Patent Publication Number: US-2020299873-A1

Title: Material having flame resistant properties

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/821,489, filed on Mar. 21, 2019. The entire disclosure of the above application is incorporated herein by reference. 
    
    
     FIELD 
     The present technology relates to a flame resistant material and, more particularly, to a flame resistant fabric and clothing incorporating the flame resistant fabric. 
     INTRODUCTION 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Various types of flame resistant articles of clothing are used to protect wearers from hazards found in certain work environments, tasks, and emergency services, etc. Examples of flame resistant clothing include coats, jackets, pants, overalls, bibs, pull-overs, gloves, socks, aprons, and hats, among others. Flame resistant clothing, however, can be uncomfortable, either by hand or by the inability to keep the wearer cool. Fibers used in flame resistant clothing may not wick moisture. Flame resistant clothing can also be heavy and/or thick and cause a wearer to perspire, resulting either from the clothing itself or from the environment in which it is worn. To combat perspiration, known flame resistant clothing can include flame resistant rayon, tencel, lyocell, and cotton, which can also be combined with moisture management finishes. 
     It would be desirable to develop a flame resistant fabric for clothing with improved humidity management properties, especially in relation to relative humidity and perspiration by the wearer, that can maintain a core body temperature of the wearer. 
     SUMMARY 
     The present technology includes articles of manufacture, systems, and processes that relate to flame resistant fabrics and articles of clothing incorporating one or more flame resistant fabrics. 
     Flame resistant fabrics are provided that include a modacrylic fiber, a fiber embedded with activated particles, and an aramid fiber. The flame resistant fabric can pass the National Fire Protection Association 2112 standards. Particular flame resistant fabrics include about 30% to about 75% of the modacrylic fiber, about 10% to about 70% of the fiber embedded with active particles, and about 5% to about 50% of the aramid fiber. A cellulosic fiber can also be included in the flame resistant fabric. The cellulosic fiber can include cotton, rayon (e.g., flame resistant rayon), and/or lyocell. Such flame resistant fabrics can be provided as bulk quantities of material, including bulk rolls of material, and can be fashioned into various articles of clothing or incorporated in various portions of articles of clothing. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     DETAILED DESCRIPTION 
     The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and/or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and/or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. 
     All documents, including patents, patent applications, and scientific literature cited in this detailed description are incorporated herein by reference, unless otherwise expressly indicated. Where any conflict or ambiguity may exist between a document incorporated by reference and this detailed description, the present detailed description controls. 
     Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein. 
     As referred to herein, disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on. 
     The present technology is drawn to articles of manufacture including flame resistant fabrics, ways of making flame resistant fabrics and clothing, and ways of using flame resistant fabrics (e.g., woven fabrics, knit fabrics, non-woven fabrics, etc.), where the flame resistant fabrics contain a blend of inherently flame resistant fiber, non-flame resistant fiber, and/or treated flame resistant fiber in various forms, including volcanic sand derived and/or coconut derived activated particles. Certain embodiments include flame resistant fabrics comprising a modacrylic fiber, a fiber embedded with activated particles, and an aramid fiber. The flame resistant fabric can be configured to pass the National Fire Protection Association (NFPA) 2112 standards. 
     The National Fire Protection Association developed NFPA 2112, an industry certification standard titled, “Standard on Flame-Resistant Clothing for Protection of Industrial Personnel Against Short Duration Thermal Exposures from Fire.” NFPA 2112 is a certification standard that provides minimum performance criteria and sets clear guidelines for testing on instrumented thermal manikins. The NFPA 2112 standard calls for short duration thermal exposure from fire testing to be conducted at 3 seconds with a pass/fail criteria of a maximum 50% total body burn under ASTM F1930 (Standard Test Method for Evaluation of Flame Resistant Clothing for Protection Against Fire Simulations Using an Instrumented Manikin) testing protocols. NFPA 2112 is used to certify flame resistant garments for protection of the wearer against flash fire. A focus of NFPA 2112 testing, using the ASTM F1930 and other test methods, is directed to rating the performance of flame resistant fabrics as opposed to actual garments or articles of clothing. It is the nature of the fabric, including composition of the fibers and portions thereof that can determine a majority of the most important characteristics of the finished garment or article of clothing. In fact, the fabric can be the primary determinant in manikin body burn test results, durability of flame resistance to laundering, and shrinkage. The fabric can also play a significant role in the level of comfort, durability, wear, and appearance of clothing made therefrom or incorporating such fabric, beyond simply the flame resistant performance. 
