Blended fiber yarns and fabrics including oxidized polymeric fibers

Abstract

An article comprising a fabric comprising: (a) a blended yarn comprising: (i) from about 10% to about 85% by weight of at least one biregional fiber comprising an oxidized polymer selected from the group consisting of acrylonitrile based homopolymers, acrylonitrile based copolymers, acrylonitrile based terpolymers, and combinations thereof; (ii) at least one companion fiber selected from the group consisting of FR polyester, FR nylon, FR rayon, FR treated cellulose, m-aramid, p-aramid, modacrylic, novoloid, melamine, wool, nylon, regenerated cellulose, polyvinyl chloride, antistatic fiber, poly(p-phenylene benzobisoxazole) (PBO), polybenzimidazole (PBI), polysulphonamide (PSA), and combinations thereof; and (b) optionally including a companion yarn different from said blended yarn; wherein said companion yarn includes p-aramid in an amount less than 20% of the fabric weight; and
wherein the fabric has a weight from about 3 oz/yd.sup.2 to about 12 oz/yd.sup.2.

Claims

1. A fabric comprising: (a) a blended yarn comprising: (i) from about 35% to about 65% by the blended yarn weight of at least one fiber comprising an oxidized polyacrylonitrile; (ii) at least one companion fiber comprising p-aramid; wherein the blended yarn is present in a fill direction in the fabric; and (b) a companion yarn different from the blended yarn; wherein the companion yarn comprises: (i) a staple fiber comprising p-aramid; and (ii) a staple fiber comprising m-aramid; wherein the companion yarn different from the blended yarn is present in a warp direction in the fabric, and wherein the fabric has a weight from about 4 oz/yd.sup.2 to about 9 oz/yd.sup.2 and a ratio of the Thermal Protective Performance (TPP) to the weight is higher than 1.

2. The fabric of claim 1, wherein the ratio of the Thermal Protective Performance to the weight is at least 1.5.

3. The fabric of claim 1, wherein the ratio of the Thermal Protective Performance to the weight is about 2.

4. The fabric of claim 1, wherein the Thermal Protective Performance is greater than 8 to about 15.

5. The fabric of claim 1, wherein the fiber comprising the oxidized polyacrylonitrile is substantially uniformly oxidized throughout the cross-section of the fiber.

6. The fabric of claim 5, wherein the fiber comprising the oxidized polyacrylonitrile which is substantially uniformly oxidized has a density from about 1.30 g/cm.sup.3 to about 1.44 g/cm.sup.3.

7. The fabric of claim 1, wherein the oxidized polyacrylonitrile has a density from about 1.20 g/cm.sup.3 to about 1.50 g/cm.sup.3.

8. The fabric of claim 1, wherein the fabric exhibits a ratio of an arc rating according to ASTM F1959 to weight greater than 1.

9. The fabric of claim 1, wherein the fabric exhibits an arc rating according to ASTM F1959 that is greater than 8.

10. The fabric of claim 9, wherein the arc rating is greater than 9 and the fabric has a weight from about 6.5 oz/yd.sup.2 to about 7.5 oz/yd.sup.2.

11. The fabric of claim 1, wherein the fabric is dyeable.

12. The fabric of claim 1, wherein the fabric comprises a twill weave.

13. A method of making the fabric of claim 1, the method comprising: forming a fabric comprising combining the blended yarn with the companion yarn different from the blended yarn.

14. An article comprising the fabric of claim 1.

15. A fabric comprising: (a) a blended yarn comprising: (i) from about 35% to about 65% by the blended yarn weight of at least one fiber comprising an oxidized polyacrylonitrile; (ii) at least one companion fiber comprising p-aramid; wherein the blended yarn is present in a fill direction in the fabric; and (b) a companion yarn different from the blended yarn; wherein the companion yarn consists of staple fibers comprising: (i) p-aramid; and (ii) m-aramid; wherein the companion yarn different from the blended yarn is present in a warp direction in the fabric, wherein the fabric has a weight from about 4 oz/yd.sup.2 to about 9 oz/yd.sup.2 and a ratio of the Thermal Protective Performance (TPP) to the weight is higher than 1.

