Reinforced Flame Resistant Fabrics

Abstract

Described are flame resistant fabrics having a warp direction, a weft direction, and a fabric weight. The flame resistant fabrics may include warp direction yarns and weft direction yarns, where the warp direction yarns include warp body yarns having a fiber blend of a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers; and the weft direction yarns include weft body yarns having a fiber blend of a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers and weft reinforcement yarns having a fiber blend of 30 wt. % to 100 wt. % non-FR synthetic fibers. The fiber blend of the weft reinforcement yarns may comprise at least two times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns.

Claims

1. A flame resistant fabric having a warp direction, a weft direction, and a fabric weight, the flame resistant fabric comprising warp direction yarns and weft direction yarns, wherein: a. the warp direction yarns comprise warp body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers; and b. the weft direction yarns comprise: i. weft body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers; and ii. weft reinforcement yarns having a fiber blend comprising 30 wt. % to 100 wt. % non-FR synthetic fibers, wherein the fiber blend of the weft reinforcement yarns comprises at least two times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns, wherein the weft direction yarns comprise a total wt. % of non-FR synthetic fibers and wherein, when a fabric tear strength in the weft direction of the flame resistant fabric and a fabric tear strength in a weft direction of a comparative flame resistant fabric (i) having substantially the same fabric weight, (ii) formed of the warp body yarns and the weft body yarns, and (iii) devoid of the weft reinforcement yarns was measured in Newtons and pursuant to ISO 13937-2, a strength percentage increase in fabric tear strength in the weft direction of the flame resistant fabric over the fabric tear strength in the weft direction of the comparative flame resistant fabric was greater than a fiber percentage increase of the total wt. % of non-FR synthetic fibers in the weft direction yarns of the flame resistant fabric over the wt. % of non-FR synthetic fibers in the weft body yarns of the comparative flame resistant fabric, and wherein the flame resistant fabric has a char length of less than 100 millimeters when tested pursuant to ISO 15025:2000.

2. The flame resistant fabric of claim 1, wherein the fiber blend of the weft reinforcement yarns further comprises cellulosic fibers.

3. The flame resistant fabric of claim 2, wherein the fiber blend of the weft reinforcement yarns comprises 40-60 wt. % non-FR synthetic fibers and 40-60 wt. % cellulosic fibers.

4. The flame resistant fabric of claim 1, wherein the warp direction yarns further comprise warp reinforcement yarns.

5. The flame resistant fabric of claim 4, wherein the warp reinforcement yarns have a fiber blend and wherein the fiber blend of the warp reinforcement yarns and the fiber blend of the weft reinforcement yarns are identical.

6. The flame resistant fabric of claim 4, wherein the warp reinforcement yarns have a fiber blend comprising 30 wt. % to 100 wt. % non-FR synthetic fibers and wherein the fiber blend of the warp reinforcement yarns comprises at least two times the wt. % of non-FR synthetic fibers in the fiber blend of the warp body yarns.

7. The flame resistant fabric of claim 1, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 70 wt. % cellulosic fibers and less than 30 wt. % non-FR synthetic fibers.

8. The flame resistant fabric of claim 7, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 80 wt. % cellulosic fibers and less than 20 wt. % non-FR synthetic fibers.

9. The flame resistant fabric of claim 1, wherein the fiber blend of the weft reinforcement yarns comprises at least three times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns.

10. The flame resistant fabric of claim 9, wherein the fiber blend of the weft reinforcement yarns comprises at least four times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns.

11. The flame resistant fabric of claim 1, wherein the fabric weight is between 5-10 osy, inclusive.

12. The flame resistant fabric of claim 1, wherein between 1 to 20 weft body yarns are provided between adjacent weft reinforcement yarns.

13. The flame resistant fabric of claim 1, further comprising an overall fiber blend, wherein the overall fiber blend comprises 70-90 wt. % cellulosic fibers and 10-30 wt. % non-FR synthetic fibers.

14. The flame resistant fabric of claim 1, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns are different.

15. A flame resistant fabric having a warp direction, a weft direction, and a fabric fiber blend, the flame resistant fabric comprising warp direction yarns and weft direction yarns, wherein: a. the warp direction yarns comprise: i. warp body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers; and ii. warp reinforcement yarns having a fiber blend comprising 40-60 wt. % cellulosic fibers and 40-60 wt. % non-FR synthetic fibers, wherein the fiber blend of the warp reinforcement yarns comprises at least three times the wt. % of non-FR synthetic fibers in the fiber blend of the warp body yarns; and b. the weft direction yarns comprise: i. weft body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers; and ii. weft reinforcement yarns having a fiber blend comprising 40-60 wt. % cellulosic fibers and 40-60 wt. % non-FR synthetic fibers, wherein the fiber blend of the weft reinforcement yarns comprises at least three times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns.

