JP2024515615A - Fabric and article having fire resistance, cut resistance, and elastic recovery, and manufacturing method thereof - Google Patents

Abstract

A fire and cut resistant fabric, and a glove or other article comprising the fabric, the fabric comprising:
(a) at least one first yarn comprising at least 50% by weight heat resistant polymeric fibers, wherein at least 30% by weight of the polymeric fibers present in the at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15; and (b) at least one second yarn having a sheath/core construction having a sheath of halogenated self-extinguishing staple fibers and a core comprising at least one continuous elastomeric filament;
Including,
60-95% by weight of at least one second yarn is halogenated self-extinguishing fiber, the halogenated self-extinguishing fiber being in contact with at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers;
A fire resistant, cut resistant fabric, and a glove or other article comprising the fabric, wherein the fabric has a maximum afterflame time of 2 seconds or less and a weight loss of 5% or less when tested in accordance with NFPA-2112-2018.

Description

The present invention relates to yarns and fabrics suitable for use in articles of protective clothing that are fire resistant, conformable, and cut resistant.

Description of Related Art. Cut-resistant and elastic recovery ply yarns and fabrics, methods for their manufacture, and their use in articles of protective clothing are disclosed in U.S. Patent No. 6,952,915.

Yarns containing modacrylic, p-aramid, and m-aramid fibers useful for producing fabrics having arc and flame protective properties are disclosed, for example, in U.S. Pat. Nos. 7,065,950 and 7,348,059. These yarns may further include, as optional components, 2-15% by weight of an abrasion resistant fiber such as nylon and/or 1-5% by weight of an antistatic component.

Yarns and fabrics having a combination of fire resistance and elastic recovery are described, for example, in U.S. Pat. Nos. 5,069,957; 5,527,597; and 5,694,981. These existing solutions utilize yarns made by covering an elastic core yarn with a substantially protective outer covering of fiber made from fire resistant fibers. In other words, these references describe protecting an elastic core by structurally shielding it from flames using another fiber within the same yarn.

As used herein, the terms "structural shielding" and "structural shielding" mean that the covering fibers simply char when exposed to flame and remain within the yarn covering the elastic filaments in the core, thereby providing a structural barrier between the flame and the elastic core. As taught in these patents, these yarns have a substantially protective outer covering of fibers made from fire resistant fibers that physically protect the elastic core yarn from degradation and/or melting when exposed to extreme temperatures and flames.

Unfortunately, in many cases, the fibers with outer textile coverings that provide adequate structural shielding also tend to be stiff fibers, so fabrics made with such yarns may not be as comfortable as desired. This ultimately leads to protective clothing that may not be as comfortable as desired, and it is well known that when it is not comfortable enough, workers tend not to wear the protective gear and put themselves at risk.

In addition, any solution to protect the elastic core must meet current protective clothing standards. Specifically, the recent NFPA 2112-2018 "Standard on Flame-Resistant Clothing for Protection of Industrial Personnel Against Short-Duration Thermal Exposures from Fire" specifies minimum design, performance, testing, and certification requirements and test methods for fire-resistant clothing, shrouds, hoods, balaclavas, and gloves for use in locations where there is a risk of brief thermal exposure from fire. The standard requires that fabrics used in the clothing have an afterflame time of 2 seconds or less. Afterflame time is the time (measured in seconds, to the nearest 0.2 seconds) that a test specimen continues to burn after the burner is removed from the flame.

The standard places a more stringent requirement on fire-resistant gloves, stating that the material consumed during the fire resistance test must not exceed 5.0 percent of the original weight of the test specimen. In other words, after applying a flame to the test specimen for the specified 12 seconds according to the standard procedure, the weight loss of the fabric must not exceed 5.0 percent.

There is therefore a need for yarns and/or fabrics that have a combination of fire resistance and elastic recovery along with cut resistance, particularly those incorporating elastic core yarns and utilizing fibers that have a fabric-like feel that meet the NFPA 2112-2018 standard and may provide more comfortable protective apparel.

The present invention relates to a fire and cut resistant fabric, and to a glove or other article comprising the fabric, the fabric comprising:
(a) at least one first yarn comprising at least 50 weight percent heat resistant polymeric fibers, based on the total weight of the first yarn, wherein at least 30 weight percent of the polymeric fibers present in the at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15; and (b) at least one second yarn having a sheath/core construction having a sheath of halogenated self-extinguishing staple fibers and a core comprising at least one continuous elastomeric filament;
Including,
60-95% by weight of at least one second yarn is halogenated self-extinguishing fiber, based on the total weight of the second yarn, the halogenated self-extinguishing fiber being in contact with at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers;
The fabric has a maximum afterflame time of 2 seconds or less and a weight loss of 5% or less when tested in accordance with NFPA-2112-2018.

The present invention relates to yarns and fabrics suitable for use in protective apparel articles that are both fire resistant and conformable, while also providing cut protection. This unique combination is created by combining elastic materials, self-extinguishing fibers, and strong, heat resistant polymeric fibers in a manner that provides high fire resistance to the yarns and fabrics while limiting consumption of the fabric during a fire.

Specifically, the present invention relates to
(a) at least one first yarn comprising at least 50 weight percent heat resistant polymeric fibers, based on the total weight of the first yarn, wherein at least 30 weight percent of the polymeric fibers present in the at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15; and (b) at least one second yarn having a sheath/core construction having a sheath of halogenated self-extinguishing staple fibers and a core comprising at least one continuous elastomeric filament;
A fire and cut resistant fabric comprising:
60-95% by weight of at least one second yarn is halogenated self-extinguishing fiber, based on the total weight of the second yarn, the halogenated self-extinguishing fiber being in contact with at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers;
The present invention relates to a fire and cut resistant fabric, wherein the fabric has a maximum afterflame time of 2 seconds or less and a weight loss of 5% or less by weight when tested in accordance with NFPA-2112-2018.

"Fire resistant cut resistant fabric" means a knitted or woven fabric that is both "fire resistant" and "cut resistant." The term "fire resistant" in reference to a fabric means that the fabric has a char length of 4 inches (100 mm) or less when tested according to ASTM 6143-15. "Cut resistant fabric" means that the fabric has at least a minimum level of cut resistance, generally a cut resistant fabric has a cut resistance of at least 200 grams force according to ASTM F2992-15. In some preferred embodiments, the fibers and yarns described herein can provide a fire resistant cut resistant fabric having a cut resistance of at least 500 grams force according to ASTM F2992-15. However, in some other embodiments, it is understood that other fibers or yarns may be incorporated into the fabric that do not necessarily provide cut resistance but may provide other desirable qualities to the fabric, so long as the fire resistance requirements described herein are met to be considered a "fire resistant" fabric, and the fabric retains a minimum cut resistance of at least 200 grams force per ASTM F2992-15.

