Flame resistant fabric and garments made therefrom
View Patent ↗Protective garments include a flame resistant fabric that is strong and yet has a soft hand. The fabric is made from a combination of filament yarns and spun yarns. The filament yarns and spun yarns are woven together such that the filament yarns are separated by from about 2 to about 5 spun yarns in both the warp direction and the fill direction. The spun yarns may contain polybenzimidazole fibers in combination with other fibers, such as aramid fibers. The filament yarns may comprise para-aramid fibers. In one embodiment, the filament yarns may have a size larger than the spun yarns.
1. A flame resistant garment comprising:
a fabric shaped to cover at least a portion of a wearer's body, the fabric comprising first yarns combined with second yarns, the first yarns comprising filament yarns comprised of an inherently flame resistant material, the second yarns comprising spun yarns containing inherently flame resistant fibers, the first yarns being present in the fabric in relation to the second yarns in a ratio greater than 1:1 to less than 1:5, and wherein the fabric includes a warp direction and a fill direction and wherein the first yarns are positioned in both the warp direction and the fill direction and wherein the second yarns are also positioned in both the fill direction and the warp direction.
2. A flame resistant garment as defined in claim 1 , wherein the garment comprises a fireman turnout coat and the fabric comprises an outer shell of the garment.
3. A flame resistant garment as defined in claim 1 , wherein the first yarns and the second yarns are positioned in the warp direction in a ratio of from greater than 1:1 to about 1:4 and wherein the first yarns and the second yarns are also positioned in the fill direction in a ratio of from greater than 1:1 to about 1:4.
4. A flame resistant garment as defined in claim 1 , wherein the first yarns and the second yarns are present in the fabric at a ratio of 1:2.
5. A flame resistant garment as defined in claim 3 , wherein the first yarns and the second yarns are present in the fabric at a ratio of 1:2.
6. A flame resistant garment as defined in claim 1 , wherein the fibers present in the spun yarns are comprised of a para-aramid.
7. A flame resistant garment as defined in claim 1 , wherein the second yarns contain polybenzimidazole fibers.
8. A flame resistant garment as defined in claim 7 , wherein the second yarns contain polybenzimidazole fibers in an amount from about 30% to about 60% by weight.
9. A flame resistant garment as defined in claim 1 , wherein the fabric has a twill weave.
10. A flame resistant garment as defined in claim 1 , wherein the fabric contains polybenzimidazole fibers in an amount from about 20% to about 70% by weight.
11. A flame resistant garment as defined in claim 1 , wherein the first yarns have a bigger size than the second yarns.
12. A flame resistant garment as defined in claim 1 , wherein the first yarns have a denier of about 600 and the spun yarns have a yarn size of about 18/2 or smaller.
13. A flame resistant garment as defined in claim 1 , wherein the first yarns have a denier of about 400 and the spun yarns have a yarn size of about 27/2 or smaller.
14. A flame resistant garment as defined in claim 1 , wherein the first yarns have a denier of about 200 and the spun yarns have a yarn size of about 54/2 or smaller.
15. A flame resistant garment as defined in claim 1 , wherein the fabric has a basis weight of from about 4 osy to about 9 osy.
16. A flame resistant garment as defined in claim 15 , wherein the fabric has a circular bend in either a warp direction or in a fill direction of from about 2 lbs. to about 5 lbs. when tested according to ASTM Test D4032.
17. A flame resistant garment as defined in claim 15 , wherein the fabric has a break strength in a fill direction of from about 600 lbs. to about 800 lbs. when tested according to ASTM Test D5034.
18. A flame resistant garment as defined in claim 15 , wherein the fabric has a trap tear in a warp direction of from about 300 lbs. to about 450 lbs. and has a trap tear in a fill direction of from about 250 lbs. to about 400 lbs. when tested according to ASTM Test D5587.
19. A flame resistant garment as defined in claim 15 , wherein the fabric exhibits a char length in a warp direction and in a fill direction of less than about 10 mm when tested according to ASTM Test D6413.
20. A flame resistant garment as defined in claim 3 , wherein the fabric has a basis weight of from about 5 osy to about 8 osy, the first yarns have a bigger size than the second yarns, the fabric has a circular bend in either a warp direction or in a fill direction of from about 2 lbs. to about 5 lbs. when tested according to ASTM Test D4032, the fabric has a break strength in a fill direction of from about 600 lbs. to about 800 lbs. when tested according to ASTM Test D5034, the fabric has a trap tear in a warp direction of from about 300 lbs. to about 450 lbs. and has a trap tear in a fill direction of from about 250 lbs. to about 400 lbs. when tested according to ASTM Test D5587 and the fabric exhibits a char length in a warp direction and in a fill direction of less than about 10 mm when tested according to ASTM Test D6413.
21. A flame resistant garment as defined in claim 1 , wherein the fabric has a break strength in a fill direction or in a warp direction of greater than about 60 lbs. per osy.
22. A flame resistant garment as defined in claim 1 , wherein the filament yarns are comprised of a para-aramid, the spun yarns comprising polybenzimidizole fibers combined with aramid fibers, the ratio between the filament yarns and the spun yarns being from about 2:3 to about 1:3.