16. The flame resistant fabric of claim 15, wherein the fiber blend of the warp reinforcement yarns and the fiber blend of the weft reinforcement yarns are identical.

17. The flame resistant fabric of claim 15, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns are different.

18. The flame resistant fabric of claim 15, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 70 wt. % cellulosic fibers and less than 30 wt. % non-FR synthetic fibers.

19. The flame resistant fabric of claim 18, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 80 wt. % cellulosic fibers and less than 20 wt. % non-FR synthetic fibers.

20. The flame resistant fabric of claim 15, wherein the flame resistant fabric comprises a fabric weight between 5-10 osy, inclusive.

Description

DESCRIPTION

[0011] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

[0012] Embodiments are directed to flame resistant fabrics that include a high percentage of cellulosic fibers for comfort and flame resistance but that have been reinforced such that the fabric complies with applicable strength requirements. Flame retardant or flame resistant (FR) is hereby defined in this application to mean flame- and/or heat-retardance/resistance conferred by a treatment to the filament, fiber, yarn or fabric. This may provide a fabric with low percentage of (estimated) body burns in thermal manikin testing, limited after-flame time and highly resilient against combustion, as well as protection against radiant heat, electric arcs, and molten metal. For example, FR fabrics disclosed herein may meet the performance requirements of ISO 11612 and the other standards disclosed herein.

[0013] Embodiments of the fabric are formed with warp body yarns and weft body yarns that form the body of the fabric (i.e., body yarns). Reinforcement yarns are provided in discrete locations among such body yarns within the warp direction and/or weft direction of the fabrics. As used herein, a reinforcement yarn is a type of yarn specifically designed to enhance one or more mechanical properties of a fabric, such as its strength, durability, and resistance to wear and tear. These yarns are typically stronger and more resilient than standard body yarns used in the fabric. When integrated into fabrics, reinforcement yarns can be strategically placed alongside body yarns to improve one or more mechanical properties of the fabric, including (but not limited to) the tensile strength, tear strength, elongation and modulus, durability, structural integrity, and dimensional stability of the fabric.

[0014] In some embodiments, the reinforcement yarns include 10-100 weight (wt.) % or 20-100 wt. % synthetic fibers. The synthetic fibers may be (but are not limited to) polyester fibers (FR or non-FR), polyamide fibers (FR or non-FR), aramid (meta-aramid and/or para-aramid) fibers, polybenzimidazole (PBI) fibers, polyphenylene benzobisoxazole (PBO) fibers, polypropylene fibers (FR or non-FR), and/or polyethylene fibers (FR or non-FR).

[0015] In some embodiments, the reinforcement yarns are a blend of cellulosic fibers and synthetic fibers. In some embodiments, the synthetic fibers used in the reinforcement yarns are not flame resistant and thus detrimentally impact the FR properties of the fabric. Thus, cellulosic fibers that may be rendered FR may be included in the reinforcement yarns to compensate for such non-FR synthetic fibers.

[0016] The cellulosic fibers used in the reinforcement yarns may be any natural and/or synthetic cellulosic fiber, such as (but not limited to) cotton fibers, rayon fibers, lyocell fibers, acetate fibers, triacetate fibers, silk fibers, hemp fibers, linen fibers, bamboo fibers, etc. In some non-limiting examples, the reinforcement yarns are a blend of cotton fibers (i.e., natural cellulosic fibers) and polyester fibers (and/or nylon fibers). While the cellulosic fibers used in the reinforcement yarns may be cotton fibers, they may be any natural and/or synthetic cellulosic fiber, such as rayon, lyocell, acetate, triacetate, silk, hemp, linen, bamboo, etc. In some embodiments, the cellulosic fibers are cotton fibers and/or lyocell fibers. In some embodiments, blends of different cellulosic fibers (e.g., a blend of cotton and lyocell fibers) and/or synthetic fibers are used in the reinforcement yarns. In some embodiments, the reinforcement yarns are formed with the same type(s), but different amounts, of the cellulosic fibers and/or synthetic fibers that form the warp and/or weft body yarns.