16. The fabric of claim 15, wherein the fiber comprising the oxidized polyacrylonitrile is substantially uniformly oxidized throughout the cross-section of the fiber.

17. An article comprising the fabric of claim 15.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) As used herein, the terms blend or blended, in referring to a spun yarn, means a mixture of fibers of at least two types, wherein the mixture is formed in such a way that the individual fibers of each type of fiber are substantially completely intermixed with individual fibers of the other types to provide a substantially homogeneous mixture of fibers, having sufficient entanglement to maintain its integrity in further processing and use.

(2) As used herein, the term “biregional fiber” includes fibers where the cross-section shows a distinguishable inner core and an outer sheath. For the oxidized biregional fiber, the sheath substantially constitutes the oxidized portion of the fiber.

(3) The heat resistant fiber such as the oxidized polymeric fiber may be combined with other yarns or fibers in other yarn constructions. These examples include covering the oxidized polymeric fiber with other yarns such as by twisting with another yarn, single or double wrapping, and core-spinning, among others. The oxidized polymeric fiber may form either the core or the sheath (the covering).

(4) Antistatic fibers which can be useful as (1) a companion fiber with the oxidized polymeric fiber or (2) can be included as or contained within, a companion yarn are known to those of skill in the art. Useful antistatic fibers include, but are not limited to metallic or other electrically conductive yarns and fibers. Yarns and fibers can include an antistatic coating or can be wrapped with a fiber or yarn having antistatic properties.

(5) Some embodiments provide fabrics such as woven, knit or nonwoven fabrics that include a yarn with at least one oxidized polymeric fiber such as a biregional fiber. The fabrics may be used in garments, insulation or any other end uses where the fabrics can provide benefit. Examples of suitable oxidized polymeric fibers are selected from the group consisting of acrylonitrile based homopolymers, acrylonitrile based copolymers, acrylonitrile based terpolymers, and combinations thereof. One suitable polymer for the oxidized polymer is polyacrylonitrile. The oxidized polymeric fibers are combined with one or more companion fibers to provide a blended yarn.

(6) Where the fabric has a woven construction, this includes, but is not limited to, plain weave, twill, satin, basket as well as more durable fabrics such as those with a rip stop construction. Where the fabric is woven, it can include a p-aramid as a companion yarn or blended in a companion yarn an amount less than 20% of the fabric weight. The woven fabric may include any other companion yarns described herein.

(7) Knit fabrics are also contemplated that have a fabric construction including, but not limited to, weft knit such as circular knit and warp knit. These knits may include a companion yarn in addition to the blended yarn which includes an oxidized polymeric fiber, such as an oxidized polymeric biregional fiber.

(8) Where the fabric is a nonwoven fabric blended yarns may include oxidized polymeric biregional fiber in combination with other yarns. Nonwoven fabrics are especially suitable for insulation.

(9) The oxidized polymer may be either substantially oxidized throughout the cross-section of the fiber or may be a biregional fiber. The biregional fiber may have an unoxidized polymeric core and an oxidized polymeric sheath.

(10) Oxidization of the polymeric fiber may occur according to any suitable method. One suitable method of oxidizing a polymeric fiber such as polyacrylonitrile (PAN) includes introducing the fiber into an oxidizing atmosphere under tension at a moderately elevated temperature of from about 150° C. to about 350° C. for a polymer such as polyacrylonitrile (PAN). The fiber will remain in the oxidizing atmosphere for a sufficient time to achieve the desired level of permeation of oxygen into the fiber (sheath oxidization or complete oxidization). The oxidized polymer may be used in any suitable denier such as from about 1 to about 6 denier, including from about 2 to about 6 denier.

(11) The companion fibers included in the blended yarn, in addition to the oxidized polymeric fiber, can be any fiber suitable for apparel yarns and fabrics. The companion fibers may also provide heat resistant properties. Specific examples of useful companion fibers include FR polyester, FR nylon, FR rayon, FR treated cellulose, m-aramid, p-aramid, modacrylic, novoloid, melamine, wool, nylon (in staple or filament form), regenerated cellulose (lyocell, modal, viscose), polyvinyl chloride, antistatic fiber, poly(p-phenylene benzobisoxazole (PBO), polybenzimidazole (P131), polysulphonamide (PSA) and combinations thereof.