     In certain embodiments, a flame resistant fabric is provided that includes about 30% to about 75% of the modacrylic fiber, about 10% to about 70% of the fiber embedded with active particles, and about 5% to about 50% of the aramid fiber. Embodiments are also provided where the flame resistant fabric includes a cellulosic fiber, such as cotton, rayon (e.g., flame resistant rayon, which can have embedded silica), and/or lyocell. The flame resistant fabric can include about 10% to about 40% of the cellulosic fiber. 
     With respect to modacrylic, such synthetic copolymers can provide soft, strong, resilient, and dimensionally stable fibers. Modacrylic can be dyed, exhibits good press and shape retention, and can be quick to dry. Modacrylic exhibits outstanding resistance to chemicals and solvents, is not attacked by moths or mildew, is nonallergenic. Modacrylic can have properties that are similar to an acrylic, however, modacrylic is flame retardant and does not combust. Fibers of modacrylic are difficult to ignite and will self-extinguish. In addition to such flame retardant properties, modacrylic has a relatively high durability that is comparable to wool. Modacrylic fibers also have a moderate resistance to abrasion and a very low tenacity. Fabrics including modacrylic can provide arc flash protection. 
     Various forms of the fiber embedded with activated particles can be incorporated into the flame resistant fabric. Activated particles can include activated carbon particles derived from coconut and/or particles derived from volcanic sand or rock. The activated particles can hence provide various properties, including odor adsorption, moisture management, and fire resistance. The particles can provide such properties because they are “activated.” That is, the particles can have the capacity to adsorb or trap substances, including substances that may themselves be a solid, liquid, and/or gas. Activated particles have an adsorptive property as each particle has a multitude of pores; e.g., pores on the order of thousands, tens of thousands, or hundreds of thousands per particle. These pores can provide the particle or, more particularly, the surface of the particle with its activity (e.g., capacity to adsorb). For example, activated particles such as activated carbon can adsorb a substance by trapping the substance in the pores of the activated carbon. The fiber to which the activated particles are embedded can include various types of fibers, including fibers formed of nylon, polyester, aramid, cellulose, modacrylic, polybenzimidazole (PBI), and/or poly(p-phenylene-2,6-benzobisoxazole) (PBO). 
     The present technology therefore provides various embodiments of flame resistant fibers, fabrics, and clothing that include or incorporate certain activated particles and that can have certain activated particles associated therewith, including embedded, coated, and impregnated activated particles. Examples include activated particles associated with fibers, yarns, and fabrics including Cocona and 37.5™ technology from Cocona Inc. (Boulder, Colo.). Further examples include articles of manufacture and ways of making and using fibers, yarns, fabrics, laminates, and coatings with activated particles as described in U.S. Pat. No. 7,850,766 to Haggquist; U.S. Pat. No. 7,247,374 to Haggquist; U.S. Pat. No. 6,998,155 to Haggquist et al.; and U.S. Pat. No. 6,844,122 to Haggquist, each of which is incorporated herein by reference. 
     Cocona is a fabric developed from fibrous coconut husks, where natural ingredients are incorporated into polymers. Activated carbon particles made from coconut shells can be embedded in a wide range fibers and knit and woven into various fabrics and incorporated into various non-woven fabrics. Such fibers including activated particles can provide effective evaporative cooling, odor adsorption, and UV protection. Fabrics made from Cocona fibers can be lightweight, comfortable, and can retain conventional product features of the base fiber material, such as stretch and wash-ability. The surface of the activated carbon particles can have a pore structure that can absorb odor molecules while also allowing moisture to escape from the skin of the wearer. Activated carbon particles from coconut shells can be embedded into polyester or nylon polymers. The coconut shells can be burned at 300 degrees C. followed by a 1000 degree C. steam-activation process. The resulting microscopic, ultra-fine activated particles can be incorporated and embedded into various fibers. 
     Fibers embedded with activated particles based upon 37.5™ technology can have a polymer base including one or more of nylon, polyester, aramid, cellulose, modacrylic, polybenzimidazole (PBI), and/or poly(p-phenylene-2,6-benzobisoxazole) (PBO, also known as Zylon) that is implanted with activated particles derived from either coconut and/or volcanic sand/rock. Certain embodiments of 37.5™ technology (coconut and/or volcanic sand/rock derived activated particles) include nylon, polyester, and/or aramid fibers. The activated particles derived from coconuts and/or volcanic sand/rock can be added to the fiber before fiber extrusion. This fiber has the ability to lower body core temperatures through moisture management-wicking, fast dry times, and lower microclimate absolute humidity by pulling moisture into the fiber before sweat can form on the wearer&#39;s skin. The fiber can also absorb odor due to the porous structure of the activated particles. The fiber can be producer colored or natural and can be in various fiber or filament forms. 
