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.

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.

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.

A flame resistant composite fabric includes a first flame resistant fabric layer, a second flame resistant fabric layer, and a barrier layer that bonds the first flame resistant fabric layer to the second flame resistant fabric layer. The barrier layer is capable of withstanding temperature of 500 F. for at least 5 minutes without substantial change in the integrity of the flame resistant composite fabric.

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.