3. The fabric of claim 2 , wherein applying the melamine-based compound to the fabric further comprises curing the melamine-based compound into fabric with heat at oven temperatures greater than approximately 300° F.

4. The fabric of claim 3 , wherein curing with heat further comprises heating the fabric to a temperature of greater than approximately 300° F.

5. The fabric of claim 4 , wherein curing with heat further comprises exposing the fabric to the heat for more than approximately 20 seconds.

6. The fabric of claim 1 , wherein the melamine-based compound further comprises trimethoxymethyl melamine.

7. The fabric of claim 1 , wherein the melamine-based compound further comprises hexamethoxymethyl melamine.

8. The fabric of claim 1 , wherein applying the THP-based aqueous solution further comprises padding the phosphorous-based compound onto the fabric.

9. The fabric of claim 8 , wherein padding the THP-based aqueous solution onto the fabric further comprises:

applying the THP-based aqueous solution to the fabric, wherein the THP-based aqueous solution includes a THP-based compound in water neutralized to a pH of approximately 3.0 to 8.0; and

pressing the THP-based aqueous solution onto fabric.

10. The fabric of claim 1 , wherein the THP-based aqueous solution comprises tetrakis(hydroxymethyl)phosphonium sulfate urea.

11. The fabric of claim 1 , wherein the THP-based aqueous solution comprises tetrakis(hydroxymethyl)phosphonium chloride urea.

12. The fabric of claim 1 , wherein fixing the melamine-based compound and phosphorous-based compound as a flame retardant in the fabric further comprises:

exposing the fabric to an ammonia source in an ammonia chamber; and

after exposing the fabric to the ammonia source, exposing the fabric to an oxidizing agent.

13. The fabric of claim 12 , wherein exposing the fabric to an ammonia source in the ammonia chamber further comprises:

drying the fabric to a moisture content of approximately 10%;

framing the fabric; and

exposing the fabric to ammonia.

14. The fabric of claim 12 , wherein exposing the fabric to an oxidizing agent comprises placing the fabric in an aqueous solution composed of approximately 10% peroxide.

15. The fabric of claim 1 , wherein the fabric further comprises a fabric made of cellulosic material.

16. The fabric of claim 1 , wherein the fabric further comprises a fabric made of a blend of nylon and one or more cellulosic materials.

17. The fabric of claim 1 , wherein the fabric further comprises a fabric made of a blend of:

one or more cellulosic materials selected from the group consisting of cotton, rayon, tencel, or flax; and

one or more synthetic materials selected from the group consisting of nylon, spandex, acrylic, acetate or triacetate.

18. The fabric of claim 1 , wherein applying the melamine-based compound precedes applying the THP-based aqueous solution.

19. The fabric of claim 1 , wherein the fabric comprising nylon comprises 52 percent nylon or less.

20. A flame retardant fabric comprising 52 percent or less nylon, and a halogen-free flame retardant comprising a THP-based compound on the nylon.

21. A flame retardant fabric comprising:

a fabric comprising a cotton and a nylon blend; and

a flame retardant composition on the fabric, wherein the flame retardant composition comprises a melamine-based compound and a THP-based compound.