FIRE RESISTANT TEXTILE MATERIAL

Abstract

A fire resistant textile material comprising a fire resistant textile material comprising a woven face fabric composed of fibres selected from: meta-aramid, para-aramid, polyamideimide and mixtures thereof; wherein the number of warp face threads, per unit width (cm) is greater than the number of weft threads, per unit length (cm).

Description

[0001] This invention relates to fire resistant textile materials and garments made from these materials. The invention relates particularly but not exclusively to articles of clothing for use by fire fighters and for textiles for manufacture of such clothing.

[0002] European legislation requires employers to provide garments which protect their employees against hazards to which they may be exposed. Clothing for protection against heat and flame must pass minimum performance requirements for flame, radiant heat, heat resistance, tensile and tear strength, abrasion resistance and penetration by water and liquid chemicals. The assembled garments must achieve levels of resistance to heat transfer by both flame and radiant heat.

[0003] One of the most effective ways to reduce second and third degree burns is to make sure that the barrier of protective clothing between the heat source and the skin remains intact during exposure. This property is referred to as the break open resistance or non-break open protection of the fabric.

[0004] Outer textile materials for fire fighting clothing have previously been manufactured from 100% meta-aramid or polyamideimide, blends of polyparaphenylene isophthalamide (meta-aramid e.g. Nomex) and polyphenylene terephthalamide copolymer (para-aramid fibres e.g. Kevlar) or by use of core spun yarns or staple mixtures with polyparaphenylene terephthalamide copolymer or fibres comprising para-aramid cores with meta-aramid or polyamideimide covers. The combination of these fibres in the fabric enhances the non-break open protection of the product. However meta-aramid and para-aramid fibres shrink, consolidate and thicken when exposed to a high temperature heat source. The presence of meta-aramid or para-aramid in either the fibre blend or as a core can be used to prevent fibre shrinkage and consequent breaking open of the garment. However the inclusion of para-aramid fibre in the blend has been found to be insufficient in tightly woven fabrics to prevent breaking open. Consequently there is a need for improved textile materials for manufacture of fire fighting garments and the like.

[0005] Fire fighting garments have been made from a plurality of textile layers, including an outer layer of woven meta-aramid fibre, for example as manufactured under the trade mark Nomex. Break open protection may be afforded by blending with para-aramid fibres, for example as manufactured under the trade mark Kevlar and as disclosed in U.S. Pat. Nos. 3,063,966 and 3,506,990. However charring of such blends may lead to cracking and embrittlement with consequent deterioration of physical properties.

[0006] EP 1173635 discloses a fire resistant textile material comprising a woven faced or warp knitted fabric composed of meta-aramid, para-aramid or mixtures thereof, the fabric including a woven mesh back of low-thermal shrinkage fibres which form an interwoven backing scrim on the face of the fabric, the ratio of face to back yarns being in the range of 6:1 to 12:1.

[0007] According to a first aspect of the present invention a fire resistant textile material comprises a woven face fabric composed of fibres selected from: meta-aramid, para-aramid, polyamideimide and mixtures thereof; wherein the fabric comprises face warp threads and back warp threads, wherein the number of face warp threads per unit width (cm) is greater than the number of weft threads per unit length (cm).

[0008] The face warp threads may be incorporated meta-aramid fibres or blends of fibres including meta-aramid fibres, particularly including more than 50% w/w meta-aramid fibres. Exemplary fibres provide good abrasion resistance, having an extension to break value of 10% or greater, preferably 15% or greater.

[0009] When meta aramid face warp fibres are used the proportion of meta-aramid fibres may be equal or greater than 90%, for example greater than 93%, for example greater than 95%. The back warp fibres may be selected from para-aramid fibres and blends including para-aramid, particularly including more than 50% para-aramid. Exemplary fibres provide good break open resistance.

[0010] When polybenzimidazole [PBI] or a high para-aramid content face warp is used advantageous abrasion resistance of the face warp threads may be provided by incorporation of a blend including a proportion, for example up to 10% w/w of polyamide (Nylon.RTM.) or by use of a blend of polyamide with up to 5% w/w antistatic fibres, for example fibres comprising a carbon core and a polyamide sheath.

