WO2026015099A1 - Fabric containing flame resistant fiber blend - Google Patents

Abstract

The invention relates to a high-strength, flame resistant fabric developed for use in the textile industry. The invention particularly relates to a fabric that can provide protection against many risks such as flame, heat, electric arc, welding, molten metal splashes and etc. developed for use in industries such as oil/gas, chemical/petrochemical, iron/steel, electricity generation/distribution/transmission/maintenance, welding, as well as in forest fires, search and rescue operations, station uniforms, and similar protective clothing.

Description

FABRIC CONTAINING FLAME RESISTANT FIBER BLEND

Technical Field

The invention relates to a high-strength, flame resistant fabric developed for use in the textile industry.

The invention particularly relates to a fabric designed to provide protection against various risks such as flame, heat, electric arc, welding, molten metal splashes, etc., developed for use in industries such as oil/gas, chemical/petrochemical, iron/steel, electricity generation/distribution/transmission/maintenance, welding, as well as in forest fires, search and rescue operations, station uniforms, and similar protective clothing.

State of Art

FR (Flame Resistant / Flame Retardant) materials are used in many textile applications. In particular, FR materials are used as a barrier layer to protect more easily combustible components found inside, such as filling materials in beds and sofas. FR materials are also used in the production of flame retardant clothing in certain industries and in the military.

Fire resistant fabrics are textiles that are obtained by chemical treatment of flame retardant or non-flammable fibers and are more resistant to fire. Flame resistant (FR) fabrics are used to produce FR clothing worn by workers in many industries as the "last stand line" against serious injury from arc flash, flash fire, molten metal, and combustible dust.

First-generation flame retardant materials, especially those used for clothing production, consist of natural fibers such as wool and cotton. The flame retardant properties are generally provided by chemically treating the materials with phosphorus- based flame retardant chemicals. Although these clothes are flame resistant, they have several disadvantages. Particularly, these early flame retardant clothes provide uncomfortable wear by imposing excessive heat and weight on the wearer. Additionally, their mechanical strength and durability are low. Their flame resistance properties can also decrease with washing, and they do not have permanent flame resistance features.

Second-generation flame resistant materials consist of a mixture of inherently flameresistant modacrylic fibers with flammable natural fibers. These materials are characterized by inherently flame resistant because their flame resistance does not decrease with washing. Although these clothes are resistant to flames, they also have disadvantages. The biggest disadvantage of these materials is that their mechanical strength, rtensile, tear strength and abrasion resistance are low.

Third-generation materials are products made entirely from synthetic flame- resistant fibers. Synthetic FR mixtures have been developed to provide long-lasting clothing that is lighter and has higher mechanical strength. However, although these synthetic FR textiles perform better than previous generations, they have some disadvantages. First, fully synthetic FR clothes are more expensive than other products. Since synthetic FR fibers are generally only available from special manufacturers, they have limited availability. Secondly, FR textiles made entirely from synthetic fibers can be very uncomfortable for the wearer due to their insufficient softness and insufficient breathability properties and low moisture absorption properties. In case that they are used as dyed fibers, color alternatives are also limited. In case that they are used as dyed fabrics, their color fastness is low.

As a result of the research carried out in the literature, the application numbered EP2004902B1 was found. Said application relates to a flame retardant textile fabric suitable for use in producing close-fitting garments that come into direct contact with the skin of wearer and provides a protective function and in non-clothing applications. Said textile product comprises a fabric consisting of continuous filament yarns with outer filaments around the yarn and inner filaments inside the yarn, a cured phosphorus-based flame retardant compound that durably affixed to filaments and imparting flame retardant properties to the fabric. The document describes that the flame retardant properties of the product are imparted by hydroxymethyl phosphonium compound, which is a phosphorus-based flame retardant compound. However, the document does not mention a product prepared with a flame resistant fiber mixture without the use of flame retardant chemicals. As a result, it has become necessary to make a development in the relevant technical field due to the flaws described above and the inadequacy of existing solutions on the subject.