The fire resistant fabric provides thermal protection from thermal events, while the cut resistant fabric provides mechanical protection from knives, sharp objects, etc. In addition to being fire resistant, the fabric has an afterflame time of 2 seconds or less and a weight loss of 5% or less when tested in accordance with NFPA-2112-2018.

In addition, it is often important or desirable that articles such as protective gloves made from such fabrics be comfortable and have good fit and conformability. "Good fit and conformability" means, for example, that the glove conforms to the shape of the wearer's hand, allowing the wearer to grasp and manipulate small objects while wearing the glove. The fire and cut resistant fabrics described herein provide articles that are both highly fire and cut resistant, while also being soft, flexible, and form-fitting. Protective apparel made from such fabrics is highly comfortable and effective against multiple threats.

The fire resistant cut resistant fabric is made from at least a first yarn providing a heat resistant polymeric fiber and at least a second yarn providing at least one continuous elastomeric filament covered with a halogenated self-extinguishing fiber in contact with the at least one continuous elastomeric filament. The at least first yarn and the at least second yarn are then used to make a fabric.

In some embodiments, at least a first yarn and at least a second yarn are twisted together to form a plied yarn. In some embodiments, the plied yarn consists of only one first yarn and only one second yarn. In another embodiment, the plied yarn consists of only one first yarn and multiple second yarns; in another embodiment, the plied yarn consists of multiple first yarns and only one second yarn. Similarly, in some embodiments, the plied yarn consists of multiple first yarns and multiple second yarns. Finally, in some embodiments, the plied yarn includes at least one first yarn and at least one second yarn. Other yarns made from any number of fibers can be included in the plied yarn, so long as the final fabric meets the performance criteria described herein.

In some alternative embodiments, at least the first yarn and at least the second yarn are used in an interwoven weft-insertion construction. By "weft-insertion" we mean a knit in which at least the second yarn is inserted into a knit construction that includes at least the first yarn, such as is done in making elastomeric cuffs for knitted gloves.

In some alternative embodiments, at least a first yarn and at least a second yarn can be used in a parallel relationship to each other in the fabric. As used herein, the term "parallel" means that the individual yarns are typically next to each other in the fabric, that the yarns are independent and separate from each other, and that they are not plyed or twisted. In knitted fabrics, this type of parallel arrangement in the fabric is also known as a type of interwoven fabric. In one interwoven manufacturing process, the interwoven is formed by combining the warp threads of two separate yarns, i.e., knitting both together on a single knitting machine. This structure and process keeps the two different yarns in close proximity in the fabric and maintains their parallel relationship. The process advantageously includes braiding the two warp threads of the yarn during knitting, so that one warp thread is placed primarily on the first surface of the garment and the other warp thread is placed primarily on the second surface of the garment. This allows the typically more comfortable warp thread to be placed primarily on the inside of the garment and the other warp thread to be placed primarily on the outside.

The present invention also relates to a glove or other article comprising a fire and cut resistant fabric, including any of the embodiments described herein, the fire and cut resistant fabric comprising:
(a) at least one first yarn comprising at least 50 weight percent heat resistant polymeric fibers, based on the total weight of the first yarn, wherein at least 30 weight percent of the polymeric fibers present in the at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15; and (b) at least one second yarn having a sheath/core construction having a sheath of halogenated self-extinguishing staple fibers and a core comprising at least one continuous elastomeric filament;
A fire and cut resistant fabric comprising:
60-95% by weight of at least one second yarn is halogenated self-extinguishing fiber, based on the total weight of the second yarn, the halogenated self-extinguishing fiber being in contact with at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers;
The fabric has a maximum afterflame time of 2 seconds or less and a weight loss of 5% or less when tested in accordance with NFPA-2112-2018.

At least a first yarn comprises at least 50% by weight of heat resistant polymer fibers, based on the total weight of the first yarn, and at least 30% by weight of the polymer fibers present in at least one first yarn are cut resistant heat resistant polymer fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15.

"Heat resistant polymer fiber" means a fiber made from a synthetic organic polymer that retains 90 percent of its original fiber weight when heated to 500°C at a rate of 20°C per minute in air. Preferred heat resistant polymer fibers have a yarn tenacity of at least 3 grams/denier (2.7 grams/dtex). Heat resistant polymer fibers include para-aramid fibers, aramid copolymer fibers, polybenzazole fibers, polybenzimidazole fibers, polyimide fibers, and mixtures thereof. A preferred heat resistant polymer fiber is para-aramid fiber, and a preferred para-aramid fiber is poly(paraphenylene terephthalamide fiber.

At least one first thread comprises at least 50% by weight of heat resistant polymeric fibers based on the total weight of the first thread. In some embodiments, at least one first thread comprises at least 60% by weight of heat resistant polymeric fibers based on the total weight of the first thread. In some embodiments, at least one first thread comprises 60-85% by weight of heat resistant polymeric fibers based on the total weight of the first thread, and in some other embodiments, at least one first thread comprises 60-80% by weight of heat resistant polymeric fibers based on the total weight of the first thread. In some embodiments, at least one first thread comprises 100% by weight of heat resistant polymeric fibers based on the total weight of the first thread.

At least 30% by weight of the polymeric fibers present in the at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or greater per ASTM F2992-15. The cut performance of the fibers is determined by measuring the cut performance of a 10 ounces per square yard (345 grams per square meter) fabric woven or knitted from 100% of the fibers being tested, and then measuring the cut resistance (gram force) per ASTM F2992-15.

Cut-resistant heat-resistant polymer fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15 include para-aramid fibers, aramid copolymer fibers, polybenzazole fibers, polybenzimidazole fibers, and mixtures thereof. A preferred cut-resistant heat-resistant polymer fiber is para-aramid fiber, and a preferred para-aramid fiber is poly(paraphenylene terephthalamide fiber. The cut-resistant heat-resistant polymer fiber in the at least one first yarn may be the same as or different from the heat-resistant polymer fiber in the at least one first yarn, provided that the heat-resistant polymer fiber has sufficient cut resistance.

Thus, cut-resistant heat-resistant polymer fibers are understood to be both heat-resistant polymer fibers as defined above and cut-resistant fibers as defined above. Furthermore, at least one first yarn may be 100% cut-resistant heat-resistant polymer fibers. That is, it is understood that such yarns having 100% cut-resistant heat-resistant polymer fibers will therefore have at least 50% by weight of heat-resistant polymer fibers and also have at least 30% by weight of cut-resistant heat-resistant polymer fibers. It is also understood that at least one first yarn may include fibers that are heat-resistant polymer fibers as defined herein but are not cut-resistant fibers as defined herein. Table 1 provides guidance giving selected exemplary compositions regarding possible percentages of non-cut-resistant heat-resistant (non-CR HR) polymer fibers and cut-resistant heat-resistant (CH-HR) polymer fibers.

