Fabric containing PBI-p fiber

Abstract

A fabric for a thermal protective application includes: 5-40 weight % PBI-p fiber and the balance being conventional fibers, where the fabric has equal or better flame-resistant and/or heat-resistant properties, and a fabric weight less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers. The fabric for a thermal protective application includes: 5-40 weight % of a blend of PBI-p fiber and PBI-s fiber, and the balance being conventional fibers, where the fabric has equal or better flame-resistant and/or heat-resistant properties and a fabric weight less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers.

Claims

1. A fabric for a thermal protective application comprises: 5-40 weight % PBI-p fiber with a denier per filament in the range of 1.0-2.0 and the balance being conventional fibers, the PBI-p fiber having an APU in the range of 4-30%, and APU is phosphoric acid pick up, where the fabric has equal or better flame-resistant and/or heat-resistant properties, a fabric weight less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers, and a Dynamic Flame property of at least 28% greater than the equivalent fabric.

2. The fabric of claim 1 wherein the fabric has a weight in the range of 1.0-6.5 ounces per square yard (osy).

3. The fabric of claim 1 wherein the thermal protective application include: fire fighter's turnout gear, tents, arc-flash protective gear, automotive applications, automotive gear, spacesuits, space vehicles, and electronic equipment.

4. The fabric of claim 1 wherein the fabric is woven, knitted, or non-woven.

5. The fabric of claim 1 wherein the conventional fibers are made of materials including: cotton, wool, polyolefin, polyamide, acrylic, polyester, aramid, cellulosic, carbon, polybenzoxazole, melamine, polyamide imide, polyimide, polyphenyl sulfide, polyflouride, poly ether ketone, and combinations and blends thereof.

6. The fabric of claim 1 wherein flame-resistant property includes: the Dynamic Flame; a Vertical Flame (ASTM D6413); a Thermal Protective Performance (NFPA1971/ISO17492); a Ball Burst (ASTM D3787) After TPP exposure (ISO17492); and combinations thereof.

7. The fabric of claim 1 wherein heat resistant property includes: a Thermal Shrinkage (ASTM F2894/ISO17493); and combinations therewith.

8. A fabric for a thermal protective application comprises: 5-40 weight % of a blend of PBI-p fiber with a denier per filament in the range of 1.0-2.0 and PBI-s fiber, and the balance being conventional fibers, the PBI-p fiber having an APU in the range of 4-30%, and APU is phosphoric acid pick up, the amount of PBI-s fiber being greater than the amount of PBI-p fiber, where the fabric has equal or better flame-resistant and/or heat-resistant properties, a fabric weight less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers, and a Dynamic Flame property of at least 28% greater than the equivalent fabric.

9. The fabric of claim 8 wherein the fabric has a weight in the range of 1.0-6.5 ounces per square yard (osy).

10. The fabric of claim 8 wherein the thermal protective application include: fire fighter's turnout gear, tents, arc-flash protective gear, automotive applications, automotive gear, spacesuits, space vehicles, and electronic equipment.

11. The fabric of claim 8 wherein the fabric is woven, knitted, or non-woven.

12. The fabric of claim 8 wherein the conventional fibers are made of materials including: cotton, wool, polyolefin, polyamide, acrylic, polyester, aramid, cellulosic, carbon, polybenzoxazole, melamine, polyamide imide, polyimide, polyphenyl sulfide, polyflouride, poly ether ketone, and combinations and blends thereof.

13. The fabric of claim 8 wherein flame-resistant property includes: the Dynamic Flame; a Vertical Flame (ASTM D6413); a Thermal Protective Performance (NFPA1971/ISO17492); a Ball Burst (ASTM D3787) After TPP exposure (ISO17492); and combinations thereof.

14. The fabric of claim 8 wherein heat resistant property includes: a Thermal Shrinkage (ASTM F2894/ISO174493); and combinations therewith.

Description

DESCRIPTION OF THE DRAWINGS

(1) Referring to the drawings, where like numerals indicate like elements, there is shown in FIGS. 1 and 2 views of the Dynamic Flame Kit (DFK) used in the Dynamic flame test.