[0011] The face warp may already comprise stretch broken para-aramid fibres; or a blend of stretch broken para-aramid and polybenzimidazole [PBI], polyetheretherketone, high tenacity viscose or carbon fibres. Back warp threads comprising para-aramid or PBI provide high thermal stability and may have a count finer, that is lighter in weight than 60/2 Nm. Relatively fine yarns having a count greater than 60/2 Nm may be employed.

[0012] A back warp yarn having high break open resistance as disclosed above may be stitched onto the back of the woven face fabric. Where blended fibres are used these may be spun into a yarn.

[0013] The back warp yarn may have a count greater than (that is finer or lighter in weight) than 60/2 Nm. Therefore the face warp yarn may be coarse (that is heavier) than the back warp yarn and may have a count of, for example, 40/2 Nm.

[0014] The proportion and count of face side yarns to reverse side yarns may be determined by-the required weight of the final fabric, the interlacing of the face weave and the degree of effectiveness required from the properties of the reverse side yarn.

[0015] The weft yarn may conveniently comprise fibres which are the same as the back warp fibres.

[0016] Fabrics in accordance with the invention may confer the advantage of increased thermal protection together with greater flexibility in comparison to traditional single layer fabrics of comparable weights.

[0017] Fabrics of this invention may serve to increase the thermal protection afforded by the garment and may increase the number of seconds needed to raise the temperature on the inner side to a level which would create pain or a second degree burn on human skin or on the type of sensor used in Thermal Protection Procedure (TPP) testing.

[0018] The presence of low thermal shrinkage fibres on the surface of a garment, for example Kevlar may result in formation of fine fibrils, due to abrasion in use. Coloured fabrics, for example dark blue fabrics as used for fire fighters' tunics may therefore develop light specks on the surface of the fabric. This gives an uneven appearance on a dark coloured garment. This effect is referred to as fabric frosting.

[0019] Fire resistant fabrics in accordance with this invention confer a further advantage in comparison to fabrics constructed in a traditional manner, by packing the face of the fabric with threads that exhibit reduced liability to abrasion. Also as described above, by facilitation of the selection of yarn constructed from blends of fibres that improve the abrasion resistance.

[0020] The low shrinkage fibres are preferably located behind the face fabric. This minimises exposure of the strengthening fibres to the heat source.

[0021] Fabrics in accordance with this invention may be produced by interweaving yarns which have been spun, plied or core spun from staple fibres and/or multifilament fibres which may comprise 100% meta-aramid, 100% para-aramid, 100% polyamide imide or intimate blends of any combination of these fibres.

[0022] In a preferred method the yarns for the warps of both the face and reverse sides of the fabric may be assembled in the specified proportions and order of working by the sectional warping process onto one or two warped beams jointly having the total number of ends required to weave the final fabric.

[0023] The weft yarns may be inserted across and interlaced with the warp yarns in the specified proportions, order of working and density selected to produce the required face and reverse side weaves.

[0024] Differential tension may be applied to the face and reverse side yarns during the weaving process and during the insertion of the weft. This is important to compensate for the varying degrees of elongation which are inherent in the different types of fibres used in those yarns and which are important to the properties of the fabric of this invention.

[0025] A preferred weaving machine which may be used to produce a fabric of this invention will supply the face and back warp yarns from individual warp beams at different feed rates to compensate for the varying degrees of elongation and the varying inter-lacings of the face fabric yarns and reverse side yarns.

[0026] Previously known firelighters' garments comprise composites of three textile layers: an outer fabric, a moisture barrier and a quilted thermal lining. The present invention may reduce the need for use of such layers or may allow the weight of the layers to be reduced.

[0027] The fabric may have a warp back construction. This construction allows for a relatively fine face appearance with to the additional fabric thickness due to the extra back warp threads.

[0028] The additional thickness may give improved thermal properties in comparison to an equivalent single fabric.

[0029] Fabrics of this invention may have a lighter weight whilst providing a high degree of thermal protection, flexibility and durability allowing comfortable use in a wide range of protective garments.

[0030] The flexibility is enhanced through the structure by packing the face with fibres/yarns arranged in one direction i.e. the warp direction and loosely interlacing the weft direction with the back warp where the packing/density/set of the weave is lower.

