Flame resistant fabrics are provided that exhibit improved protection from molten metal spills, metal splatter, electric arc, and related thermal hazards illustratively including open flame and radiant heat. The flame resistant fabrics are made from a combination of cellulosic fibers and thermoplastic fibers, where the flame resistant fabric forms a char layer that does not become brittle when contacted by molten metal, metal splatter, electric arc, and related thermal hazards. By not becoming brittle the likelihood of break out of the fabric is minimized, thereby improving the level of protection to the user. As a result, the flame resistant fabric retains the desirable properties of fibers formed of organic materials in terms of comfort, weight, and durability.

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 cotton—low durability—is 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 garment comprising a flame-resistant fabric, and the flame resistant fabric, each comprising a yarn comprising a) 85 to 97 weight percent of a meta-aramid fiber component, and b) 3 to 15 weight percent of a fiber made from para-aramid polymer, based on the total amount of a) and b) in the yarn; wherein the meta-aramid fiber component is: i) 50 to 100 weight percent fiber made from a polymer blend of meta-aramid polymer and polyvinylpyrrolidone (PVP) polymer, the polymer blend comprising 88 to 95 weight percent meta-aramid polymer and 5 to 12 weight percent PVP polymer, and ii) 0 to 50 weight percent fiber made solely from meta-aramid polymer, based on the total amount of i) and ii) in the meta-aramid fiber component.

An arc resistant fabric containing a plurality of first yarns disposed in a first direction in the fabric and a plurality of second yarns disposed in a second direction perpendicular to the first direction forming a woven pattern. The first and second yarns contain non-FR cellulosic fibers, modacrylic fibers, and aramid fibers intimately blended together. The woven fabric has a sateen weave. The arc resistant fabric has a weight less than about 6 oz/yd.sup.2, an arc thermal protective value (atpv) of least about 8.0 cal/cm.sup.2, and a greater thickness than a fabric using the same yarns in a plain weave.

A composite yarn comprising a continuous multifilament core yarn incorporated in a matrix, is characterized in that the matrix comprises at least one polymer material and at least one reinforcing filler, the reinforcing filler being formed from functionalized particles, said particles having a median size (d.sub.v50) of less than 40 μm.

A process for manufacturing such a composite yarn, comprises at least one step of depositing, by coating or extrusion, a matrix comprising a polymer and a reinforcing filler, onto a core yarn.

A textile surface comprises at least one such composite yarn.

The application relates to a fire-resistant textile composite having an upper surface and a lower surface. The composite contains a nonwoven layer and a knit layer. The nonwoven layer has a first and second side and contains a nonwoven textile. The nonwoven textile contains a plurality of first fire-resistant fibers, where the first fire-resistant fibers are non-thermoplastic. The nonwoven layer forms the lower surface of the textile composite. The knit layer contains a knit textile having a first and second side and the second side of the knit layer is adjacent to the first side of the nonwoven layer. The knit textile contains a plurality of second fire-resistant yarns, where the second fire-resistant yarns are non-thermoplastic. At least a portion of the first fire-resistant fibers from the nonwoven layer extend through the first side of the knit layer and form the upper surface of the textile composite.

The invention addresses the problem of providing a cloth and a protective product, which are excellent not only in flame retardancy but also in protection performance against electric arcs, and can further be provided with any color appearance. As a means for resolution, in a cloth including a flame-retardant fiber, a UV absorber or carbon particles are contained in the cloth, and the cloth is configured to have a lightness index L-value of 25 or more.

A composite yarn comprising a continuous multifilament core yarn incorporated in a matrix is characterised in that the matrix comprises at least one polymer material and at least one reinforcing filler, the reinforcing filler being formed from functionalized particles, said particles having a median size (d.sub.v5o) of less than 40 μm. A process for manufacturing such a composite yarn, comprises at least one step of depositing, by coating or extrusion, a matrix comprising a polymer and a reinforcing filler, onto a core yarn. A textile surface comprises at least one such composite yarn.

A dispenser is described for dispensing nanofiber yarns that includes a housing that defines an inlet, an outlet, and a chamber. A spool, around which is wound a length of nanofiber yarn, is disposed within the chamber defined by the housing. The nanofiber yarn is threaded from the chamber through the outlet and can be dispensed in a controlled way that reduces the likelihood of developing knots within the nanofiber yarn, and which facilitates convenient application of the yarn onto an underlying surface. In some cases, the dispenser can be used to concurrently dispense an adhesive or other polymer along with the nanofiber yarn.

A flame resistant knit fabric containing a first weft yarn set and a second weft yarn set. The first yarn set contains first flame resistant yarns which contain flame resistant rayon fibers. The second weft yarn set contains second weft yarns. The knit fabric is knitted such that the first weft yarns are interlinked with one another by a plurality of knit stitches, the second weft yarns are interlinked with one another by a plurality of knit stitches, and the first weft yarns are not interlinked with the second weft yarns. A flame resistant support article containing the flame resistant knit fabric as well as methods for making the knit fabric and support article are also disclosed.