(12) In the blended yarn useful in some embodiments, which includes an oxidized polymeric fiber, the weight percent of the different fiber components may vary. The oxidized polymeric fiber may be present in an amount from about 10% to about 90% by weight of the blended yarn, including from about 10% to about 85%, from about 15% to about 50%, from about 20% to about 60%, from about 20% to about 75%, from about 30% to about 85%, and from about 35% to about 65%. The weight percent of the companion fibers in the blend will vary depending on how many companion yarns are included and the desired properties of fabric. There may be one, two, three, four or more companion fibers in addition to the oxidized polymeric fiber. FR rayon may be present in an amount from 0 to about 60% by weight of the yarn, m-aramid may be present in an amount from 0 to about 30% by weight of the yarn, p-aramid may be present in an amount from 0 to about 40% by weight of the yarn, modacrylic may be present in an amount from 0 to about 40% by weight of the yarn, wool may be present in an amount from 0 to about 60% by weight of the yarn, nylon (as staple or filament) may be present in an amount from 0 to about 30% by weight of the yarn, polyvinyl chloride (PVC) may be present in an amount from 0 to about 20% by weight of the yarn, and antistatic or steel fiber may be present in an amount from 0 to about 10% by weight of the yarn. Other fibers may be included in suitable amounts that would be determinable by the person of skill in the art. Useful examples containing three companion fibers were included in the blend are (a) the combination of FR rayon, nylon, regenerated cellulose (lyocell, modal, viscose), and p-aramid; and (b) the combination of wool, modacrylic and nylon and regenerated cellulose (lyocell, modal, viscose).

(13) The fabrics of some embodiments optionally include one or more companion yarns in addition to the blended yarn comprising the oxidized polymeric fiber. The article can include one or more companion yarns where the amount of p-aramid in the companion yarns is less than 20% by weight of the fabric. Examples of companion yarns include yarns comprised of fibers selected from the group consisting of FR polyester, FR nylon, FR rayon, FR treated cellulose, m-aramid, p-aramid, modacrylic, wool, nylon, regenerated cellulose (lyocell, modal, viscose), polyvinyl chloride, antistatic fiber, steel fiber, poly(p-phenylene benzobisoxazole (PBO), polybenzimidazole (FBI), polysulphonamide (PSA) and combinations thereof and combinations thereof. The companion yarns may include blended yarns, spun yarns, covered yarns, and twisted yarns, as well as filaments yarns. The companion yarn may also include a heat resistant fiber or yarn and can include an oxidized polymeric fiber.

(14) The density of the oxidized polymeric fiber will vary depending on the extent of the oxidation. For example, the density may be from about 1.20 g/cm.sup.3 to about 1.50 g/cm.sup.3, including from 1.20 g/cm.sup.3 to about 1.44 g/cm.sup.3, about 1.30 g/cm.sup.3 to about 1.44 g/cm.sup.3 and, from about 1.20 g/cm.sup.3 to about 1.40 g/cm.sup.3. Where the oxidized polymeric fiber is only partially oxidized, a biregional fiber, such as a sheath-core fiber may result.

(15) The core region, which is not oxidized may have radius (r), while the cross-section of the fiber may have radius (R). The ratio of the core region to the total radius of the fiber (r:R) will vary depending on the extent of the oxidation. This ratio (r:R) may vary from about 1:1.03 to about 1:7; such as from about 1:1.03 to about 1:1.4, from about 1:2 to about 1:9, from about 1:2 to about 1:6; and from about 1:1.05 to about 1:1.8, including from about 1:1.105 to about 1:1.4.