SUMMARY OF THE INVENTION

(2) A fabric for a thermal protective application includes: 5-40 weight % PBI-p fiber and the balance being conventional fibers, where the fabric has equal or better flame-resistant and/or heat-resistant properties, and a fabric weight less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers. The fabric for a thermal protective application may include: 5-40 weight % of a blend of PBI-p fiber and PBI-s fiber, and the balance being conventional fibers, where the fabric has equal or better flame-resistant and/or heat-resistant properties and a fabric weight less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers.

DETAILED DESCRIPTION OF THE INVENTION

(3) The fabric may be characterized, in one embodiment as, has having 5-40 weight % PBI-p fiber and the balance being other conventional fibers, where the fabric has equal or better flame-resistant and heat-resistant properties and a fabric weight (e.g., basis or areal weightosy [ounces per square yard] or gsm [grams per square meter]) less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers. The fabric may be characterized, in another embodiment as, has having 5-40 weight % of a blend of PBI-p fiber and PBI-s fiber, and the balance being other conventional fibers, the amount of PBI-s fiber being greater than the amount of PBI-p fiber, where the fabric has equal or better flame-resistant and heat-resistant properties and a fabric weight (e.g., basis or areal weightosy [ounces per square yard] or gsm [grams per square meter]) less than an equivalent fabric made with a like amount of PBI-s fiber in place of the PBI-p fibers.

(4) Fabric, as used herein, refers to any fabric. A fabric may be a woven fabric, a knit fabric, a nonwoven fabric, or a combination thereof. The fabric may have any weight (e.g., basis or areal weightosy [ounces per square yard] or gsm [grams per square meter]). In some embodiments, the fabric weight may be in the range of 1.0-6.5 osy (and all or any subsets included therein). In some embodiments, the lower end of the fabric weight (osy) range may be: 1.0, 1.25. 1.5, 1.75, 2.0, 2.25, 2.5, 2.75, 3.0, 3.25, 3.5; 3.75, 4.0, 4.25, 4.5, 4.75, and 5.0. In some embodiments, the upper end of the fabric weight (osy) range may be: 6.5, 6.25, 6.0, 5.75, 5.5, 5.25, 5.0, 4.75, 4.5. In some embodiments directed to woven fabrics, the fabric may have a weight in the range of 4.0-6.5 osy, or in a range of 4.5-6.0 osy, or 4.75-6.0 osy.

(5) The fabric may be used in any application (or end use). The fabric may be used in thermal protective applications. Exemplary thermal protective applications include, but are not limited to: fire fighter's turnout gear, tents, arc-flash protective gear, automotive applications, automotive gear, spacesuits, space vehicles, and electronic equipment.

(6) Fibers, as used herein, refer to any fiber. Fibers may be staple (or short cut lengths) or filament (or fiber length>>fiber diameter or infinite length). Fibers may have any weight (e.g., denier or TEX).

(7) PBI-p fibers refer to PBI fibers phosphonated with phosphoric acid in the range of 4-30 wt. % (or 4-30% phosphoric acid pick up (APU)). Phosphoric acid (aqueous) concentration may range from 10-85 wt. %; further details on acid concentration and APU may be found in, for example, U.S. Ser. No. 15/193,206 filed Jun. 27, 2016, incorporated herein by reference. The PBI-p fiber has higher thermo-oxidative stability as compared to commercially available sulfonated PBI fibers. The phosphoric acid range includes any and all sub-ranges included therein. In another embodiment, the PBI-p fiber has a phosphoric acid (APU) in the range of 5-25 wt. %. In still another embodiment, the PBI-p fiber has a phosphoric acid (APU) in the range of 6-20 wt. %. In yet another embodiment, the PBI-p fiber has a phosphoric acid (APU) of about 18 wt. %. The upper end of the phosphoric acid range may be: 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, and 10. In another embodiment, the PBI-p fibers may have an LOI of 60+%. LOI, or Limiting Oxygen Index, is measured by ATSM D2863. LOI is a fiber property and not a fabric property. Accordingly, one may obtain a thermo-oxidatively stable fiber without a 27 wt. % phosphoric acid pick-up. This may be important because of the negative implications associated with phosphates in the environment. The PBI-p fiber may have a weight in the range of 1.0-2.0 denier per filament (dpf), and in one embodiment, the fiber weight may be 1.5 dpf.