It is therefore understood that at least 30% by weight of the polymer fibers present in the at least one first yarn are both cut resistant and heat resistant polymer fibers as defined herein. In some embodiments, the cut resistant heat resistant polymer fibers are present in the at least one first yarn in an amount of 50% to 100% by weight based on the total amount of polymer fibers in the at least one first yarn. In some other embodiments, the cut resistant heat resistant polymer fibers are present in the at least one first yarn in an amount of 80% to 100% by weight based on the total amount of polymer fibers in the at least one first yarn. In other embodiments, the cut resistant heat resistant polymer fibers are present in the at least one first yarn in an amount of 80% to 95% by weight based on the total amount of polymer fibers in the at least one first yarn.

In addition to the various exemplary percentages of cut-resistant heat-resistant polymeric fibers and non-cut-resistant heat-resistant polymeric fibers shown in Table 1, in some embodiments, the at least one first yarn further comprises other synthetic or organic fibers or filaments that are not heat-resistant polymeric fibers, i.e., do not meet the definition of heat-resistant polymeric fibers as defined herein. Essentially any type of fiber can be included, so long as the final fabric meets the composition and performance criteria described herein. That is, the composition of the at least one first yarn comprises at least 50% by weight of heat-resistant polymeric fibers, based on the total weight of the polymeric fibers in the first yarn, and at least 30% by weight of the polymeric fibers are cut-resistant heat-resistant fibers; the final fabric is a fire-resistant fabric having a longest flame time of 2 seconds or less and a weight loss of 5% or less when tested according to NFPA-2112-2018. Preferably, the fibers or filaments that are not heat-resistant polymeric fibers are organic fibers, and in some embodiments are polymeric organic fibers. Also, in some embodiments, the fibers or filaments that are not heat-resistant polymeric fibers, when present, are synthetic or organic staple fibers.

In some preferred embodiments, the at least one first yarn may further comprise a fire resistant fiber. By "fire resistant fiber" it is meant that a fabric made solely from the fabric has a char length of 4 inches or less and an afterflame time of 2 seconds or less according to the ASTM D6143-99 Vertical Burn Test, but the fabric does not meet the cut resistance criteria previously described herein for cut resistant heat resistant polymeric fibers. Suitable fire resistant fibers include meta-aramid fibers, with a preferred meta-aramid being poly(metaphenylene isophthalamide). Other potentially useful fire resistant fibers include blends of meta-aramids, flame retardant (FR) cellulose, FR cotton, FR lyocell, or mixtures thereof. In some embodiments, the at least one first yarn has 30-70% by weight of fire resistant fiber based on the total weight of the polymeric fibers in the first yarn. In some other preferred embodiments, at least one first yarn has 50-70% by weight of fire resistant fibers based on the total weight of the polymer fibers in the first yarn.

The heat-resistant polymer fiber and the cut-resistant heat-resistant polymer fiber in the at least one first yarn are both staple fibers having a length of preferably about 2-20 cm, preferably about 3.5-6 cm. The heat-resistant polymer fiber and the cut-resistant heat-resistant polymer fiber in the at least one first yarn are both staple fibers having a diameter of preferably 5-25 μm and a linear density of 0.5-7 dtex. Also, in some embodiments, the fibers or filaments that are fire-resistant fibers or are not heat-resistant polymer fibers, if present, are staple fibers having dimensions similar to the above ranges of the heat-resistant polymer fibers and the cut-resistant heat-resistant polymer fibers.

In some embodiments, the at least one first yarn comprises at least 50% by weight of heat resistant polymeric fibers based on the total weight of the first yarn, at least 30% by weight of the polymeric fibers present in the at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or more according to ASTM F2992-15, and the at least one first yarn further comprises a sheath/core construction having a sheath comprising the cut resistant heat resistant polymeric fibers and a core comprising inorganic fibers. For applications that require or require superior cut resistance, at least one inorganic fiber is preferably added to the yarn. A sheath/core construction is used because the staple fibers in the sheath provide a covering and protect the inorganic filaments in the core from direct abrasive contact with the skin, thereby improving the comfort of the fabric comprising the sheath/core yarn.

In some embodiments, when inorganic fibers are present in at least one first yarn, the inorganic fibers are present in an amount of 15-40% by weight of the total weight of the first yarn. Similarly, when inorganic fibers are present, the maximum amount of heat resistant polymer fibers in these sheath-core first yarns is 85% by weight based on the total weight of the first yarn. In some preferred embodiments, the sheath/core yarns have 60-80% by weight of heat resistant polymer fibers in the sheath and 20-40% by weight of organic fibers in the core. Preferably, the inorganic fibers in the core are steel or tungsten. Preferably, the fibers in the core are present as one or more continuous filaments.

The sheath fibers can be wrapped or spun around the inorganic filament core. Specifically, this can be accomplished by known means such as conventional ring spinning, including modifications of conventional processes such as those utilizing COTSON technology; corespun spinning, such as DREF spinning; air jet spinning using so-called core insertion by Murata (now Muratec) jet-like spinning; and open-end spinning. Preferably, the staple fibers are packed around the inorganic filament core with a density sufficient to cover the core. The degree of coverage varies depending on the process used to spin the yarn, with corespun spinning, such as DREF spinning (disclosed, for example, in U.S. Pat. Nos. 4,107,909, 4,249,368, and 4,327,545), providing better coverage than ring spinning. Conventional ring spinning provides only partial coverage of the central core, but partial coverage can provide sufficient sheath/core coverage. The sheath may also contain some fibers of other materials to the extent that the reduced cut resistance caused by the other materials can be tolerated.

The incorporation of at least one inorganic filament as a core in this embodiment of the first yarn can be accomplished, for example, in its simplest practical application, by passing a roving, sliver, or aggregate of heat-resistant cut-resistant fibers and optional non-heat-resistant fibers through a set of drafting rolls to form a drafted fiber mass that is to be ring-twisted into a single yarn. The at least one inorganic filament is typically fed from a bobbin through a set of feed rolls and then into a staple fiber before a final set of drafting rollers. Because the inorganic core filament is not elastomeric, there is no need to apply excessive tension when inserting it into the yarn, only sufficient tension is required on either the sheath fiber or the core as is conventionally used.

At least one first yarn in the form of a sheath/core yarn typically comprises 15-50% by weight of inorganic filaments having a sheath/core yarn total linear density of 100-5000 dtex. The core comprising the inorganic fibers may be single filament or multifilament, preferably a single metal filament or multiple metal filaments, depending on the specific application or the degree of cut protection required or desired. By metal filament is meant a filament or wire made from ductile metals such as stainless steel, copper, aluminum, bronze, tungsten, or the metal fiber structure commonly known as "microsteel". Stainless steel is the preferred metal. The metal filament is typically a continuous wire. Useful metal filaments are 1-150 μm in diameter, preferably 25-75 μm in diameter.