[0031] Fabrics of this invention may have a lighter weight while providing a high degree of thermal protection, flexibility and durability including high abrasion resistance and stability to multiple washing cycles, while giving comparable or superior performance than heavier weight fabrics currently in the market place. The lighter weight fabrics of this invention may also reduce heat stress experienced by a wearer and may contribute to reduction in overall weight of the garment.

[0032] Fabrics in accordance with this invention may have a gaberdine face effect. Gaberdine is a fabric having a surplus of ends over picks. In exemplary gaberdine fabrics the excess of ends to picks may be in the range of 1.25:1 to 2:1 although the range may vary dependent on the required fabric weight and yarn count used.

[0033] Exemplary fabrics of this invention may have a weave structure selected from: 2.times.1 twill or 2.times.1 twill with rip stop.

[0034] A 2.times.1 twill is a weave comprising units in which each warp thread passes over two weft threads then under one weft thread, successive units being offset by one weft interlaced thread.

[0035] Further advantageous fabrics of this invention include 2.times.2 twill, 3.times.1 twill, 3.times.1 satin weave, end warp satin weave, 3.times.1 Broken Crow, Devon, Venetian, Doeskin and the like; all of the aforementioned fabrics being either with or without rip stop.

[0036] The ratio of face warp yarns to back warp yarns may be in the range from about 1:1 to 20:1, for example about 1:1 to about 16:1, for example about 1:1 to about 15:1.

[0037] The proportion of face ends to back ends may be in the ratio of 5:1.

[0038] Alternative ratios may be selected from 1F (face) to 1B (back), 2F to 1B, 4F to 1B, 7F to 1B, 8F to 1B, 10F to 1B, 11F to 1B, 13F to 1B, 14F to 1B, 16F to 1B, 17F to 1B, 19F to 1B, or 20F to 1B.

[0039] An increased ratio of ends to picks may give a steep twill appearance to the finished cloth. This may improve runoff of water or other liquids in use.

[0040] In contrast to a conventional warp back construction, each back end may be interlaced with a weft pick. This has the advantage that if the face warp is stripped from the fabric in use, the back warp and weft may continue to form a loosely woven fabric.

[0041] Preferably the face:back ratios which are divisible by the repeat number of face ends in the weave are avoided.

[0042] In an exemplary embodiment the repeat number of face ends is 3. In this case proportions of 3F (face) to 1B (back), 6F to 1B, 9F to 1B, 12F to 1B, 15F to 1B and 18F to 1B are not used.

[0043] Use of a warp back stitched to the weft increases the weight of the fabric while maintaining the fineness of the face. The back warp yarn and weft may be selected from para-aramid, PBI or blends thereof, the back warp being interlaced with every thread of the weft. This has the advantage that there are no loose yarns which may burn away when exposed to a high level of heat.

[0044] The yarns employed in a fabric of this invention may be selected to have weft tensile and tear strengths sufficient to meet the requirements for use in a specific fabric with a relatively reduced number of picks per unit measure.

[0045] For example the weft yarn may be selected from: (1) a relatively high strength, Nm50/1 (Numerometric, including single or multiple folding of yarns) 100% para-aramid yarn or (2) a combination of Nm50/1 and Nm 50/2 100% para-aramid yarns with Nm20/2 or (3) Nm 50/1 with Nm40/2 meta-aramid yarns.

[0046] According to a second aspect of this invention there is provided a firefighter's garment comprising a textile material in accordance with the first aspect of this invention. Garments in accordance with this invention are advantageous in comparison to previously known garments.

[0047] The invention is further described by means of an example, but not in any limitative sense, with reference to the accompanying drawings of which:

[0048] FIG. 1 illustrates a first fabric in accordance with this invention;

[0049] FIG. 2 illustrates the second fabric in accordance with this invention;

[0050] FIG. 3 illustrates the third fabric in accordance with this invention; and

[0051] FIG. 4 illustrates a fourth fabric in accordance with this invention.

[0052] FIG. 1 is a diagram showing a fabric in accordance with this invention in which face warp threads A interlace with weft threads C to form a 2.times.1 twill gaberdine effect face

[0053] to the cloth. Back warp threads B interlace with weft threads C but hang on the back of the cloth, unseen on the face adding bulk and weight to the fabric.