(8) PBI-s fibers refer to the commercially available FBI fibers that are currently available from FBI Performance Products, Inc. of Charlotte, N.C.

(9) Conventional fibers, as used herein refer to any conventional fiber. In one embodiment, these conventional fibers refer to natural and synthetic fibers. The conventional fibers may or may not be treated with a flame retardant (FR treated). Natural fibers may be cotton and/or wool. Synthetic fibers may be made of, for example, polyolefin (e.g., polyethylene, polypropylene, and the like), polyamide (e.g., nylon and the like), acrylic (and/or modacrylic), polyester (e.g., PET, PBT, PEN), aramid (e.g., meta-aramid, para-aramid), cellulosic (e.g., rayon, Lyocel), carbon, polybenzoxazole (PBO), melamine, polyamide imide, polyimide, polyphenyl sulfide (PPS), polyflouride (e.g., PTFE), poly ether ketone (e.g., PEK, PEEK, PEEKK, PEKK, and the like), and combinations and blends thereof.

(10) The fibers are spun into yarns by any conventional means. The yarns may be made of a single fiber or blends of fibers. Exemplary blends include, but are not limited to, PBI-p fibers and conventional fibers, or PBI-p, PBI-s, and conventional fibers, and the like. The yarns may include PBI-p in the weight range of 5-40% of the fabric. Yarns with a blend of PBI-p fiber and PBI-s fiber may have a PBI-p:PBI-s weight ratio in the range of 20-100:0-80. In one embodiment, the yarn may be a blend of PBI-p and aramid (e.g., para-aramid) with exemplary weight ratios of 5-40 wt % PBI-p and 60-95 wt % aramid e.g., para-aramid). In another embodiment, the yarns may be blend of PBI-p, PBI-s, and aramid (e.g., para-aramid) with exemplary weight ratios of, for example, 7-40:0-33:60 or 10-40:0-30:60 (PBI-p:PBI-s: aramid (e.g., para-aramid)).

(11) The fabric, in one embodiment, may have PBI-p fibers in the weight range of about 5-40% based on the fabric weight. The fabric, in another embodiment may have a blend of PBI-p and PBI-s fibers in a weight range of about 5-40% based on the fabric weight. In one embodiment, the fabric may be a blend of PBI-p and aramid (e.g., para-aramid) with exemplary weight ratios of 5-40 wt % PBI-p and 60-95 wt % aramid. In another embodiment, the fabric may be blend of PBI-p, PBI-s, and aramid (e.g., para-aramid) with exemplary weight ratios of, for example, 7-40:0-33:60 or 10-40:0-30:60 (PBI-p:PBI-s: aramid (e.g., para-aramid)).

(12) The fabric made with the PBI-p fibers, in one embodiment, may have a lesser weight (e.g., basis or areal weightosy [ounces per square yard] or gsm [grams per square meter]) and equivalent or better flame-resistant and heat-resistant properties than an equivalent fabric made with a like amount of PBI-s fiber. For example, a first fabric is made with X % by weight PBI-s and conventional fibers will have a given weight (e.g., basis or areal weightosy [ounces per square yard] or gsm [grams per square meter]) and given flame-resistant and heat-resistant properties (discussed in greater detail below) and a second fabric made with X % by weight PBI-p fiber and the same conventional fibers as the first fabric, the second fabric will weigh less than the first fabric and have equivalent or better flame-resistant and heat-resistant properties.