     With respect to the aramid fiber, such fibers are in a class of heat-resistant and strong synthetic fibers. Aramid fibers are used in aerospace and military applications, for ballistic-rated body armor fabric and ballistic composites and heat resistant applications. Chain molecules in the aramid fibers can be highly oriented along the fiber axis. As a result, a higher proportion of the chemical bonds therein can contribute more to fiber strength as compared to other synthetic fibers. Aramid fibers can include para-aramids and can have a very high melting point (e.g., &gt;500° C.), which can contribute to flame resistant properties. Certain para-aramid fibers, such as Kevlar and Twaron, provide outstanding strength-to-weight properties, as well. 
     With respect to the cellulosic fiber, also referred to as cellulose fiber, such fiber can be made from ethers or esters of cellulose obtained from bark, wood, and/or leaves of various plants, or from other plant-based materials. In addition to cellulose, the fibers can also contain hemicellulose and lignin, with different percentages of these components altering the mechanical properties of the fibers. Manufactured cellulosic fibers are derived from plant material processed into a pulp and extruded in the similar ways that synthetic fibers like polyester or nylon are made. Rayon is one example of a manufactured cellulosic fiber originating from wood pulp. As rayon is manufactured from natural cellulose, it is not considered to be synthetic, and rayon is classified as a fiber formed by regenerating natural materials into a usable form. Specific types of rayon include viscose, modal, and lyocell, each of which differs in its respective manufacturing process and the properties of the finished product. Lyocell is a form of rayon that includes cellulose fiber made from dissolving pulp (e.g., bleached wood pulp) and using dry jet-wet spinning. Cotton is another cellulosic fiber and is derived from cotton plants, where cotton fiber is almost pure cellulose. Cotton fiber can add softness and breathability to fabric. 
     Flame resistant fabrics as provided herein can include about 30-75% modacrylic, about 10-70% 37.5™ fiber technology, and about 5-50% aramid fiber. For example, certain flame resistant fabrics further include about 30-75% modacrylic, about 10-30% 37.5 fiber technology, about 5-50% aramid fiber, and about 10-40% cellulosic fiber, where the cellulosic fiber can include both flame resistant and non flame resistant variants of tencel, lyocell, modal, rayon, cotton, or other cellulosic fibers. One or more of the various fibers used herein can be natural, dyed, or printed with various colors, designs, indicia, including high visibility colors and markings. 
     The flame resistant fabrics provided herein are particularly useful for flash fire protection and can meet the following National Fire Protection Association 2112 standards: (1) having 50% or less predicted body burn in 3 seconds, according to the specifications of NFPA 2112 (ASTM F1930 test method); (2) the fabric must not melt, drip, or have more than 2 seconds after flame or 4.0 inches char length when tested before and after 25 launderings when using ASTM D6413 test method. Other uses of the present flame resistant fabrics include arc flash protection per the 70E standard as well as military garments and base-layer garments. The flame resistant fabrics can be used in various Hi-Vis applications and in construction of various safety equipment and safety garments. The flame resistant fabrics described herein and clothing made from the same provide several benefits and advantages over other flame resistant fabrics. Such benefits and advantages include improved comfort for the wearer by maintaining a lower core temperature for the wearer while also providing efficient moisture management. Moisture vapor from a wearer&#39;s skin can be absorbed before turning to sweat and the flame resistant fabric can provide a faster drying time to move moisture from the wearer to the atmosphere. The flame resistant fabric can also lower absolute humidity in the skin/garment microclimate. Due to the porous structure of the activated particles in the flame resistant fabric, odor can be trapped to creates a more comfortable user experience. The activated particles further provide increased flame resistance, contributing to the overall performance of the flame resistant fabric. 
     Specific fabric blends for fabrics contemplated by this disclosure include the following examples. 
     Fabric 1: 45% modacrylic; 20% fiber embedded with active particles (e.g., 37.5 fiber); 20% cotton; 15% producer colored aramid. 
     Fabric 2: 50% modacrylic; 20% fiber embedded with active particles (e.g., 37.5 fiber) r; 15% cotton; 15% producer colored aramid. 
     Fabric 3: 40% modacrylic; 20% fiber embedded with active particles (e.g., 37.5 fiber); 20% cotton; 20% producer colored aramid. 
     Fabric 4: 30% modacrylic; 20% fiber embedded with active particles (e.g., 37.5 fiber); 30% FR rayon; 20% producer colored aramid. 
     Fabric 5: 35% modacrylic; 20% fiber embedded with active particles (e.g., 37.5 fiber); 30% FR rayon; 15% producer colored aramid. 
     Fabric 6: 30% modacrylic; 20% fiber embedded with active particles (e.g., 37.5 fiber); 35% FR rayon; 15% producer colored aramid. 
     Fabric 7: 40% modacrylic; 20% producer colored fiber embedded with active particles (e.g., 37.5 fiber); 20% flame-resistant rayon; 20% producer colored aramid (e.g., Kermel). 
     Fabric 8: 40% modacrylic; 20% producer colored fiber embedded with active particles (e.g., 37.5 fiber); 20% lyocell; 20% producer colored aramid. 
     Flame resistant fabric made of three different fiber blends were tested for flame resistant efficacy, as detailed in the following tables. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Flame Resistant Fabric Testing 
               
