US 12,371,824 B2
Flame resistant fabrics formed with stretchable yarns
Elijah Dufty, Atlanta, GA (US); Robert Self, Peachtree City, GA (US); Michael A. Laton, Peachtree City, GA (US); and Kevin Hilton, Zebulon, GA (US)
Assigned to Southern Mills, Inc., Union City, GA (US)
Filed by Southern Mills, Inc., Union City, GA (US)
Filed on May 20, 2022, as Appl. No. 17/749,670.
Claims priority of provisional application 63/191,485, filed on May 21, 2021.
Prior Publication US 2022/0372671 A1, Nov. 24, 2022
Int. Cl. D02G 3/44 (2006.01); D02G 3/04 (2006.01); D02G 3/32 (2006.01); D03D 15/513 (2021.01)
CPC D02G 3/443 (2013.01) [D02G 3/047 (2013.01); D02G 3/32 (2013.01); D03D 15/513 (2021.01); D10B 2201/22 (2013.01); D10B 2321/101 (2013.01); D10B 2331/021 (2013.01); D10B 2401/062 (2013.01); D10B 2501/04 (2013.01)] 20 Claims
 
1. A flame resistant fabric having a warp direction and a fill direction, the fabric comprising:
a plurality of spun body yarns provided in both the warp direction and the fill direction, wherein each of the plurality of spun body yarns formed of are spun from a body yarn fiber blend comprising modacrylic fibers, cellulosic fibers, and aramid fibers; and
a plurality of stretch yarns extending between at least some of the spun body yarns in at least one of the warp direction or the fill direction of the fabric, wherein each stretch yarn comprises an elastic core surround by a sheath, wherein the sheath comprises a sheath fiber blend comprising modacrylic fibers, cellulosic fibers, and aramid fibers, wherein:
i. the fabric has a char length of 6 inches or less and an afterflame of 2 seconds or less when tested pursuant to ASTM D6413 (2015);
ii. the fabric has an arc rating of at least 8 cal/cm2 when tested pursuant to ASTM F1959 (2014);
iii. the fabric exhibits thermal shrinkage of no more than 10% in both the warp and fill directions when tested pursuant to ASTM F 2894 (2021); and
iv. the fabric comprises a percent stretch and a percent recovery in the at least one of the warp direction or the fill direction in which the plurality of stretch yarns extend, wherein the percent stretch is at least 10% and the percent recovery is at least 90% after 100 industrial launderings, whereby in each industrial laundering the fabric is subjected to a standard 140° Fahrenheit industrial wash for 30 minutes and the fabric is dried for 30 minutes in an industrial dryer with a stack temperature not exceeding 155° Fahrenheit.