[0017] In some embodiments, the reinforcement yarns include 0-70 wt. % cellulosic fibers, 10-60 wt. % cellulosic fibers, 20-60 wt. % cellulosic fibers, 30-60 wt. % cellulosic fibers, and/or 40-60 wt. % cellulosic fibers. In some embodiments, some or all of the cellulosic fibers in the reinforcement yarns are natural (e.g., cotton) fibers. In some embodiments, the reinforcement yarns include 30-100 wt. % synthetic fibers, 40-90 wt. % synthetic fibers, 40-80 wt. % synthetic fibers, 40-70 wt. % synthetic fibers, and/or 40-60 wt. % synthetic fibers. In some embodiments, the reinforcement yarns include a higher weight percentage of synthetic fibers than cellulosic (e.g., natural) fibers. In some embodiments, the reinforcement yarns include a higher weight percentage of cellulosic (e.g., natural) fibers than synthetic fibers. In some examples, the weight percentage of cellulosic (e.g., natural) and synthetic fibers in the reinforcement yarn is substantially the same (e.g., 50/50).

[0018] The body yarns are formed of a large percentage of cellulosic fibers, such as the cellulosic fibers disclosed above for inclusion in the reinforcement yarns. For example, in some embodiments the body yarns include at least 60 wt. %, at least 65 wt. %, at least 70 wt. %, at least 75 wt. %, at least 80 wt. %, at least 85 wt. %, at least 90 wt. %, at least 95 wt. %, and/or at least 100 wt. % cellulosic fibers. The cellulosic fibers in embodiments of the fabric are not inherently flame resistant but are treated with a chemical (e.g., phosphorous) to render them flame resistant. While the FR treatment may occur at the fiber stage or at the yarn stage, in some embodiments the FR treatment is carried out on the fabric after fabric formation. Given the large percentage of cellulosic fibers in embodiments of the fabric, phosphor may be present in the final fabric in percentages from 1.0 wt. %-6.0 wt. % phosphor; 1.0 wt. %-4.0 wt. % phosphor; 1.5 wt. %-3.5 wt. % phosphor; 1.5 wt. %-5.5 wt. % phosphor; and/or 2.0 wt %-5.0 wt % phosphor.

[0019] In some embodiments, a relatively small percentage of synthetic fibers are added to the body yarns to stabilize the yarns against shrinkage and impart some strength. In general, a low percentage of synthetic fiber may be preferred as its primary purpose is strength compensation and it negatively influences the degree of FR of the overall fabric (assuming the synthetic fiber is non-FR). In some embodiments the body yarns include synthetic fibers in an amount of 40 wt. % or less, 35 wt. % or less, 30 wt. % or less, 25 wt. % or less, 20 wt. % or less, 15 wt. % or less, and/or 10 wt. % or less.

[0020] The body yarns may be the same or different within the fabric. For example, in some embodiments the warp and weft body yarns are identical (i.e., have the identical fiber blend) while in other embodiments they are different. An exemplary fabric according to an embodiment may comprise in the warp direction body yarns that are formed with 10-50 wt. % lyocell fibers; 40-70 wt. % cotton fibers; and 10-30 wt. % non-FR synthetic (e.g., polyester) fibers and in the weft direction body yarns that are formed with 70-99 wt. % cotton fibers; and 1-20 wt. % non-FR synthetic (e.g., polyester) fibers.

[0021] The reinforcement yarns include a larger percentage of synthetic fibers than the body yarns. In some embodiments, the reinforcement yarns include at least two times, at least three times, at least four times, at least five times, at least six times, at least seven times, at least eight times, at least nine times, and/or at least ten times the weight percentage of synthetic fibers provided in either or both of the warp and weft body yarns. In this way, sufficient synthetic fibers are concentrated in the reinforcement yarns such that the reinforcement yarns are able to impart and maintain the required strength to the fabric when located in discrete locations within the fabric. This concentration of synthetic fibers in the reinforcement yarns enables the body yarns to include a larger percentage of fibers that impart comfort and the requisite flame resistance and thermal protection to the fabric (e.g., cellulosic fibers such as cotton fibers or lyocell fibers).

[0022] In some embodiments, the overall fiber blend for a fabric with reinforcement yarns is 65-95 wt. %, 70-90 wt. %, 70-80 wt. %, 75-85 wt. %, and/or 80-90 wt. % cellulosic (e.g., natural) fibers and 5-35% wt. %, 10-30 wt. %, 15-25% wt. %, 20-30 wt. %, and/or 10-20 wt. % synthetic (e.g., polyester) fibers.