(13) Flame-resistant and heat-resistant properties may be any such conventional properties. Exemplary flame-resistant, or flammability, (FR) properties may include, but are not limited to: Dynamic Flame Testsee discussion below; Vertical Flame TestASTM D6413; Thermal Protective Performance (TPP)NFPA1971/ISO17492; and Ball Burst (ASTM D3787) After TPP exposure (ISO17492); and combinations thereof. In one embodiment, the flame-resistant property may be the Dynamic Flame Test. Exemplary heat-resistant (HR) properties may include, but are not limited to: Thermal ShrinkageASTM F2894/ISO17493; and combinations therewith.

(14) The Dynamic Flame test is explained, with reference to FIGS. 1 and 2, as follows:

(15) The Dynamic Flame test uses the Dynamic Flame Kit (DFK) shown in FIGS. 1 and 2. The DFK 10 generally includes: a propane source 12, a propane distribution manifold 16 with two identical burners 18 and a knob 19, and a propane tube 14 interconnecting the source 12 with the distribution manifold 16 and burners 18, and a fabric frame 20 with clips 22 for holding fabric strips 24 and weights 24 (e.g., 225 g) at the bottom ends of the fabric strips 24. In a first position, FIG. 1, the burners 18 are in a vertical, or upright, position (flame not pointed at fabric strip 24). In a second position, FIG. 2, the burners 18 are in a horizontal, or engaged, position (flame pointed at the fabric strip 24).

(16) The Dynamic Flame test is conducted as follows: assemble the DFK; connect a new propane bottle 12 to tubing 14; ignite a first burner 18 and then the second burner 18; allow the burners 18 to warm-up for a minimum of 5 minutes; prepare fabric strips (control and test strips), 1 width and 8 long and condition them under the same conditions; attach the conditioned fabric strips 24 to the fabric frame 20 by folding about of the top of the strip and fastening the folded edge to the fabric frame 20 with the clip 22 (e.g., binder clip); attach the weight 26 to the lower end of the fabric strip 24; ensure that the clip 22 position are the same between the strips 24 being tested and that from test to test the clip 22 position is the same, also ensure that the flame is aligned the same for both test strips 24 and between tests; at the start of the test make sure each strip 24 is motionless; quickly rotate (using knob 19) the burners 18 from the first position to the second position and simultaneously start the timer; when the weight 26 drops, stop the timer and record the time; repeat with new samples nine (9) time for a total of ten (10) replicates; and report the average of times of the ten tested samples.

EXAMPLES

(17) In the following examples, data presented in the tables compares fabrics made with PBI-s fibers to fabrics made with PBI-p fibers. In each table, the compared fabrics are identical and are made by identical processes, the only difference being one fabric is made with PBI-s fiber and the other is made with PBI-p fiber. Table 1 lists data according to testing done for fabrics marketed to the international market; while Tables 2 and 3 list data according to testing done for fabrics marketed to the domestic (or US) market.