Object of the Invention

The invention is inspired by current situations and aims to solve the above-mentioned deficiencies.

The main object of the invention is to provide a flame-retardant fabric that provides protection against flame, heat, electric arc, welding, molten metal splashes and similar risks in the Personal Protective Clothing industry and its production method. Its object is to provide use in the production of protective clothing, in oil/gas, chemistry/petrochemical, iron / steel, electricity production / distribution / transmission / maintenance, welding and similar industries, and in forest fires, search and rescue, and station uniforms.

The object of the invention is to provide a product with increased flame resistance and mechanical strength (tensile, tear strength, abrasion resistance, etc.) with the Aramid (meta-aramid and/or para-aramid) fibers in its content.

An object of the invention is to present a fabric with increased comfort, easy dyeing, flame retardant, electric arc resistance, welding and molten metal splash resistance with the modacrylic fiber in its content.

Another object of the invention is to provide a product with increased moisture absorption, improved moisture management and easy dyeing by containing natural and/or synthetic cellulosic fibers (cotton, lyocell, modal, modal PR, viscose, viscose FR, etc.). In addition, comfort is increased and the touch of the material is improved.

Another object of the invention is to provide a product with increased mechanical strength and abrasion resistance with the polyamide fibers in its content.

Another object of the invention is to provide a product with antistatic and flexible stretch properties. In order to achieve the objects described above, the invention is a fabric with high mechanical strength, flame resistant and flame retardant properties, comprises warp and/or weft yarns obtained from a fiber blend comprising aramid fiber and/or poly-p- phenylenebenzobisoxazole (PBO) fiber, modacrylic fiber, natural and/or synthetic cellulosic fibers, polyamide fiber and antistatic fiber.

In order to achieve the objects described above, the invention is a method for obtaining a high mechanical strength, flame resistant, flame retardant fabric and comprises the following process steps; i. Preparing the fiber blend comprising aramid fiber and/or poly-p- phenylenebenzobisoxazole (PBO) fiber, modacrylic fiber, natural and/or synthetic cellulosic fibers, polyamide fiber and antistatic fiber, ii. Obtaining warp and/or weft yarns from the fiber blend, iii. Determining the weaving pattern suitable for the desired fabric properties, iv. Obtaining raw fabric by weaving the resulting yarns according to the determined weaving pattern.

The structural and characteristic features and all the advantages of the invention will be understood more clearly by means of the detailed description given below, and therefore the evaluation needs to be made by taking this detailed description into consideration.

Detailed Description of the Invention

In this detailed description, the preferred embodiments of the fabric and its production method subject to the invention are described only for a better understanding of the subject.

The present invention relates to a high mechanical strength, flame resistant, flame retardant fabric and its production method. Said fabric comprises warp and/or weft yarns obtained from a fiber blend comprising aramid and/or poly-p- phenylenebenzobisoxazole (PBO) fiber, modacrylic fiber, natural and/or artificial cellulosic fibers, polyamide fiber and antistatic fiber. The preferred and usable amounts of the said fiber blend by weight are given in Table 1 .

Table 1. Preferred and usable amounts of fiber mixture by weight

Said fiber blend further comprises elastane fiber to provide stretch.

Said fiber blend further comprises PBI fiber to increase the flame resistance (incombustibility) and carbonization values and provide comfort.

The fabric, which is subject of the invention comprises warp and weft yarns obtained from the fiber blend comprising preferably 20-40% aramid and/or poly-p- phenylenebenzobisoxazole (PBO) fibers, 20-40% modacrylic fibers, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fibers and 1-5% antistatic fiber and 0-10% elastane fiber by weight.

The fabric, which is subject of the invention comprises warp and weft yarns obtained from the fiber blend comprising preferably 20-40% aramid and/or poly-p- phenylenebenzobisoxazole (PBO) fibers, 20-40% modacrylic fibers, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fibers and 1-5% antistatic fiber and 0-20% Polybenzimidazole (PBI) fiber by weight. The fabric, which is subject of the invention comprises warp and weft yarns obtained from the fiber blend comprising preferably 20-40% aramid and/or poly-p- phenylenebenzobisoxazole (PBO) fibers, 20-40% modacrylic fibers, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fibers and 1-5% antistatic fiber and 0-10% elastane fiber and 0-20% Polybenzimidazole (PBI) fiber by weight.