            
           
           
               
               
               
               
               
            
               
                   
                 Fiber 
                 Example 1 
                 Example 2 
                 Example 3 
               
               
                   
                   
               
               
                   
                 % Protex A 
                 45 
                 45 
                 40 
               
               
                   
                 %37.5 fiber 
                 20 
                 20 
                 20 
               
               
                   
                 % FR Rayon 
                 n/a 
                 20 
                 n/a 
               
               
                   
                 % Lyocell 
                 20 
                 n/a 
                 20 
               
               
                   
                 % PC Black Kermel 
                 15 
                 15 
                 20 
               
               
                   
                 Weave 
                 Sock 
                 Sock 
                 Sock 
               
               
                   
                 Yarn Count 
                 18/1 
                 18/1 
                 18/1 
               
            
           
           
               
            
               
                 Vertical Flame 
               
            
           
           
               
               
               
               
               
            
               
                   
                 After Flame 
                   0.4 
                   0.4 
                   0.4 
               
               
                   
                 Char Length 
                   2.3 
                   2.6 
                  2 
               
               
                   
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Flame Resistant Fabric Testing 
               
            
           
           
               
               
               
               
            
               
                   
                 Trial 1-1 
                 Trial 1-2 
                 Trial 1-3 
               
               
                   
                   
               
            
           
           
               
               
               
               
            
               
                 SSM Style 
                 SD2351.00 
                 SD2351.01 
                 SD2351.02 
               
            
           
           
               
            
               
                 Blend 
               
            
           
           
               
               
               
               
            
               
                 % Protex M 
                 60 
                 60 
                 60 
               
               
                 %37.5 fiber 
                 25 
                 25 
                 25 
               
               
                 % PC Black Twaron 
                 15 
                 15 
                 15 
               
               
                 Weave 
                 2 × 1 Twill 
                 2 × 1 Twill 
                 2 × 1 Twill 
               
               
                 Yarn Count 
                 30/2 Vortex 
                 30/2 Vortex 
                 30/2 Vortex 
               