[0054] FIG. 2 is a diagram showing a fabric in accordance with this invention in which face warp threads A interlace with weft threads C and D to form a 2.times.1 rip stop twill gaberdine effect face to the cloth. Back warp threads B interlace with weft threads C and D but hang on the back of the cloth, unseen on the face adding bulk and weight to the fabric.

[0055] FIG. 3 is a diagram showing a fabric in accordance with this invention in which a face warp threads A interlace with weft threads C and E to form a 2.times.1 twill gaberdine effect face to the cloth. Back warp threads B interlace with weft threads C and E but hang on the back of the cloth, unseen on the face adding bulk and weight to the fabric.

[0056] FIG. 4 is a diagram showing a fabric in accordance with this invention in which a face warp threads A interlace with weft threads C, D and F to form a 2.times.1 rip stop twill gaberdine effect face to the cloth. Back warp threads B interlace with weft threads C, D and F but hang on the back of the cloth, unseen on the face adding bulk and weight to the fabric.

Claims

1. A fire resistant textile material comprises a woven face fabric composed of fibres selected from: meta-aramid, para-aramid, polyamideimide and mixtures thereof; wherein the fabric comprises face warp threads and back warp threads, wherein the number of face warp threads per unit width is greater than the number of weft threads per unit length.

2. A fire resistant textile material as claimed in claim 1, wherein the face warp threads are selected from meta-aramid fibres including more than 50% meta-aramid fibres.

3. A fire resistant textile material as claimed in claim 1 wherein the warp face threads comprise a blend of meta-aramid fibres with up to 10% w/w polyamide fibres or 10% w/w of a blend of polyamide with up to 5% w/w antistatic fibres.

4. A fire resistant textile material as claimed in claim 3 wherein the face warp threads comprise a proportion of meta-aramid fibres equal or greater than 90%, for example greater than 93%, for example greater than 95%.

5. A fire resistant textile material as claimed in claim 4 wherein the back warp fibres are selected from para-aramid fibre blends including more than 50% para-aramid fibres.

6. A fire resistant textile material as claimed in claim 5 wherein the face warp threads comprise: stretch broken para-aramid fibres or a blend of stretch broken para-aramid and polybenzymidazole (PBI), polyetherketone, high-tenacity viscose or carbon fibres.

7. A fire resistant textile material as claimed in claim 6 in the back warp fibres comprising para-aramid or PBI have a count finer than 60/2 Nm.

8. A fire resistant textile material as claimed in claim 1, wherein the face of the fabric contains abrasion resistant fibres.

9. A fire resistant textile material as claimed in claim 1, wherein low shrinkage fibres are located behind the face fabric.

10. A fire resistant textile material as claimed in claim 1, having a gaberdine face effect.

11. A fire resistant textile material as claimed in claim 10 wherein the excess of face warp yarns to weft yarns is in the range of 1.25:1 to 2:1.

12. A fire resistant textile material as claimed in claim 1, wherein the fabric is a 2.times.1 twill or 2.times.1 twill with rip stop.

13. A fire resistant textile material as claimed in claim 1, wherein the fabric is selected from: 2.times.2 twill, 3.times.1 twill, 3.times.1 satin weave, end warp satin weave, 3.times.1 Broken Crow, Devon and Venetian and Doeskin; all of the aforementioned fabrics being either with or without rip stop.

14. A fire resistant textile material as claimed in claim 1, wherein the ratio of face warp yarns to back warp yarns is in the range from 1:1 to 20:1.

15. A fire resistant textile material as claimed in claim 14, wherein the ratio of face warp yarns to back warp yarns is in the range of 1:1 to 16:1.

16. A fire resistant textile material as claimed in claim 15, wherein the ratio of face warp yarns to back warp yarns is in the range of 1:1 to 15:1.

17. A fire resistant textile material as claimed in claim 1, wherein the ratio of face ends to back ends is 5:1.

18. A fire resistant textile material as claimed in claim 17, wherein the ratio is selected from 1F (face) to 1B (back), 2F to 1B, 4F to 1B, 7F to 1B, 8F to 1B, 1.degree. F. to 1B, 11F to 1B, 13F to 1B, 14F to 1B, 16F to 1B, 17F to 1B, 19F to 1B, or 20F to 1B.

19. A fire resistant textile material as claimed in claim 1, wherein each back end is interlaced with a weft pick.

20. A firefighter's garment comprising a textile material in accordance with claim 1.