In some embodiments, the inorganic fiber is a glass filament. This may be one or more glass filaments, such as, for example, 110 dtex (100 denier) glass filaments. However, glass is less preferred because it has lower cut resistance per linear density than metal, and it is much more important that the glass is adequately covered by the staple fiber sheath to minimize skin irritation when the yarn is used in gloves, sleeves, or other areas where the fabric comes into contact with the skin. Thus, in many embodiments, the inorganic fiber is a metal filament.

Again, for these sheath/core yarns, it is understood that the cut resistant heat resistant polymer fibers are both heat resistant polymer fibers as defined above and cut resistant fibers as defined above. It is also understood that the at least one first yarn can include fibers that are heat resistant polymer fibers as defined herein but are not cut resistant fibers as defined herein. Table 2 provides guidance providing selected exemplary compositions of possible percentages of total heat resistant (CH-HR) polymer fibers and total inorganic filaments in the at least one first yarn, and further provides possible percentages showing possible amounts of non-cut resistant (non-CR-HR) polymer fibers and cut resistant heat resistant (CH-HR) polymer fibers.

The at least one second yarn has a sheath/core structure having a sheath of halogenated self-extinguishing staple fibers and a core including at least one continuous elastomeric filament, wherein 60-95% by weight of the at least one second yarn is halogenated self-extinguishing fibers, based on the total weight of the second yarn, the halogenated self-extinguishing fibers are in contact with the at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers.

The at least one second yarn has a sheath/core structure, with a sheath of halogenated self-extinguishing staple fibers in contact with and covering the core of the at least one continuous elastomeric filament. It is believed that the halogenated self-extinguishing staple fibers provide an active fire-extinguishing covering for the core of the at least one continuous elastomeric filament. This differs from cover fibers that provide a "structural shield" for the core, i.e., cover fibers that simply char and remain in place when exposed to a flame, thereby providing a structural barrier between the flame and the elastomeric core. Instead, the sheath of halogenated self-extinguishing staple fibers decomposes in the presence of a high heat flux, such as a flame, releasing halogen gas from the yarn that replaces the local oxygen and prevents the core of the at least one continuous elastomeric filament from burning. It is therefore believed that the halogenated self-extinguishing staple fibers are required not only to cover the core, but also to be in direct contact with the core to locally displace oxygen from the surface of the core of the at least one continuous elastomeric filament.

The sheath of halogenated self-extinguishing staple fibers can be wrapped or spun around at least one continuous elastomeric filament. This can be accomplished by known means such as conventional ring spinning, including modifications of conventional processes such as those utilizing COTSON technology; core-spun spinning such as DREF spinning; air-jet spinning using so-called core insertion by Murata (now Muratec) jet-like spinning; and open-end spinning. Preferably, the staple fibers are packed around the core of at least one continuous elastomeric filament at a density sufficient to coat the core. The degree of coating varies with the process used to spin the yarn, with core-spun spinning such as DREF spinning (disclosed, for example, in U.S. Pat. Nos. 4,107,909, 4,249,368, and 4,327,545) providing better coating than ring spinning. Conventional ring spinning only results in partial coverage of the central core, but for the purposes of this specification, even partial coverage is considered a possible sheath/core structure.

The extinguishing effect of the halogenated self-extinguishing staple fiber is considered adequate when 60-95% by weight of the at least one second yarn is halogenated self-extinguishing fiber, based on the total weight of the second yarn. In some embodiments, it is desirable for 80-95% by weight of the at least one second yarn to be halogenated self-extinguishing fiber, based on the total weight of the second yarn. The sheath may also contain some fibers of other materials, to the extent that a reduction in extinguishing effect due to the other materials is acceptable.

Halogenated self-extinguishing fibers include those made from halogenated polymers. One particularly preferred halogenated self-extinguishing fiber is a fiber made from a modacrylic polymer. By "modacrylic polymer" it is preferably meant that the polymer is a copolymer comprising 30-70% by weight acrylonitrile and 70-30% by weight halogen-containing vinyl monomer. The halogen-containing vinyl monomer is at least one monomer selected from, for example, vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, and the like.

In some embodiments, the modacrylic copolymer is of acrylonitrile combined with vinylidene chloride. In some embodiments, the modacrylic copolymer further comprises antimony oxide or antimony oxides. In some preferred embodiments, the modacrylic copolymer has either less than 1.5 weight percent antimony oxide or the copolymer is completely free of antimony. By limiting or completely eliminating the amount of any antimony compounds added to the copolymer during manufacture, very low antimony content polymers and antimony-free polymers can be produced. Representative processes for modacrylic polymers, including those that can be modified in this manner, are disclosed in U.S. Pat. No. 3,193,602, which contains 2 weight percent antimony trioxide; U.S. Pat. No. 3,748,302, which is made with various antimony oxides present in amounts of at least 2 weight percent, preferably no more than 8 weight percent; and U.S. Pat. Nos. 5,208,105 and 5,506,042, which contain 8 to 40 weight percent antimony compounds. In some embodiments, the modacrylic polymer has an LOI of at least 26. In one preferred embodiment, the modacrylic polymer is antimony-free while having an LOI of at least 26.

The halogenated self-extinguishing staple fibers in the at least one second yarn are preferably staple fibers having a length of about 2-9 cm, preferably about 3.5-6 cm. The halogenated self-extinguishing staple fibers in the at least one second yarn are preferably staple fibers having a diameter of 5-25 μm and a linear density of 0.5-7 dtex.

The fabric includes at least one second yarn having a sheath/core structure having a sheath of halogenated self-extinguishing staple fibers and a core including at least one continuous elastomeric filament. The halogenated self-extinguishing fiber is in contact with the at least one continuous elastomeric filament, eliminating the need for the entire surface of the elastomeric filament to be actually completely covered by the staple fiber sheath.

In some embodiments, preferably at least 90% of the core is covered by the sheath when viewed under a microscope in the relaxed yarn state, i.e., when the sheath-core yarn is not under tension. The actual coverage of the core may vary depending on the degree to which the yarn is under tension. However, as long as the modacrylic is in contact with the elastomeric core, it is believed that the modacrylic provides a shielding effect.

In some embodiments, 5-40 wt. % of the total weight of the at least one second yarn is at least one continuous elastomeric filament. In some embodiments, the ring-spun second yarn has a core comprising at least one elastomeric filament and a partial covering of halogenated self-extinguishing staple fiber. In some preferred embodiments, the elastomeric filament core comprises 5-25 wt. % of the total sheath/core single yarn linear density of 100-1500 dtex.