(16) The fabrics of some embodiments can be prepared as lightweight fabrics while maintaining properties needed for industrial clothing. The fabrics can have a weight less than 12 oz/yd.sup.2, including less than 7.5 oz/yd.sup.2, about 3 oz/yd.sup.2 to about 12 oz/yd.sup.2, from about 3 oz/yd.sup.2 to about 7.5 oz/yd.sup.2, from about 4 oz/yd.sup.2 to about 9 oz/yd.sup.2, and from 3 oz/yd.sup.2 to about 6.5 oz/yd.sup.2.

(17) The fabrics of some embodiments perform exceptionally well for certain industrial clothing applications, such as ASTM F1959, “Standard Test Method for Determining the Arc Rating of Materials for Clothing,” where the fabrics either meet or exceed the standards while maintaining a low fabric weight. It is understood that the heavier the fabric, the better it will perform for protection from hazards such as heat, chemical, electric, etc. However, the fabrics of some embodiments can have an arc rating of 8 or greater, including an arc rating of 9 or greater. The arc rating of 9 can be achieved with a fabric of 7.5 oz/yd.sup.2 or less such as from about 6.5 oz/yd.sup.2 to about 7.5 oz/yd.sup.2. These properties are very important for garments for which the combination of lightweight and protective fabrics is needed for industrial uses where the wearer of the garment may be subjected to hazardous conditions. The fabrics or garments may also be dyed when desired.

(18) The fabrics of some embodiments can have other beneficial properties in addition to meeting the standards for arc rating described above. The fabrics of some embodiments can provide a Vertical flammability char length <4 in (per test method ASTM D6413), Thermal protective performance rating (spaced) >10 cal/cm.sup.2, and thermal manikin % body burn <50% (per test method ASTM F1930) when tested in accordance with National Fire Protection Association Standard (NFPA) 2112 (2007), “Standard on Flame-Resistance Garments for Protection of Industrial Personnel Against Flash Fire.”

(19) The yarns including the oxidized polymeric fiber can be prepared by any suitable yarn spinning process, such as those conventionally used for staple fibers.

(20) Examples of useful processes include the spinning processes typically used for wool to make wool yarns. Accordingly, the yarns used in some embodiments may be blended worsted yarns, or in other words, yarns made on a worsted spinning system. These yarns may be prepared using worsted carding or using a converted tow. Process used for short fibers including staple fibers, such as cotton, can also be useful.

(21) The features and advantages of the present invention are more fully shown by the following examples which are provided for purposes of illustration, and are not to be construed as limiting the invention in any way.

EXAMPLES

(22) Test Methods: Test methods and minimum requirements for thermal protection include: a. ASTM D6413: Test method for Flame Resistance of Textiles (Vertical Test) b. NFPA 2112: (National Fire Protection Association) Standard on Flame-Resistant Garments for Protection of Industrial Personnel Against Flash Fire. Section 8.2 (Thermal Protective Performance Test) c. NFPA 1977: (National Fire Protection Association) Standard on Protective Clothing and Equipment for Wildland Fire Fighting. d. NAFPA 1951: (National Fire Protection Association) Standard on Protective Ensembles for Technical Rescue Incidents. e. ASTM F1930: Test Method for Evaluation of Flame Resistant Clothing for Protection Against Flash Fire Simulations Using an Instrumented Manikin f. ASTM F1959: Standard Test Method for Determining the Arc Rating of Materials for Clothing

(23) The following tables include fabric samples (TABLE 1) and the results (TABLES 2-4) according to each testing method. The fabrics were prepared as a twill using only the blended yarn including the fibers indicated in TABLE 1. The minimal requirements for each test method are included for comparison. Each of the inventive fabrics (1), (2), (3), and (4), respectively, met the minimum criteria required for its intended end use application.