In an embodiment, the fabric, which is subject of the invention comprises warp and weft yams obtained from the fiber blend containing preferably 33% aramid and/or poly-p- phenylenebenzobisoxazole (PBO) fibers, 32% modacrylic fibers, 23% natural and/or synthetic cellulosic fibers, 10% polyamide fibers and 2% antistatic fibers by weight.

In an example embodiment, the fabric, which is subject of the invention comprises warp and weft yams obtained from the fiber blend containing 33% Meta-aramid, 32% modacrylic, 23% modal, 10% polyamide 66, 2% antistatic fiber by weight.

Another example comprises warp and weft yams obtained from the fiber blend containing 20% Meta-aramid, 13% para-aramid, 32% modacrylic, 13% lyocell, 10% cotton, 10% polyamide 66, 2% antistatic fiber by weight.

In another example, the fabric comprises warp and weft yams obtained from the fiber blend containing 65% Meta-aramid, 35% lyocell mixtured by weight and 80% modacrylic, 18% polyamide 66, 2% antistatic fiber mixtured by weight.

Said aramid fiber is preferably meta-aramid and/or para-aramid fiber.

Said natural and/or synthetic cellulosic fibers are preferably selected from, but not limited to, cotton, lyocell, modal, modal FR, viscose, viscose FR and combinations thereof.

The properties provided by the fibers mentioned in the fiber blend are stated below. The use of aramid (preferably meta-aramid and/or para-aramid) and/or poly-p- phenylenebenzobisoxazole (PBO) fibers increases the flame retardancy and mechanical strength (tensile, tear strength, abrasion resistance, etc.) of the fabric, which is subject of the invention. With the use of modacrylic fiber, the comfort of the fabric of the invention is increased, easy dyeing is ensured, flame retardancy, electric arc resistance, resistance to welding and molten metal splashes are increased. By using natural and/or synthetic cellulosic fibers (cotton, lyocell, modal, modal FR, viscose, viscose FR, etc.), the moisture absorption properties of the fabric of the invention are increased, moisture management is improved and easy dyeability is provided. With the use of polyamide fibers, the mechanical strength of the inventive fabric is increased and the abrasion resistance is increased to the highest level. Antistatic fiber ensures that the fabric of the invention has antistatic properties.

The elastane fiber used in the preferred applications of the product, which is subject of the invention ensures that the fabric is flexible/stretch.

Polybenzimidazole (PBI) fiber used in the preferred applications of the product, which is subject of the invention, increases the protection in case of flame exposure by increasing the flame retardancy (incombustibility) and carbonization values of the fabric, contributes to increasing the arc performance value by preventing the fabric from breaking open during arc exposure.

The fabric, which is subject of the invention can preferably be between 150 and 450 g/m².

The invention relates to a method for obtaining a fabric with high mechanical strength, flame resistance and flame retardant properties. Said method comprises the following process steps: i. Preparing the fiber blend comprising aramid fiber and/or poly-p- phenylenebenzobisoxazole (PBO) fiber, modacrylic fiber, natural and/or synthetic cellulosic fibers, polyamide fiber and antistatic fiber, ii. Obtaining warp and/or weft yarns from the fiber blend, iii. Determining the weaving pattern suitable for the desired fabric properties, iv. Obtaining raw fabric by weaving the yarns according to the determined weaving pattern.

In the process step i) of the method according to the invention, the fiber blend comprising 20-40% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fiber, 20-40% modacrylic fiber, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fiber, 1-5% antistatic fiber and 0-10% elastane fiber by weight is prepared.

In the process step i) of the method according to the invention, the fiber blend comprising 20-40% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fiber, 20-40% modacrylic fiber, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fiber, 1-5% antistatic fiber and 0-20% Polybenzimidazole (PBI) fiber by weight is prepared.