As used herein, "core comprising at least one continuous elastomeric filament" means a core formed from or comprising an elastomeric filament, which preferably has the ability to rapidly return to its original length after being repeatedly stretched to at least twice its original length. Preferred elastomeric cores include polyurethane-based yarns such as spandex or elastane, although generally any fiber having stretch and recovery properties can be used. Suitable well-known elastomeric yarns also include products sold under the trade names Dorlastan® and Lycra®.

The preferred at least one continuous elastomeric filament is a spandex fiber. As used herein, "spandex" has its usual definition, i.e., a manufactured fiber in which the fiber-forming material is a long-chain synthetic polymer composed of at least 85% by weight of segmented polyurethane. Among the spandex-type segmented polyurethanes are, for example, those described in U.S. Pat. Nos. 2,929,801; 2,929,802; 2,929,803; 2,929,804; 2,953,839; 2,957,852; 2,962,470; 2,999,839; and 3,009,901.

In some processes for making spandex elastomeric filaments, coalescing jets are used to solidify the spandex filaments immediately after extrusion. It is also well known that dry spun spandex filaments are tacky immediately after extrusion. The combination of bringing together groups of such tacky filaments and using coalescing jets produces a fused multifilament yarn, which is then typically coated with a silicone or other finish before winding to prevent sticking in the package. Such fused groupings of filaments, which are actually many very small individual filaments that adhere to each other along their length, are superior in many ways to single filaments of spandex of the same linear density.

The elastomeric filaments in the elastomeric single yarn are preferably continuous filaments and may be present in the second yarn in the form of one or more individual filaments or one or more fused groupings of filaments. However, in the preferred elastomeric single yarn, it is preferred to use only one fused group of filaments. Whether present as one or more individual filaments or one or more fused groupings of filaments, the overall linear density of the elastomeric filaments in the relaxed state is generally 17 to 560 dtex (15 to 500 denier), with a preferred linear density range of 44 to 220 dtex (40 to 200 denier).

It is preferred to incorporate at least one continuous elastomeric filament into the second yarn under tension by drawing or stretching the at least one continuous elastomeric filament prior to combining it with the staple fibers by using a slow conveying speed relative to the final second yarn speed. This drawing can be described as a stretch ratio of the continuous elastomeric filament, which is the final second yarn speed divided by the conveying speed of the continuous elastomeric filament.

Typical stretch ratios are 1.5-5.0, with 1.5-3.50 being preferred. Low stretch ratios result in poor elastic recovery, while very high stretch ratios make the single yarn difficult to process and the fabric too tight and uncomfortable. The optimum stretch ratio also depends on the weight percent content of the elastomeric core. Tensioning devices can be used to tension and stretch the elastomeric fibers, but are less preferred because the tension and stretch are difficult to reproduce and control. The optimum stretch ratio is ultimately determined for each fabric based on the desired fit and feel of the fabric.

Incorporation of at least one continuous elastomeric filament into a second yarn of halogenated self-extinguishing staple fiber can be accomplished, for example, in its simplest practical application, by passing a roving, sliver, or aggregate of halogenated self-extinguishing staple fiber through a set of drafting rolls to form a drafted fiber mass that is to be ring-twisted into a single yarn. The at least one continuous elastomeric filament is typically fed from a bobbin through a set of feed rolls and then fed into the staple fiber before a final set of drafting rollers. The slowness of the surface speed of the feed rollers relative to the surface speed of the drafting rollers is increased or decreased to determine the amount of elastic stretch and tension in the final ring-twisted single yarn using conventional techniques.

In some embodiments, the sheath of at least one second yarn can further include heat resistant polymer fibers as described hereinabove. In some other embodiments, the sheath of at least one second yarn can further include cut resistant heat resistant polymer fibers as described hereinabove.

In some embodiments, the sheath of the at least one second yarn may further comprise a fire resistant fiber. By "fire resistant" fiber, it is meant that a fabric made solely from that fabric has a char length of 4 inches or less and an afterflame time of 2 seconds or less according to the ASTM D6143-99 vertical burn test. Suitable fire resistant fibers include aramid fibers, with meta-aramid fibers being particularly preferred. A preferred meta-aramid is poly(metaphenylene isophthalamide). Potentially useful fire resistant fibers include meta-aramid, polyamide-imide, flame retardant (FR) cellulose, FR cotton, FR lyocell, or mixtures thereof. In some embodiments, the at least one second yarn preferably has 5% to 35% fire resistant fiber by weight based on the total weight of the polymeric fiber in the at least one second yarn. Also, in some embodiments, the at least one first yarn preferably has 5% to 35% fire resistant fiber by weight based on the total weight of the polymeric fiber in the at least one first yarn.

Any number of fibers can be included in the second yarn as long as the second yarn and final fabric meet the performance criteria described herein.

When used in the second yarn, the heat resistant polymer fiber, the cut resistant heat resistant polymer fiber, or the fire resistant fiber are preferably staple fibers having a length of about 2-20 cm, preferably about 3.5-6 cm. When used in the second yarn, the heat resistant polymer fiber, the cut resistant heat resistant polymer fiber, and the fire resistant fiber are preferably staple fibers having a diameter of 5-25 μm and a linear density of 0.5-7 dtex.

In some embodiments, the sheath of the at least one second yarn may further comprise what is known in the art as antistatic fibers, or fibers that have the ability to reduce charge buildup in the yarn or resulting fabric. In some preferred embodiments, the sheath of the at least one second yarn comprises at least 1-5 wt. % antistatic fibers, based on the total weight of the at least one second yarn. Preferred antistatic fibers are those that function due to the presence of carbon within the fiber, either as a carbon coating or carbon particles; in particular, antistatic fibers are useful in eliminating charge buildup, but are not considered conductive in a practical sense. In some embodiments, aramid fibers containing carbon particles are preferred.

In a preferred embodiment, the second yarn is free or substantially free of inorganic fibers. The cut resistance benefit of the inorganic fibers is obtained by the first yarn, eliminating the need to add inorganic fibers to the second yarn for most intended applications.

In some embodiments, plied yarns are formed from at least a first yarn and at least a second yarn. Plied yarns are produced by twisting together at least two separate single yarns. The phrase "twisting together at least two separate single yarns" means that two single yarns are twisted together without one yarn completely covering the other. This distinguishes plied yarns from covered or wrapped yarns, where a first single yarn is substantially or completely wrapped around a second single yarn such that ideally only the first single yarn is exposed on the surface of the resulting covered yarn.