(18) TABLE-US-00001 TABLE 1 (nominal 6 osy fabric) Test Description/Conditions Control (PBI-s) Invention (PBI-p) Composition 65% p-aramid/35% PBI-s 65% p-aramid/35% PBI-p weave filament twill filament twill Basis Weight osy gsm osy gsm ASTM D3776 as received (AR) 5.99 203 5.68 192 5x wash 6.21 211 5.78 196 10x wash 6.37 216 5.87 199 Laundry Shrinkage 5x wash 2.77 +0.88 1.97 +0.9 % W F 10x wash 4.2 +0.33 .16 +1.17 ISO 6330 4M Thermal shrinkage 260 C. - 5 min 1.67 0.0 0.88 +0.5 ISO 17493 Tear Strength (Trapezoid Tear) Lbs. Newtons Lbs. Newtons W F as received (AR) 158.1 159.7 703 710 164.5 236.7 732 1053 ASTM D5587 5x wash 183.9 235.3 818 1047 114.2 202.2 508 899 NFPA (5 highest peaks) 10x wash 165.5 233.6 736 1039 131.7 212.1 586 944 Tensile (2 inch strip) as received (AR) 497.7 475.6 2214 2116 600.0 508.4 2668 2263 W F 5x wash 430.5 512.1 1915 2278 523.3 550.7 2327 2450 ISO 13934-1 10x wash 415.3 483.6 1847 2151 478.5 538.0 2128 2393 Tensile (TPP Residual Strength) as received (AR) 497.7 2214 600 2669 2 inch strip - (Warp only) 2 sec 516 2295 556.7 2476 ISO 17492 @ 84 kw heat flux 4 sec 409.5 1822 306.5 1363 ISO 13934-1 6 sec 309.1 1375 180.1 801 8 sec 137.1 610 84.2 375 Tensile (Grab) as received (AR) 347.1 383.6 1544 1706 361.1 370.0 1606 1646 W F 5x wash 331.3 365.6 1474 1626 328.7 382.8 1462 1703 ISO 13934-2 10x wash 340.7 378.5 1516 1684 338.9 377.2 1508 1678 Tear Strength (Trouser Tear) as received (AR) 61.1 50.3 272 224 60.7 63.5 270 283 ISO 13937-2 Ball Burst Strength as received (AR) 464.9 2068 660.8 2939 ASTM D3787 AR + 8 sec TPP 69.1 307 44.9 200 5x wash (W) 508.3 2261 635.3 2826 5 W + 8 sec TPP 82.9 369 32.7 145 10x wash 496 2206 664.9 2958 10 W + 8 sec TPP 89.8 399 32.2 143 Vertical Flame afterflame sec. 0 0 0 0 ASTM D6413 afterglow sec. 9.04 6.04 2.99 3.00 char length in. .66 .43 .75 .90 Dynamic Flame as received seconds W F 23.5 22.6 36.6 35.0 Abrasion Resistance (Taber) H-18/500 g/w vac Cycles to 1st hole >400 >400 ASTM D3884 Thermal Protective Performance (TPP)/ TPP rating* 35.92 36.23 Heat Transfer Index (HTI) ISO 17492 TPP + HTI HTI24* 19.62 19.66 HTI12* 14.3 14.34 HTI 24-12* 5.32 5.32 *Composite Materials: Bristol Q01 Thermal Liner, Gore Fireblocker Moisture Barrier

(19) TABLE-US-00002 TABLE 2 (nominal 5.5 osy fabric) Test Description/Conditions Control (PBI-s) Invention (PBI-p) Composition 60% p-aramid/40% PBI-s 60% p-aramid/40% PBI-p weave ripstop ripstop Basis Weight osy gsm osy gsm ASTM D3776 as received (AR) 5.67 192 5.65 192 5x wash 5.93 201 6.08 206 10x wash 6.11 207 6.33 215 Laundry Shrinkage 5x wash 3.50 1.08 1.75 1.67 % W F 10x wash 4.25 2.00 4.67 2.5 AATCC 135:1, V, Ai Thermal shrinkage 260 C. - 5 min 3.0 1.0 1.5 0.3 ASTM F2894 Tear Strength (Trapezoid Tear) Lbs. Newtons Lbs. Newtons W F as received (AR) 28.3 22.1 126 98 35.9 29.3 160 130 ASTM D5587 5x wash 25.8 19.5 115 87 31.9 27.5 142 122 NFPA (5 highest peaks) 10x wash 25.9 18.3 115 81 28.9 25 129 111 Tensile (2 inch strip) as received (AR) 451.9 308.1 2010 1370 501.1 385.4 2229 1714 W F 5x wash 397.9 272.4 1770 1212 459.7 370.4 2045 1648 ASTM D5035 10x wash 359.9 286.6 1601 1275 432.4 341.0 1923 1517 Tensile (TPP Residual Strength) as received (AR) 451.9 2010 501.1 2229 2 inch strip - (Warp only) 2 sec 251 1116 227.5 1012 ISO 17492 @ 84 kw heat flux 4 sec 138.7 617 174.8 778 ASTM D5035 6 sec 135.1 601 102.5 456 8 sec 64.8 288 50.7 226 Tensile (Grab) as received (AR) 275 185.8 1223 826 327.5 227.9 1457 1014 W F 5x wash 249.5 165.8 1110 738 293.1 205.2 1304 913 ASTM D5034 10x wash 233.8 161.1 1040 717 278.9 206.5 1241 919 Ball Burst Strength as received (AR) 377.3 1678 459.5 2044 ASTM D3787 AR + 10 sec TPP 28.3 126 14.1 63 5x wash(W) 273.6 1217 429.1 1909 5 W + 10 sec TPP 22.3 99 13.3 59 10x wash 260.6 1159 371 1650 10 W + 10 sec TPP 15.7 70 15.4 69 Vertical Flame afterflame sec. 0 0 0 0 ASTM D6413 afterglow sec. 1.97 1.87 1.12 1.17 char length in. 0.92 0.72 0.7 0.54 Dynamic Flame as received seconds W F 37.3 37.2 47.7 48.5 Abrasion Resistance (Taber) H-18/500 g/w vac cycles to first hole 433 465 ASTM D3884 Thermal Protective Performance (TPP) ISO 17492 TPP TPP Rating** 34.17 36.3 **Composite Materials: Glide w/PBI G2 Thermal Liner, Stedair Gold Moisture Barrier