In the process step i) of the method according to the invention, the fiber blend comprising 20-40% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fiber, 20-40% modacrylic fiber, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fiber, 1 -5% antistatic fiber, 0-10% elastane fiber and 0-20% Polybenzimidazole (PBI) fiber by weight.

While fabric can be produced by weaving a single type of yarn produced from the fiber blends specified in the method of the invention, it is also possible to achieve the desired results by producing a fabric with different blends by weaving different yarns produced from different blend of fibers.

In an embodiment of the method, which is subject of the invention, in the process step ii) single-ply warp and weft yarns of the desired count are obtained from the fiber blend. Herein, the fiber blend, preferably passing through lines such as carding, drawing, roving, ring, open-end and vortex, is turned into single-layered yarn in the desired number. In another embodiment, the yarns obtained from the fiber blend are folded and twisted into plied yarns. Here, plied yarn is preferably produced by folding and twisting the yarn. In these processes, elastane fiber is added to the fiber blend to provide stretch properties to the fabric.

In an embodiment of the method, which is subject of the invention, dyeing/printing processes are applied to the raw woven fabrics obtained after the iv) process step.

In an embodiment of the method, which is subject of the invention, finishing processes are applied to the raw woven fabrics obtained after process step iv) in finishing machines. The said finishing processes are preferably water-repellent finishing and applications for antibacterial properties.

In an embodiment of the method, which is subject of the invention, quality control and packaging processes are applied to the prepared fabric.

In order to obtain a preferred example of the invention, the following processes are followed:

Step 1 : Fiber blend comprising 33% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fibers, 32% modacrylic fibers, 23% natural and/or synthetic cellulosic fibers, 10% polyamide fibers and 2% antistatic fibers by weight is prepared,

Step 2: Single-ply warp and/or weft yarns are obtained from the fiber blend,

Step 3: The weaving pattern suitable for the desired fabric properties is determined,

Step 4: Obtaining raw fabric by weaving the obtained yarns according to the determined weaving pattern and application of dyeing/printing processes to the fabric obtained.

The fabric, which is subject of the invention is a multi-functional product to be used in the production of protective clothing against various risks such as flame, heat, electric arc, welding, molten metal splashes, and to be used in industries such as oil/gas, chemical/petrochemical, iron/steel, electricity generation / distribution / transmission/ maintenance, welding, as well as in forest fires, search and rescue operations, station uniforms.

The fiber blend in the yarns of which the fabric of the invention is formed consists of a combination of both synthetic and natural fibers. Meta-aramid and/or para-aramid and/or poly-p-phenylenebenzobisoxazole (PBO), modacrylic, natural and/or synthetic cellulosic fibers (cotton, lyocell, modal, modal FR, viscose, viscose FR etc.), the mixture of polyamide and antistatic fibers and elastane which used when necessary creates optimum synergy. It increases mechanical strength with the synthetic fibers used. In particular, fabric is provided with natural or synthetic cellulosic fiber, providing breathability and softness for the wearer. The moisture management properties of the resulting fabric are improved by means of the moisture absorption properties resulting from the synergistic combination of natural and synthetic materials. The production method of the invention enables optimal utilization of the advantages brought by the fibers contained in the yarns.

The fabric, which is subject of the invention can be obtained by weaving after the production of warp and/or weft yarns preferably comprising 33% aramid and/or poly-p- phenylenebenzobisoxazole (PBO) fibers, 32% modacrylic fibers, 23% natural and/or artificial cellulosic fibers, 10% polyamide fibers and 2% antistatic fibers. Herein, the weft yarn may contain a different blend than the specified ratio, and the warp yarn may contain a different blend.

In another example of the invention, fabric can be produced preferably from a fiber blend of 33% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fibers, 32% modacrylic fibers, 23% natural and/or artificial cellulosic fibers, 10% polyamide fibers and 2% antistatic fibers.

The invention provides a product that is both comfortable, highly durable, economical and can provide protection against many risks.