[0023] The reinforcement yarns may be located in the fabric relative to the body yarns (such as those described above) in any desired ratio. The frequency of the reinforcement yarns within the fabric may depend on the desired strength properties of the fabric and may be the same or different within and/or between the warp and/or weft direction of the fabric. Reinforcement yarns may be provided in either or both the warp and weft fabric directions for every 20 body yarns, 19 body yarns, 18 body yarns, 17 body yarns, 16 body yarns, 15 body yarns, 14 body yarns, 13 body yarns, 12 body yarns, 11 body yarns, 10 body yarns, 9 body yarns, 8 body yarns, 7 body yarns, 6 body yarns, 5 body yarns, 4 body yarns, 3 body yarns, 2 body yarns, and 1 body yarn. The frequency at which reinforcement yarns are provided may be the same or different (1) within a direction of the fabric and/or (2) in different directions of the fabric. In some embodiments, between 1 to 20 body yarns, inclusive; between 2 and 15 body yarns, inclusive; between 3 and 12 body yarns, inclusive; between 4 and 10 body yarns, inclusive; between 5 and 10 body yarns, inclusive; between 7 and 9 body yarns, inclusive; between 10 and 20 body yarns, inclusive; between 10 and 15 body yarns, inclusive; or between 8 and 13 body yarns, inclusive, are provided between adjacent reinforcement yarns in one or both directions of the fabric. In some embodiments, the reinforcement yarns are provided in both directions of the fabric and optionally at the same frequency to form a grid pattern within the fabric.

[0024] The body and/or reinforcement yarns may be provided as singles yarns or plied yarns (e.g., two or more yarns are plied together to form one end). While spun yarns (i.e., yarns formed with an intimate blend of the constituent fibres) are specifically contemplated herein, the body and/or reinforcement yarns could also be filament yarns, stretch broken yarns, and/or ribbon (slit-film) yarns. The yarns can be woven or knitted to form a fabric. Some embodiments are woven fabrics having any appropriate construction, being formed from warp and weft yarns in a chosen weave or pattern.

[0025] Fabrics incorporating reinforcement yarns may be, but not have to be, treated with FR treatments and other optional treatments as described in WO 2022/263615, the entirety of which is incorporated herein by reference.

[0026] In some embodiments, the fabrics disclosed herein have a weight between 6-15 ounces per square yard (osy), inclusive; 6.5-12 osy, inclusive; 7-10 osy, inclusive; and/or 5-10 osy, inclusive. In some embodiments, the fabric weight is greater than or equal to 6 osy and less than or equal to 9 osy.

[0027] Specific, non-limiting embodiments of fabrics with reinforcement yarns in accordance with the present disclosure (Reinforced Inventive Fabric) were compared against fabrics that did not include reinforcement yarns (Non-Reinforced Fabric). The fabrics are described below. Non-Reinforced Fabric 1 is identical to Reinforced Inventive Fabrics 1 and 2 except that it does not contain the reinforcement yarns present in Reinforced Inventive Fabrics 1 and 2.

[0028] Reinforced Inventive Fabric 1: A 7.7 osy twill weave fabric was formed with the following yarns: [0029] Warp Body Yarns: 20/1 cotton count (cc) spun yarns having a fiber blend of 55 wt. % cotton/20 wt. % lyocell/25 wt. % non-FR polyester. [0030] Weft Body Yarns: 18/1 cc spun yarns having a fiber blend of 90 wt. % cotton/10 wt. % non-FR polyester. [0031] Reinforcement Yarns: 18/1 cc 100% non-FR polyester spun yarn in the weft direction only in a reinforcement yarn to body yarn ratio of 1:15, meaning that fifteen weft body yarns were provided between adjacent reinforcement yarns in a repeating pattern across the weft direction.
The warp and weft densities were 96 ends/inch and 64 picks/inch, respectively, and Reinforced Inventive Fabric 1 had an overall blend of 79 wt. % cellulosic (cotton and lyocell) fibers and 21% synthetic (non-FR polyester) fibers. The overall percentage of synthetic fibers in the weft direction was 16% (with the remaining 84% being cellulosic fibers).