(24) TABLE-US-00001 TABLE 1 FABRICS 1 2 3 4 Fabric weight, 5.5 6.2 6.8 8.5 oz/yd Fabric 35% FR rayon 35% FR rayon 54% oxidized 44% oxidized composition 22% oxidized 24% oxidized biregional PAN biregional PAN by weight biregional PAN biregional PAN 20% FR rayon 18% p-aramid 22% modacrylic 20% modacrylic 16% m-aramid 16% FR rayon 6% polyamide 6% polyamide 9% polyamide 12% PVC 15% p-aramid 15% p-aramid 1% antistat 10% polyamide

(25) TABLE-US-00002 TABLE 2 TEST RESULTS NFPA 70E (Electrical Workers) Minimum Requirements Fabric 1 Fabric 2 Fabric 3 ATPV >8 8.9 10.7 10.8 HRC Class HRC-2 HRC-2 HRC-2 Arc Rating

(26) TABLE-US-00003 TABLE 3 TEST RESULTS NFPA 2112 (Chemical Workers) Minimum Requirements Fabric 1 Fabric 2 Fabric 3 Vertical Flammability <2 sec AF 0 × 0 0 × 0 0 × 0 Afterflame, W × F.sup.1 Vertical Flammability Char <4″ char length 0.8 × 1.2 2.7 × 3.3 2.8 × 1.8 Length, W × F.sup.1 TST Shrinkage (500° F./ <10% 5.8 × 6.7 4.4 × 7.7 9.9 × 5.2 5 min.) as received), W × F.sup.1 TST Shrinkage (500° F./5 min.) <10% 7.2 × 7.6 5.6 × 6.7 8.2 × 6.1 after 3 launderings, W × F.sup.1 TPP (Thermal Protective 3 cal/cm.sup.2/.sub.6 8.7/12.1  9.5/12.2  9.2 × 12.8 Performance) as received cal/cm.sup.2 Contact.sup.2/Spaced.sup.3 TPP (Thermal Protective 3 cal/cm.sup.2/.sub.6 8.7/11.8 10.3/13.2 10.3/13.9 Performance) after 3 cal/cm.sup.2 launderings Contact.sup.2/Spaced.sup.3 % Manikin Body Burn <50% 27.0 21.6 24.0 .sup.1Warp × Fill .sup.2Fabric in contact with thermal sensor .sup.3Fabric spaced ¼ inch from thermal spacer

(27) TABLE-US-00004 TABLE 4 TEST RESULTS NFPA 1977 (Wildland Fire Fighters) Minimum Requirements Fabric 4 Vertical Flammability <2 sec AF (after 100X 0 Afterflame, W × F.sup.1 washes @105° F.) Vertical Flammability Char <4″ char length (after 0.45″ Length, W × F.sup.1 100X washes 105° F.) TST Shrinkage <10% (OX washes) 3.9 × 4.8 (500° F./5 min.) Radiant Protective >7 (after 5X 9.7 Performance washes @ 105° F.) Heat Loss >450 W/m.sup.2 697 Trap Tear Strength >22N 182 Laundry Shrinkage, W × F.sup.1 <5% (after 5X 3.0 × 1.4 washes @ 105° F.) .sup.1Warp × Fill

(28) TABLE-US-00005 TABLE 5 TEST RESULTS NFPA 1951 (Technical Rescue) Minimum Requirements Fabric 4 Vertical Flammability <2 sec AF (before and 10X 0 Afterflame, W × F′ washes@140° F.) Vertical Flammability Char <4″ char length (before and 0.45″ Length, W × F′ after 10Xwashes @140° F.) TST Shrinkage (500° F./5 <10% (before and after 3.9 × 4.8 min.), W × F′ 10X washes @ 140° F.) TPP (Thermal Protective >10 (after 10X washes 18.7 Performance) Spaced.sup.2 @ 140° F.) Heat Loss >650 W/m.sup.2 697 Grab Tensile >400N (after 10X washes 622 @140° F.) Trap Tear Strength >30N (after 10X washes 182 @140° F.) Strength After Stoll Abrasion >250N (after 500 abrasion 378 cycles) Laundry Shrinkage, W × F.sup.1 <5% (after 5X washes 3.0 × 1.4 @140° F.) .sup.1Warp × Fill .sup.2Fabric in contact with thermal sensor

(29) While there have been described what are presently believed to be the preferred embodiments of the invention, those skilled in the art will realize that changes and modifications may be made thereto without departing from the spirit of the invention, and it is intended to include all such changes and modifications as fall within the true scope of the invention.