            
           
           
               
            
               
                 Weight 
               
            
           
           
               
               
               
               
            
               
                 oz/yd 2   
                 7.2 
                 7.66 
                 8.3 
               
            
           
           
               
            
               
                 Greige Weight 
               
            
           
           
               
               
               
               
            
               
                 oz/yd 2   
                 6.13 
                 6.77 
                 7.2 
               
            
           
           
               
            
               
                 Greige Width 
               
            
           
           
               
               
               
               
            
               
                 inches 
                 64.25 
                 64.25 
                 64.3 
               
            
           
           
               
            
               
                 Finished Width 
               
            
           
           
               
               
               
               
            
               
                 inches 
                 59.7 
                 60 
                 59.2 
               
            
           
           
               
            
               
                 Greige Construction 
               
            
           
           
               
               
               
               
            
               
                 w × f 
                 71 × 44 
                 71 × 52 
                 72 × 58 
               
            
           
           
               
            
               
                 Finished Construction 
               
            
           
           
               
               
               
               
            
               
                 w × f 
                 77 × 44 
                 75 × 53 
                 75 × 58 
               
            
           
           
               
            
               
                 Finished Theoretical Weight 
               
            
           
           
               
               
               
               
            
               
                 oz/yd 2   
                 6.4 
                 6.6 
                 6.9 
               
               
                 Theoretical Ends 
                 108 
                 110 
                 110 
               
            
           
           
               
            
               
                 Weight 
               
            
           
           
               
               
               
               
            
               
                 oz/yd 2   
                 7.2 
                 7.66 
                 8.3 
               
               
                 Total Ends 
                 121 
                 128 
                 133 
               
            
           
           
               
            
               
                 Greige Theoretical Weight 
               
            
           
           
               
               
               
               
            
               
                 oz/yd 2   
                 5.4 
                 5.7 
                 6 
               
               
                 Theoretical Ends 
                 101 
                 104 
                 108 
               
            
           
           
               
            
               
                 Weight 
               
            
           
           
               
               
               
               
            
               
                 oz/yd 2   
                 6.13 
                 6.77 
                 7.2 
               
               
                 Total Ends 
                 115 
                 123 
                 130 
               
            
           
           
               
            
               
                 Vertical Flame 
               
            
           
           
               
               
               
               
            
               
                 After Flame 
                 0.3 × 0.3 
                 0.4 × 0.4 
                 0.3 × 0.4 
               
               
                 After Glow 
                 2.1 × 2.1 
                 2.3 × 2.2 
                 2.3 × 2.6 
               
               
                 Char Length 
                 5.2 × 5   
                 5.4 × 5.4 
                 5.8 × 5.1 
               
               
                   
               
            
           
         
       
     
     The flame resistant fabric can be manufactured in various ways and in various sizes. Bulk flame resistant fabric can be manufactured, stored, and shipped as a roll. For example, various bolts of flame resistant fabrics can be provided for cutting, stitching, and sewing, among other assembly methods, into various articles of clothing, various types of protective equipment, and various articles of manufacture. Bolts of flame resistant fabrics can provide a unit of measurement and can be used as a standard for the flame resistant fabric as stored in a roll. Length can vary according to the type of material measured. Examples of lengths include from 40 to 100 yards (37 or 91 m), but can vary depending on the weight and other factors of the flame resistant fabric. The width of a bolt can be from 45 to 60 inches (110 or 150 cm), but widths can include 35-36 inches (890-910 mm), 39 inches (990 mm), 41 inches (1,000 mm), 44-45 inches (1,100-1,100 mm), 50 inches (1,300 mm), 52-54 inches (1,300-1,400 mm), 58-60 inches (1,500-1,500 mm) and 66 inches (1,700 mm), 72 inches (1,800 mm), 96 inches (2,400 mm), and 108 inches (2,700 mm). 
     Various articles of clothing can be formed entirely of one or more flame resistant fabrics as described herein. Various portions of articles of clothing can incorporate one or more flame resistant fabrics as described herein. Examples of such articles of clothing include coats, jackets, pants, overalls, bibs, pull-overs, gloves, socks, aprons, and hats, among others. 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.