[0032] Reinforced Inventive Fabric 2: A 7.7 osy twill weave fabric was formed with the following yarns: [0033] Warp Body Yarns: 20/1 cc spun yarns having a fiber blend of 55 wt. % cotton/20 wt. % lyocell/25 wt. % non-FR polyester. [0034] Weft Body Yarns: 18/1 cc spun yarns having a fiber blend of 90 wt. % cotton/10 wt. % non-FR polyester. [0035] Reinforcement Yarns: 18/1 cc 100% non-FR polyester spun yarn in the weft direction only in a reinforcement yarn to body yarn ratio of 1:5, meaning that five weft body yarns were provided between adjacent reinforcement yarns in a repeating pattern across the weft direction.
The warp and weft densities were 96 ends/inch and 64 picks/inch, respectively, and Reinforced Inventive Fabric 2 had an overall blend of 75 wt. % cellulosic (cotton and lyocell) fibers and 25% synthetic (non-FR polyester) fibers. The overall percentage of synthetic fibers in the weft direction was 25% (with the remaining 75% being cellulosic fibers).

[0036] Non-Reinforced Fabric 1: A 7.7 osy twill weave fabric was formed with the following yarns: [0037] Warp Body Yarns: 20/1 cc spun yarns having a fiber blend of 55 wt. % cotton/20 wt. % lyocell/25 wt. % non-FR polyester. [0038] Weft Body Yarns: 18/1 cc spun yarns having a fiber blend of 90 wt. % cotton/10 wt. % non-FR polyester.
The warp and weft densities were 96 ends/inch and 64 picks/inch, respectively, and the Non-Reinforced Fabric 1 had an overall blend of 82 wt. % cellulosic (cotton and lyocell) fibers and 18% synthetic (non-FR polyester) fibers. The overall percentage of synthetic fibers in the weft direction was 10% (with the remaining 90% being cellulosic fibers).

[0039] The Reinforced Inventive Fabrics and the Non-Reinforced Fabric 1 were formed and treated generally in accordance with the manufacturing process set forth in paragraph [0046] of WO 2022/263615, except that they were not treated with an oil and water repellent finish.

[0040] Non-Reinforced Fabric 2: A 5.9 osy twill weave fabric was formed with the following yarns: [0041] Warp Body Yarns: 20/1 cc spun yarns having a fiber blend of 35 wt. % cotton/65 wt. % non-FR polyester. [0042] Weft Body Yarns: 20/1 cc spun yarns having a fiber blend of 35 wt. % cotton/65 wt. % non-FR polyester.
The warp and weft densities were 94 ends/inch and 72 picks/inch, respectively, and the Non-Reinforced Fabric 2 had an overall blend of 35 wt. % cellulosic fibers and 65% synthetic (non-FR polyester) fibers. One of skill in the art would understand that the Non-Reinforced Fabric 2 would not comply with flammability standardssuch as having a char length of less than 100 millimeters when measured pursuant to the testing methodology set forth in ISO 15025:2000 (Protective clothingProtection against heat and flameTest methods for Limited Flame Spread for limited flame spread, incorporated herein by reference)given its high percentage of non-FR synthetic fibers. Thus, one of skill in the art would understand that the Non-Reinforced Fabric 2, even if FR treated, would be incapable of attaining a char length of less than 100 millimeters (in either the warp or weft direction) when tested pursuant to ISO 15025.

[0043] The tear strength of fabrics according to embodiments of the invention can be enhanced by inclusion of reinforcement yarns in the fabric. Tear strength is a measure of the amount of force required to propagate in a fabric a tear after its initiation. The tear strength of fabrics can be measured pursuant to NEN-EN-ISO 13937-2:2000 (TextilesTear properties of fabricsPart 2: Determination of tear force of trouser-shaped test specimen (Single tear method), incorporated herein by reference) or ASTM D1424 (Standard Test Method for Tearing Strength of Fabrics by Falling-Pendulum (Elmendorf-Type) Apparatus (2021 edition), incorporated herein by reference).

