Flame resistant fabrics comprising a blend of modacrylic, aliphatic polyamide, and cellulosic fibers. Some embodiments are printed and/or dyed with vat dyes so as to comply with the color requirements (including the color, colorfastness, and IR requirements) set forth in the relevant sections of GL-PD-07-12 and/or MIL-PRF-EFRCE. Some embodiments further include reinforcing yarns that improve the strength of the fabrics. Still other embodiments are flame resistant fabrics for use in electrical applications that comply with some or all of the requirements of ASTM F 1506.

Embodiments of the present invention relate to flame resistant fabrics formed with inherently flame resistant fibers that provide the requisite thermal and arc protection, that have improved comfort, and that, in some embodiments, are less expensive than other fabrics formed with inherently flame resistant fibers. Improved comfort and lower cost can be achieved by predominantly locating the inherently flame resistant fibers on the front face of the fabric to impart the requisite thermal and arc protection and predominantly locating the more comfortable (and less expensive) fibers on the back face of the fabric positioned next to the wearer. In this way, overall protection of the fabric is maintained while improving comfort. Some embodiments of such fabrics may also achieve NFPA 70E PPE Category 2 protection.

Embodiments of the present invention replace relatively bulky nonwoven thermal insulating materials used in thermal liners with thin, lightweight, flexible films that maintain or improve TPP performance while reducing the thickness, and enhancing the flexibility, of the thermal liner so as to increase wearer comfort. Moreover, the films incorporated into the thermal liners can be both air and vapor permeable such that the TPP performance is not realized at the expense of THL performance. Rather, the THL performance of garments incorporating embodiments of thermal liners contemplated herein is comparable toif not improved overgarments formed with traditional thermal liners.

A woven flame-resistant fabric for garments, the warp and fill yarns being made up of at least about 30 wt. % inherently flame-resistant fibers. The fabric is woven from a plurality of warp yarn groups consecutively arranged across the width direction in a recurring pattern, each warp yarn group consisting of a plurality of adjacent consecutively arranged warp yarns. At least one warp yarn in each warp yarn group is woven with the fill yarns in a plain (1/1) weave and at least one warp yarn in each warp yarn group is woven in one or more non-plain weaves each selected from the group consisting of 1/2, 2/1, 2/2, 1/3, and 3/1. Approximately half of the warp yarns in the fabric are woven in a plain (1/1) weave and the remaining warp yarns in the fabric are woven in the one or more non-plain weaves, in an alternating fashion.

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.

Flame resistant fabrics comprising a blend of modacrylic, aliphatic polyamide, and cellulosic fibers. Some embodiments are printed and/or dyed with vat dyes so as to comply with the color requirements (including the color, colorfastness, and IR requirements) set forth in the relevant sections of GL-PD-07-12 and/or MIL-PRF-EFRCE. Some embodiments further include reinforcing yarns that improve the strength of the fabrics. Still other embodiments are flame resistant fabrics for use in electrical applications that comply with some or all of the requirements of ASTM F 1506.

A mattress, foundation, or other upholstered sleep product or article includes a core and barrier material surrounding the core. The barrier material includes flame and heat-resistant material that is configured to prevent combustion of the core when the upholstered article is impinged with a gas flame according to California Technical Bulletin 603 of the State of California Department of Consumer Affairs. The barrier material may include an intumescent material that is configured to swell and char in the presence of a flame so as to form a barrier to the flame and to heat generated by the flame.

Unique blends of fibers that incorporate synthetic cellulosic fibers to render fabrics made with such blends more durable than fabrics made with natural cellulosic fibers such as cotton. While more durable than cotton, the synthetic cellulosic fibers used in the blends are still inexpensive and comfortable to the wearer. Thus, the benefits of cotton (affordability and comfort) are still attained while a drawback of cottonlow durabilityis avoided. In one embodiment, the fiber blend includes FR modacrylic fibers and synthetic cellulosic fibers, preferably, but not necessarily non-FR lyocell fibers such as TENCEL and TENCEL A100. Other fibers may be added to the blend, including, but not limited to, additional types of inherently FR fibers, anti-static fibers, anti-microbial fibers, stretch fibers, and/or high tenacity fibers. The fiber blends disclosed herein may be used to form various types of FR fabrics. Desired colors may be imparted in a variety of ways and with a variety of dyes to the fabrics disclosed herein. Fabrics having the fibers blends disclosed herein can be used to construct the entirety of, or various portions of, a variety of protective garments for protecting the wearer against electrical arc flash and flames, including, but not limited to, coveralls, jumpsuits, shirts, jackets, vests, and trousers.

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.

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.