In a preferred embodiment, the ply-twisted yarn is made from at least two single yarns, the first single yarn being (a) at least one first yarn comprising at least 50% by weight of heat resistant polymer fibers, based on the total weight of the first yarn, and at least 30% by weight of the polymer fibers present in the at least one first yarn being resistant to heat resistant polymer fibers, based on the total weight of the first yarn, The at least one first yarn further has a sheath/core structure, the sheath comprising a cut-resistant heat-resistant polymer fiber and the core comprising an inorganic fiber; the second single yarn is (b) at least one second yarn having a sheath/core structure having a sheath of halogenated self-extinguishing staple fiber and a core comprising at least one continuous elastomeric filament, wherein 60-95% by weight of the at least one second yarn is halogenated self-extinguishing fiber, based on the total weight of the second yarn, the halogenated self-extinguishing fiber is in contact with at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fiber. Each of the single yarns may have some twist.

In some embodiments, a ply-ply yarn made from two single yarns has a total linear density of 200-3000 dtex. Any individual staple fiber in the single yarn can have a linear density of 0.5-7 dtex, with a preferred linear density range of 1.5-3 dtex. Ply-ply yarns, and the single yarns that make up those ply-ply yarns, can contain other materials so long as the functionality or performance of the yarn or the fabric made from that yarn is not compromised for the desired application.

Ply-twisted yarns can be made from single yarns by the process disclosed in U.S. Patent No. 6,952,915 to Prickett, and the ply-twisted yarns can have a wide range of plies as disclosed therein.

The plied yarns can then be combined with other plied yarns of the same or different kind to form a yarn bundle to form a fabric, or individual plied yarns can be used to form a fabric depending on the requirements of the desired fabric. For example, two or more of the plied yarns described above can be combined to form a yarn bundle that can be fed into a knitting machine with or without twist. Alternatively, a yarn bundle can be made using one or more of the plied yarns described above with one or more different single yarns to impart desired properties to the final fabric. Since modern knitting machines can be fed multiple plied yarns to knit fabrics, it is not necessary for the bundle of plied yarns fed into the machine to have twist, although twist can be added to the bundle if desired.

At least the first yarn used in the preferred ply yarn in the absence of an inorganic core is preferably a ring spun 420 dtex (380 denier, equivalent to 14 cotton count) single yarn. The yarn has a poly(paraphenylene terephthalamide) (PPD-T) staple sheath, the PPD-T having a cut length of 3.8 cm (1.5 inches) and a filament density of 1.7 dtex per filament (1.5 denier per filament).

At least one second yarn used in the preferred ply yarn is a ring spun 330 dtex (295 denier, equivalent to 18 cotton count) single yarn. The yarn has a modacrylic staple sheath at least partially covering an elastomeric core filament, the modacrylic staple having a cut length of 4.8 cm (1.89 inches) and a filament density of 1.7 dtex per filament (1.5 denier per filament). The elastomeric core is a 78 dtex (70 denier) spandex fused filament yarn having a stretch ratio of 3.0 times (approximately 200 percent elongation). In some preferred embodiments, approximately 92% by weight of the second yarn is composed of modacrylic staple and 8% by weight of the second yarn is elastomeric core.

The present invention also relates to a cut-resistant woven or knitted fabric made from a yarn or yarn bundle comprising at least one first yarn and one second yarn. The present invention further relates to a cut-resistant woven or knitted fabric made from a plied yarn or a yarn bundle comprising plied yarn, the plied yarn comprising at least one first yarn and one second yarn as described herein.

Specifically, the present invention relates to a cut-resistant woven or knitted fabric made from a ply yarn made from at least two single yarns, the first single yarn being (a) at least one first yarn comprising at least 50% by weight of heat resistant polymer fibers, based on the total weight of the first yarn, and at least 30% by weight of the polymer fibers present in the at least one first yarn being at least 50% by weight of heat resistant polymer fibers, based on the total weight of the first yarn, and at least 30% by weight of the polymer fibers present in the at least one first yarn being at least 50% by weight of heat resistant polymer fibers, based on the total weight of the first yarn, The second single yarn is a cut-resistant heat-resistant polymeric fiber having a cut resistance of 500 grams force or more according to F2992-15; the second single yarn is (b) at least one second yarn having a sheath/core structure having a sheath of halogenated self-extinguishing staple fiber and a core including at least one continuous elastomeric filament, wherein 60-95% by weight of the at least one second yarn is halogenated self-extinguishing fiber, based on the total weight of the second yarn, and the halogenated self-extinguishing fiber is in contact with the at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers; the fabric has a maximum afterflame time of 2 seconds or less and a weight loss of 5% or less when tested according to NFPA-2112-2018.

In some embodiments, the first single yarn comprises at least one first yarn further having a sheath/core structure having a sheath comprising cut-resistant heat-resistant polymeric fibers and a core comprising inorganic fibers.

The at least one first yarn and the at least one second yarn function synergistically in both the yarn and the fabric. The at least one continuous elastomeric filament incorporated in the yarn provides improved stretch and recovery, while the heat resistant staple fibers provide structure in fire, and the heat resistant cut resistant organic staple fibers and inorganic filaments, if present, provide excellent cut resistance to the yarn and fabric. Fabrics made from such yarns are soft, comfortable, non-abrasive, and cut resistant.

Plying the first yarn with the second yarn is preferred because it helps the elastomeric single yarn to remain elongated without looping when relaxed. However, if the sheath/core elastomeric single yarn is fed simultaneously in a bundle with other single yarns (without plying) to a knitting or weaving machine with good tension control, an acceptable fabric can be produced. When the bundle is composed of plied yarns, tension control of the yarns during knitting and weaving is less important.

The preferred fabric is a knitted fabric, with any suitable knit pattern being acceptable. Cut resistance and comfort are affected by the tightness of the knit, which can be adjusted to meet any particular need. A highly effective combination of cut resistance and comfort in many cut resistant articles has been found, for example, in single jersey and terry knit patterns. The fabric has a basis weight of about 4-30 oz/ ^yd2 , preferably 6-25 oz/ ^yd2 , with fabrics at the higher end of the basis weight range providing greater warmth and cut protection.

Test Method Afterflame and weight loss were determined according to the procedures outlined in NFPA 2112-2018 "Standard on Flame-Resistant Clothing for Protection of Industrial Personnel Against Short-Duration Thermal Exposures from Fire", specifically section 8.8 of the standard.

The determination of "heat resistant polymer fibers" as described herein can be made by using ASTM E2105-2016-Standard Practice for General Techniques of Thermogravimetric Analysis (TGA) Coupled With Infrared Analysis (TGA/IR). Analysis of whether a synthetic organic polymer retains 90 percent of the original fiber weight is performed by heating the sample in air at a rate of 20°C per minute to 500°C.

Knits Made from Ply-Twisted Yarns Ply-twisted yarns and knits made from the yarns are exemplified in Examples 1, 2, 3, and Comparative Example A and are summarized in Table 6.