[0044] Some embodiments of the fabrics with reinforcement yarns have a minimum tear strength of 10 Newtons (N) in both the machine and cross-machines directions when tested in accordance with ISO 13937-2. Some embodiments of fabrics with reinforcement yarns as disclosed herein have a tear strength in one or both of the machine and cross-machine directions of at least 12 Newtons, 15 Newtons, 18 Newtons, 20 Newtons, 25 Newtons, 30 Newtons, 35 Newtons, and/or 40 Newtons or greater when tested in accordance with ISO 13937-2. Some embodiments of the fabrics with reinforcement yarns comply with the minimum tear strength requirements set forth in ASTM F1506 (Standard Performance Specification for Flame Resistant and Arc Rated Protective Clothing Worn by Workers Exposed to Flames and Electric Arcs (2022 edition), incorporated herein by reference). The tear strength of some embodiments of fabrics with reinforcement yarns disclosed herein is greater or equal to 2.5 pounds force in one or both of the warp and weft directions for fabrics weighing 3.0-5.9 osy; greater or equal to 4.0 pounds force in one or both of the warp and weft directions for fabrics weighing 6.0-8.4 osy; and/or greater or equal to 5 pounds force in one or both of the warp and weft directions for fabrics weighing 8.5 osy or higher.

[0045] The tear strength of each of the Reinforced Inventive Fabrics and the Non-Reinforced Fabrics was tested in accordance with NEN-EN-ISO 13937-2:2000 and measured both before wash (BW) and after fifty washes (50) pursuant to the methodology set forth in NEN-EN-15797:2017 (TextilesIndustrial washing and finishing procedures for testing of workwear, incorporated herein by reference), with the results set forth in Table 1 below:

TABLE-US-00001 TABLE 1 Non- Reinforced Reinforced Reinforced Non- Fabric 1 Inventive Inventive Reinforced Test (NRF1) Fabric 1 Fabric 2 Fabric 2 Method Char Length, <100 <100 <100 <100 <100 <100 >100 >100 ISO 15025 warp weft, Pass Pass Pass Would not pass BW (mm) given high non- FR synthetic fiber content Char Length, <100 <100 <100 <100 <100 <100 >100 >100 ISO 15025 warp weft, Pass Pass Pass Would not pass 50 (mm) given high non- FR synthetic fiber content Tear Strength, 21 16 22 35 20 58 35 30 ISO 13937 warp weft, BW Newtons (N) Tear Strength, 20 17 21 29 21 52 ISO 13937 warp weft, 50 (N) % of Synthetic 10 16 25 65 Fibers in Weft Direction (wt. %) % Increase in 118% 262% Tear Strength over NRF1, weft, BW, (N) % Increase in 71% 206% Tear Strength over NRF1, weft, 50, (N) % Increase of 60% 150% Synthetic Fibers over NRF1 in Weft Direction

[0046] As reflected in Table 1, the weft tear strength of the Non-Reinforced Fabric 1 was significantly less than the weft tear strengths of Reinforced Inventive Fabrics 1 and 2, which included reinforcement yarns but were otherwise identical to the Non-Reinforced Fabric 1. Inclusion of reinforcement yarns in the weft direction of Reinforced Inventive Fabrics 1 and 2 led to significant percentage increases in tear strength over the tear strength of the Non-Reinforced Fabric 1. In some embodiments, inclusion of reinforcement yarns in a fabric direction increases the tear strength of the fabric in that direction by at least 30%; at least 40%; at least 50%; at least 60%; at least 70%; at least 80%; at least 90%; at least 100%; at least 110%; at least 120%; at least 130%; at least 140%; at least 150%; at least 160%; at least 170%; at least 180%; at least 190%; at least 200%; at least 210%; at least 220%; at least 230%; at least 240%; at least 250%; at least 260%.

[0047] Moreover, Reinforced Fabrics 1 and 2 enjoyed percentage increases in weft tear strength that were greater than the percentage increase of synthetic (e.g., polyester) fibers provided in the weft direction, when compared with the Non-Reinforced Fabric 1. In some embodiments, the difference between the percentage increase in tear strength in a fabric direction (e.g., the weft direction) and the percentage increase of synthetic fibers in that direction is greater than 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, and/or 150%. It is believed that this increase in tear strength without a commensurate increase in synthetic fiber percentage is attributable to the strategic concentration of the synthetic (e.g., polyester) fibers in the reinforcement yarns as compared to evenly distributing the synthetic (e.g., polyester) fibers throughout the fabric.

[0048] In some embodiments, the tear strength of fabrics that include reinforcement yarns is greater than the tear strength of fabrics that do not include reinforcement yarns but that have a higher percentage of synthetic (e.g., polyester) fibers in the overall fabric blend. In other words, in such embodiments the reinforced fabrics are stronger despite possessing lower percentages of the stronger (e.g., synthetic or polyester) fibers than the non-reinforced fabrics.