In the method of the invention, since the weaving pattern affects many values of the fabric such as strength, abrasion, hairiness and comfort, the weaving pattern suitable for the desired purpose is selected. The produced yarns are woven in accordance with the determined weaving pattern and a raw fabric is obtained in the mentioned blend ratios. Weaving is carried out by preparing the warp (sizing can also be done if necessary) according to the yarns produced and the determined weaving pattern.

Dyeing/printing operations can be performed on the fabric obtained by the method of the invention, depending on the desired color/pattern. Depending on the fibers used, many dyeing methods such as indanthrene, cationic and others can be used to obtain high color fastness.

Necessary finishing treatments can be applied to the fabric obtained by the method of the invention, depending on the need. If there are additional requirements other than color (water repellency, antibacterial properties, etc.), these treatments are also carried out in the dyehouse.

Claims

1. A fabric with high mechanical strength, flame resistant and flame retardant properties, characterized by comprising; warp and weft yarns obtained from the fiber blend comprising aramid fiber and/or poly-p- phenylenebenzobisoxazole (PBO) fiber, modacrylic fiber, natural and/or synthetic cellulosic fibers, polyamide fiber and antistatic fiber.

2. The fabric according to claim 1 , wherein; the said fiber blend comprises 20- 40% aramid and/or poly-p-phenylenebenzobisoxazole fibers, 20-40% modacrylic fibers, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fibers and 1 -5% antistatic fibers by weight.

3. The fabric according to claim 1 , wherein; the said fiber blend further comprises elastane fiber to provide stretch.

4. The fabric according to claim 1 , wherein; the said fiber blend further comprises Polybenzimidazole (PBI) fiber to provide incombustibility.

5. The fabric according to claim 3 or 4, wherein; the said fiber blend comprises 20-40% aramid and/or poly-p-phenylenebenzobisoxazole fibers, 20-40% modacrylic fibers, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fibers and 1-5% antistatic fibers and 0% -10 elastane fibers and/or 0- 20% PBI by weight.

6. The fabric according to claim 3 or 4, wherein; the said fiber blend comprises 33% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fibers, 32% modacrylic fibers, 23% natural and/or synthetic cellulosic fibers, 10% polyamide fibers and 2% antistatic fibers by weight.

7. The fabric according to any of the previous claims, wherein; the said aramid fiber is meta-aramid and/or para-aramid fiber.

8. A method for obtaining a fabric with high mechanical strength, flame resistance, and flame retardant properties, characterized by comprising; the following process steps: i. Preparing fiber blend comprising aramid fiber and/or poly-p- phenylenebenzobisoxazole (PBO) fiber, modacrylic fiber, natural and/or synthetic cellulosic fibers, polyamide fiber and antistatic fiber, ii. Obtaining warp and/or weft yarns from the fiber blend, iii. Determining the weaving pattern suitable for the desired fabric properties, iv. Obtaining raw fabric by weaving the yarns according to the determined weaving pattern.

9. The method according to claim 8, wherein; in the process step i), the fiber blend comprising 20-40% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fibers, 20-40% modacrylic fibers, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fibers and 1-5% antistatic fibers by weight is prepared.

10. The method according to claim 8, wherein; in the process step i), the fiber blend comprising 20-40% aramid and/or poly-p-phenylenebenzobisoxazole (PBO) fiber, 20-40% modacrylic fiber, 15-35% natural and/or synthetic cellulosic fibers, 5-20% polyamide fiber and 1-5% antistatic fiber and 0-10% elastane fiber and/or and 0-20% PBI fiber by weight is prepared.

11. The method according to claim 8, wherein; in the process step ii), the fiber blend is formed into a single-ply yarn.

12. The method according to claim 8, wherein; in the process step ii), the yarn obtained from the fiber blend is formed into plied yarn by folding and twisting.

13. The method according to claim 8, wherein; dyeing/printing processes are applied to the raw woven fabrics obtained after the process step iv).

14. The method according to claim 8, wherein-, finishing treatments are applied in finishing machines to the raw woven fabrics obtained after the process step iv).