(20) TABLE-US-00003 TABLE 3 (nominal 5 osy fabric) Test Description/Conditions Control (PBI-s) Invention (PBI-p) Composition 60% p-aramid/40% PBI-s 60% p-aramid/40% PBI-p weave ripstop ripstop Basis Weight osy gsm osy gsm ASTM D3776 as received (AR) 4.92 167 4.80 163 5x wash 5.07 172 5.19 176 10x wash 5.12 174 5.28 179 Laundry Shrinkage 5x wash 5.5 0.0 3.7 0.0 % W F 10x wash 6.1 1.0 4.9 0.0 AATCC 135:1, V, Ai Thermal shrinkage 260 C. - 5 min 2.4 0.5 1.6 0.0 ASTM F2894 Tear Strength (Trapezoid Tear) Lbs. Newtons Lbs. Newtons W F as received (AR) 23.0 13.5 102 60 27.9 16.6 124 74 ASTM D5587 5x wash 21.8 12.9 97 57 25.6 14.1 114 63 NFPA (5 highest peaks) 10x wash 21.7 11.3 97 50 23.3 12.3 104 55 Tensile (2 inch strip) as received (AR) 380.6 248.6 1693 1106 419.4 249.3 1866 1109 W F 5x wash 341.5 217.2 1519 966 400.7 217.4 1782 967 ASTM D5035 10x wash 353.7 212.4 1573 945 387.9 205.9 1725 916 Tensile (TPP Residual Strength) as received (AR) 380.6 1693 419.4 186 2 inch strip - (Warp only) 2 sec 170 756 185.7 826 ISO 17492 @ 84 kw heat flux 4 sec 136 605 138.4 616 ASTM D5035 6 sec 103.2 459 97.9 435 8 sec 50.4 224 47.1 210 Tensile (Grab) as received (AR) 254.3 156.8 1131 697 282.7 149.3 1258 664 W F 5x wash 225.8 139.4 1004 620 238.1 130.7 1059 581 ASTM D5034 10x wash 222.8 129.6 991 576 249.3 144.0 1109 641 Ball Burst Strength as received (AR) 180.1 801 269.9 1201 ASTM D3787 AR + 10 sec TPP 9.4 42 11 49 5x wash(W) 187.1 832 239.2 1064 5 W + 10 sec TPP 14.1 63 7.2 32 10x wash 181.4 807 203.7 906 10 W + 10 sec TPP 14.5 64 9.9 44 Vertical Flame afterflame sec. 0 0 0 0 ASTM D6413 afterglow sec. 3.1 3.9 1.3 2.5 char length in. 0.9 0.5 0.6 0.2 Dynamic Flame as received seconds W F 25.0 35.0 53.6 53.3 Abrasion Resistance (Taber) H-18/500 g/w vac cycles to first hole 460 297 ASTM D3884 Thermal Protective Performance (TPP) ISO 17492 TPP TPP Rating** 35.3 35.3 **Composite Materials: Glide w/PBI G2 Thermal Liner, Stedair Gold Moisture Barrier

(21) The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.