[0049] However, inclusion of the reinforcement yarns (particularly yarns with such a high non-FR polyester content) does not detrimentally impact other properties of the fabric. Overall, such fabrics meet the minimum performance requirements set forth in ISO 11612:2015 (Protective clothingClothing to protect against heat and flameMinimum performance requirements, incorporated herein by reference). For example, embodiments of the reinforced fabrics disclosed herein (including Reinforced Inventive Fabrics 1 and 2) have a char length of less than 100 millimeters when measured pursuant to the testing methodology set forth in ISO 15025:2000 (Protective clothingProtection against heat and flameTest methods for Limited Flame Spread for limited flame spread, incorporated herein by reference).

[0050] The ability of the inventive reinforced fabrics to demonstrate such high tear strengths while still passing the char length requirements is surprising and is attributable to the strategic concentration of the non-FR synthetic fibers in the reinforcement yarns. Concentration of the non-FR synthetic fibers in the reinforcement yarns to impart strength to the fabric allows the body yarns in the fabric to contain a higher percentage of fibers that can be rendered FR (such as cellulosic fibers), such that the fabric may pass char length requirements. This is despite the fact that such fabrics may contain a higher overall percentage of non-FR synthetic fibers, as can be seen with Reinforced Inventive Fabrics 1 and 2 which have a higher percentage of non-FR synthetic fibers but yet still pass the char length requirements.

[0051] Moreover, fabrics possessing comparable (or even weaker) strength properties but devoid of such reinforcing yarns cannot pass the char length requirement. For example, Non-Reinforced Fabric 2-in which the fibers are all evenly distributed throughout the fabrichas a tear strength value in the weft direction (30 N) that is less than that of Reinforced Inventive Fabric 1 (35 N). However, 65 wt. % of the fibers in the weft direction must be non-FR synthetic fibers to achieve this (weaker) strength, as compared to only 16 wt. % of the fibers in the Non-Reinforced Fabric 2. Such a high amount of non-FR synthetic fibers in the Non-Reinforced Fabric 2 ensures that it will be unable to pass the char length requirements, as discussed above.

[0052] Embodiments of the reinforced fabrics disclosed herein (including Reinforced Inventive Fabrics 1 and 2) may also have a char length of 6 inches or less (and even 4 inches or less) and a two second or less afterflame when measured pursuant to the testing methodology set forth in ASTM D6413 (Standard Test Method for Flame Resistance of Textiles (Vertical Test) (2022 edition), incorporated herein by reference). Thus, incorporating a yarn with a high non-FR polyester content as a reinforcement allows the fabric to be stronger without sacrificing flame resistant performance.

[0053] Moreover, because the reinforcement yarns in some embodiments are formed with a blend of fibers present in other yarns of the fabric (e.g., polyester and cotton), when dyed the reinforcement yarns are virtually (if not entirely) indistinguishable from the other yarns in the fabric such that the resulting fabric has a uniform appearance.

[0054] Embodiments. A collection of exemplary embodiments, including at least some explicitly enumerated as Examples providing additional description of a variety of example types in accordance with the concepts described herein are provided below. These examples are not meant to be mutually exclusive, exhaustive, or restrictive; and the invention is not limited to these example examples but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0055] Embodiment 1. A flame resistant fabric having a warp direction, a weft direction, and a fabric weight, the flame resistant fabric comprising warp direction yarns and weft direction yarns, wherein the warp direction yarns comprise warp body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers; and the weft direction yarns comprise weft body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers and weft reinforcement yarns having a fiber blend comprising 30 wt. % to 100 wt. % non-FR synthetic fibers, wherein the fiber blend of the weft reinforcement yarns comprises at least two times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns, wherein the weft direction yarns comprise a total wt. % of non-FR synthetic fibers and wherein, when a fabric tear strength in the weft direction of the flame resistant fabric and a fabric tear strength in a weft direction of a comparative flame resistant fabric (i) having substantially the same fabric weight, (ii) formed of the warp body yarns and the weft body yarns, and (iii) devoid of the weft reinforcement yarns was measured in Newtons and pursuant to ISO 13937-2, a strength percentage increase in fabric tear strength in the weft direction of the flame resistant fabric over the fabric tear strength in the weft direction of the comparative flame resistant fabric was greater than a fiber percentage increase of the total wt. % of non-FR synthetic fibers in the weft direction yarns of the flame resistant fabric over the wt. % of non-FR synthetic fibers in the weft body yarns of the comparative flame resistant fabric, and wherein the flame resistant fabric has a char length of less than 100 millimeters when tested pursuant to ISO 15025:2000.