Example 1
The plied elastomeric yarn was produced by plied together a first yarn and a second yarn.
The first yarn was a 14 cotton count sheath-core yarn having a para-aramid fiber sheath and a 50 micron stainless steel wire core, and was ring spun. The para-aramid fiber was 2 inch poly(paraphenylene terephthalamide) staple.

The second yarn was an 18 cotton count sheath-core yarn made by ring-spinning 2 inch modacrylic staple around a 70 denier spandex core. The spandex core was stretched 3 times as it was incorporated (spun) into the sheath-core yarn.

The resulting ply-twisted elastic yarn produced by plying the first and second yarns had a total cotton count of 16/2, or 675 denier. The relative amounts of the yarn components are shown in Table 3.

The resulting ply-twisted elastic yarn was knitted into a 13-gauge sleeve on a Shima-Seiki glove knitting machine. The resulting sleeve had excellent hand and form fit. Fabric samples from the resulting sleeve were flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have a 0-second afterflame with 4.8% weight consumption during the test. This was below the 2-second maximum afterflame requirement and 5% weight loss limit allowed by the standard.

Example 2
The ply-twisted elastic yarn of Example 1 was repeated with the following exceptions.

The first yarn was a 26 cotton count yarn with a para-aramid fiber sheath and a 35 micron stainless steel wire core. The second yarn was a 32 cotton count yarn with a modacrylic sheath and a 40 denier spandex core that was stretched 3 times during spinning.

As in Example 1, the resulting ply-twisted elastic yarn produced by plying the first and second yarns had a total cotton count of 29/2, or 371 denier. The relative amounts of the yarn components are shown in Table 4.

The resulting ply-twisted elastic yarn was knitted into an 18-gauge sleeve on a Shima-Seiki glove knitting machine. The resulting sleeve had excellent form fit. Fabric samples from the resulting sleeve were washed to remove knitting oils and finishes and flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have a 0 second afterflame with 3.3% weight loss during testing. This was below the 2 second maximum afterflame requirement and 5% weight loss limit allowed by the standard.

Example 3
The ply-twisted elastic yarn of Example 1 was repeated with the following exceptions.

The first yarn was a 19.5 cotton count yarn with a para-aramid fiber sheath and a stainless steel wire core made with a 45 micron stainless steel wire core that was stretched 3 times during spinning. The second yarn was a 32 cotton count sheath-core yarn with a 40 denier spandex core, except that the sheath was a blend of 82% modacrylic staple fiber by weight and 10% meta-aramid staple fiber blend with a 2 inch cut length by weight. Specifically, the meta-aramid blend included 93% poly(metaphenylene isophthalamide) staple fiber, 5% poly(paraphenylene terephthalamide) staple, and 2% carbon core nylon antistatic fiber by weight.

As in Example 1, the resulting ply-twisted elastic yarn produced by plying the first and second yarns had a total cotton count of 24/2, or 439 denier. The relative amounts of the yarn components are shown in Table 5.

The resulting ply-twisted elastic yarn was knitted into an 18-gauge sleeve on a Shima-Seiki glove knitting machine. The resulting sleeve had excellent shape fit.

Fabric samples of the produced sleeves were washed to remove knitting oils and finishes and then flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have a 0 second afterflame with 3.9% weight loss during testing, below the 2 second maximum afterflame requirement and 5% weight loss limit allowed by the standard.

A separate fabric sample of the produced sleeve was subjected to a flame test according to the fire resistant glove test method detailed in the EN 407:2020 standard. The resulting stretchable fabric was found to have 0 seconds of flame and 0 seconds of afterglow after 3 and 15 seconds of exposure to flame, which was below the maximum flame and afterglow requirements of 2 seconds and 5 seconds, respectively, to achieve the highest rank as stated in the standard.

Comparative Example A
Comparative plied elastic yarns similar to that of Example 3 were made, except that the first yarn, having a para-aramid fiber sheath and a stainless steel wire core, was made with 1.5 inch poly(paraphenylene terephthalamide) staple and a 45 micron stainless steel wire core. The second yarn, also a 32 cotton count sheath-core yarn, had a cut length 1.5 inch nylon staple only sheath core spun around a 40 denier spandex core.

The resulting 24/2 count ply yarn was knitted into an 18 gauge sleeve on a Shima-Seiki glove knitting machine. The resulting sleeve had excellent form fit.

However, the produced samples were subjected to a flame test according to the fire resistant glove test method detailed in the EN 407:2020 standard. The resulting stretchable fabric was found to have an afterflame of at least 25 seconds after 3 seconds of exposure to flame. This was longer than the maximum afterflame requirement of 20 seconds to achieve the minimum rank stated in the standard.

Subsequent testing for both the 15 second exposure in the EN407 test and the 12 second exposure in the NFPA-2112 test were not performed due to excessive afterflame generation after only 3 seconds of flame exposure.

Knits made by interlacing two parallel warp yarns Knits made by feeding individual warp yarns or bundles of individual warp yarns to a knitting machine and interlacing the yarns are exemplified in Example 4 and Comparative Example B and summarized in Table 4.

Example 4
The first warp yarn (a two-ply para-aramid ring spun yarn, each yarn made from 2 inch poly(paraphenylene terephthalamide) staple yarn, each of the two plies being 16 cotton count) was interwoven with the second warp yarn, which was the 18 cotton count sheath-core yarn of Example 1.

The two warp yarns were then interwoven into a sleeve on a 13-gauge knitting machine. The resulting sleeve had excellent feel and shape fit.

Fabric samples of the produced sleeves were washed to remove knitting oils and finishes and then flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have a 0 second afterflame with 2.5% weight loss during testing, below the 2 second maximum afterflame requirement and 5% weight loss limit allowed by the standard.

Comparative Example B
A warp of 12 cotton count modacrylic ring spun yarn made from 2 inch modacrylic staple was interwoven with a warp of the 18 cotton count sheath-core yarn of Example 1. The two warp yarns were interwoven into a sleeve on a 13 gauge knitting machine. The resulting sleeve had excellent hand and form fit.

The produced samples were washed to remove knitting oils and finishes and then flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have a 2.3 second afterflame with 5.8% weight loss during testing, exceeding the 2 second maximum afterflame requirement and 5% weight loss limit allowed by the standard.

Knits Made by Weft Insertion Knits made by interlacing yarns by weft insertion are illustrated in Example 3 and Comparative Examples B and C and are summarized in Table 4.

Example 5
The first warp yarn (a two-ply para-aramid ring spun yarn, each yarn made from 2 inch poly(paraphenylene terephthalamide) staple yarn, each of the two-ply yarns being 16 cotton count) was interwoven with the second warp yarn (a modacrylic sheath-spandex core elastic yarn made by ring spinning 1200 denier core spun fiber with a 440 denier spandex core and stretched 3 times during the yarn spinning process) to produce a fire resistant yarn. The composition of the elastic core yarn was about 12% spandex and about 88% modacrylic staple fiber.