[0056] Embodiment 2. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the weft reinforcement yarns further comprises cellulosic fibers.

[0057] Embodiment 3. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the weft reinforcement yarns comprises 40-60 wt. % non-FR synthetic fibers and 40-60 wt. % cellulosic fibers.

[0058] Embodiment 4. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the warp direction yarns further comprise warp reinforcement yarns.

[0059] Embodiment 5. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the warp reinforcement yarns have a fiber blend and wherein the fiber blend of the warp reinforcement yarns and the fiber blend of the weft reinforcement yarns are identical.

[0060] Embodiment 6. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the warp reinforcement yarns have a fiber blend comprising 30 wt. % to 100 wt. % non-FR synthetic fibers and wherein the fiber blend of the warp reinforcement yarns comprises at least two times the wt. % of non-FR synthetic fibers in the fiber blend of the warp body yarns.

[0061] Embodiment 7. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 70 wt. % cellulosic fibers and less than 30 wt. % non-FR synthetic fibers.

[0062] Embodiment 8. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 80 wt. % cellulosic fibers and less than 20 wt. % non-FR synthetic fibers.

[0063] Embodiment 9. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the weft reinforcement yarns comprises at least three times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns.

[0064] Embodiment 10. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the weft reinforcement yarns comprises at least four times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns.

[0065] Embodiment 11. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fabric weight is between 5-10 osy, inclusive.

[0066] Embodiment 12. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein between 1 to 20 weft body yarns are provided between adjacent weft reinforcement yarns.

[0067] Embodiment 13. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, further comprising an overall fiber blend, wherein the overall fiber blend comprises 70-90 wt. % cellulosic fibers and 10-30 wt. % non-FR synthetic fibers.

[0068] Embodiment 14. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns are different.

[0069] Embodiment 15. A flame resistant fabric having a warp direction, a weft direction, and a fabric fiber blend, the flame resistant fabric comprising warp direction yarns and weft direction yarns, wherein the warp direction yarns comprise warp body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers and warp reinforcement yarns having a fiber blend comprising 40-60 wt. % cellulosic fibers and 40-60 wt. % non-FR synthetic fibers, wherein the fiber blend of the warp reinforcement yarns comprises at least three times the wt. % of non-FR synthetic fibers in the fiber blend of the warp body yarns, and the weft direction yarns comprise weft body yarns having a fiber blend comprising a wt. % of non-FR synthetic fibers and at least 60 wt. % cellulosic fibers and weft reinforcement yarns having a fiber blend comprising 40-60 wt. % cellulosic fibers and 40-60 wt. % non-FR synthetic fibers, wherein the fiber blend of the weft reinforcement yarns comprises at least three times the wt. % of non-FR synthetic fibers in the fiber blend of the weft body yarns.

[0070] Embodiment 16. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the warp reinforcement yarns and the fiber blend of the weft reinforcement yarns are identical.

[0071] Embodiment 17. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns are different.

[0072] Embodiment 18. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 70 wt. % cellulosic fibers and less than 30 wt. % non-FR synthetic fibers.

[0073] Embodiment 19. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the fiber blend of the warp body yarns and the fiber blend of the weft body yarns each comprises at least 80 wt. % cellulosic fibers and less than 20 wt. % non-FR synthetic fibers.

[0074] Embodiment 20. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the flame resistant fabric comprises a fabric weight between 5-10 osy, inclusive.

[0075] Embodiment 21. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein between 1 to 20 warp body yarns are provided between adjacent warp reinforcement yarns and wherein between 1 to 20 weft body yarns are provided between adjacent weft reinforcement yarns.

[0076] Embodiment 22. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the overall fiber blend comprises 70-90 wt. % cellulosic fibers and 10-30 wt. % non-FR synthetic fibers.

[0077] Embodiment 23. The flame resistant fabric of any of the preceding or subsequent embodiments or combination of embodiments, wherein the flame resistant fabric has a char length of less than 100 millimeters when tested pursuant to ISO 15025:2000.

[0078] The preceding description has been provided to enable others skilled in the art to best utilize various aspects of the exemplary embodiments disclosed herein. This exemplary description is not intended to be exhaustive or to be limited to any precise form disclosed. Many modifications and variations are possible without departing from the spirit and scope of the instant disclosure. The embodiments disclosed herein should be considered in all respects illustrative and not restrictive. Reference should be made to the appended claims and their equivalents in determining the scope of the instant disclosure.