The first and second warp yarns were interwoven on a Shima-Seiki flat knitting machine into a 13-gauge knitted cuff using a weft insertion technique in which a modacrylic sheath-spandex core elastic yarn was inserted every third stitch. The resulting sleeve had excellent form fit.

The produced samples were washed to remove knitting oils and finishes and then flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have a 0 second afterflame with 4% weight loss during testing, below the 2 second maximum afterflame requirement and 5% weight loss limit allowed by the standard.

Comparative Example C
The first warp yarn of the two-ply para-aramid ring spun yarn of Example 5 was combined with a different second warp yarn. This second warp yarn was a polyester fiber wrapped and covered elastomeric cord from Supreme Elastic Corporation, and the first warp yarn and the second warp yarn were interwoven on a Shima-Seiki flat knitting machine to produce an elasticated cuff. The composition of the elastomeric cord was estimated to be 75% polyester fiber and 25% rubber. The warp yarns were interwoven using a weft insertion technique that inserted the polyester fiber wrapped and covered elastomeric cord into every third stitch of the 13 gauge knitted cuff. The resulting sleeve had excellent form fit.

Fabric samples of the produced sleeves were washed to remove knitting oils and finishes and then flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have consumed 9% of its weight during the test and had a 43 second afterflame, exceeding the 2 second maximum afterflame and 5% weight loss limits allowed by the standard.

Comparative Example D
Four warp yarns of ring spun yarn made from 2 inch modacrylic staple, each yarn having a 35 cotton count, were interwoven with a sheath-core elastic yarn having a modacrylic sheath and a spandex core. The sheath-core elastic yarn was made by ring spinning a 1200 denier modacrylic staple yarn having a 440 denier spandex core, and the spandex was stretched three times during spinning to produce a sheath-core elastic yarn having a composition of approximately 12% spandex and 88% modacrylic staple fiber. The elastic yarn was interwoven using a weft insertion technique into every third stitch of a 13 gauge knit sleeve knitted on a glove knitting machine. The resulting sleeve had excellent form fit.

Fabric samples of the produced sleeves were washed to remove knitting oils and finishes and then flame tested according to the fire-resistant glove test method detailed in the NFPA-2112-2018 standard. The resulting stretch fabric was found to have a 0 second afterflame with 10% weight consumption during testing. This was below the maximum afterflame requirement of 2 seconds allowed by the standard, but exceeded the 5% weight loss limit.

Claims (27)

(a) at least one first yarn comprising at least 50 weight percent heat resistant polymeric fibers, based on the total weight of the polymeric fibers in the first yarn, wherein at least 30 weight percent of the polymeric fibers present in said at least one first yarn are cut resistant heat resistant polymeric fibers having a cut resistance of 500 grams force or greater according to ASTM F2992-15; and (b) at least one second yarn having a sheath/core construction having a sheath of halogenated self-extinguishing staple fibers and a core comprising at least one continuous elastomeric filament;
A fire and cut resistant fabric comprising:
60-95% by weight of the at least one second yarn is halogenated self-extinguishing fiber, based on the total weight of the second yarn, the halogenated self-extinguishing fiber being in contact with the at least one continuous elastomeric filament, and the second yarn is free or substantially free of inorganic fibers;
1. A fire resistant, cut resistant fabric, wherein the fabric has a maximum afterflame time of 2 seconds or less and a weight loss of 5% or less by weight when tested according to NFPA-2112-2018. The fabric of claim 1, wherein the at least one first yarn has a sheath/core structure having a sheath including the cut-resistant, heat-resistant polymeric fiber and a core including inorganic fiber. The fabric according to claim 1 or 2, wherein the heat-resistant polymer fiber or the cut-resistant heat-resistant polymer fiber is an aramid copolymer, a para-aramid, a polybenzazole, a polybenzimidazole, a polyimide, or a mixture thereof. The fabric according to claim 3, wherein the heat-resistant polymer fiber or the cut-resistant heat-resistant polymer fiber is para-aramid. The fabric of claim 3, wherein the para-aramid fiber is poly(paraphenylene terephthalamide). The fabric of any one of claims 1 to 5, wherein the at least one first yarn further comprises a fire resistant fiber that is not cut resistant. The fabric of claim 6, wherein the fire-resistant fiber is meta-aramid, polyamide-imide, flame-retardant (FR) cellulose, FR cotton, FR lyocell, or a mixture thereof. The fabric of claim 7, wherein the fire-resistant fiber is meta-aramid. The fabric of claim 8, wherein the meta-aramid is poly(metaphenylene isophthalamide). The fabric according to any one of claims 1 to 9, wherein 80 to 95% by weight of the total weight of the at least one second yarn is the halogenated self-extinguishing fiber. The fabric according to any one of claims 1 to 10, wherein the halogenated self-extinguishing fiber is a modacrylic fiber. The fabric according to any one of claims 1 to 11, wherein 5 to 40% by weight of the total weight of the at least one second yarn is the at least one continuous elastomeric filament. The fabric according to any one of claims 1 to 12, wherein the at least one continuous elastomeric filament is a spandex filament. The fabric according to any one of claims 1 to 13, wherein the inorganic fibers are metal filaments. The fabric according to any one of claims 1 to 14, wherein the inorganic fibers are glass filaments. The fabric of any one of claims 1 to 15, wherein the sheath of the at least one second yarn further comprises heat resistant polymer fibers. The fabric of any one of claims 1 to 16, wherein the sheath of the at least one second yarn further comprises fire resistant fibers that are not cut resistant. The fabric of claim 17, wherein the fire resistant fiber is meta-aramid, polyamide-imide, flame retardant (FR) cellulose, FR cotton, FR lyocell, or a mixture thereof. The fabric of claim 18, wherein the fire-resistant fiber is meta-aramid. The fabric of claim 19, wherein the meta-aramid is poly(metaphenylene isophthalamide). The fabric of any one of claims 1 to 20, wherein the sheath of the at least one second yarn further comprises antistatic fibers. The fabric according to any one of claims 1 to 21, comprising a ply-twisted yarn of the at least one first yarn and the at least one second yarn. The fabric according to any one of claims 1 to 22, wherein the fabric is a knitted fabric. The fabric according to any one of claims 1 to 21, having an interwoven structure of the at least one first yarn and the at least one second yarn. 25. The fabric of claim 24, wherein the at least one first yarn and the at least one second yarn are in a parallel relationship to one another in the interwoven structure. The fabric of claim 24, wherein the at least one second yarn is a weft insertion in the interwoven structure. A glove or other article comprising the fabric according to any one of claims 1 to 26.