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US-12624481-B1 - Flame-resistant elastic plaited fabric

US12624481B1US 12624481 B1US12624481 B1US 12624481B1US-12624481-B1

Abstract

A flame-resistant elastic plaited fabric made of a first yar containing a flame-resistant fiber or a blend of flame-resistant fibers, and a second yarn being an elastomeric yarn covered by a synthetic yarn, wherein the first yarn and the second yarn are plaited in a knitted construction. A method of making and an article are also provided.

Inventors

  • Donald W. Trexler
  • Tyler J. Henson

Assignees

  • Coville, Inc.

Dates

Publication Date
20260512
Application Date
20220225

Claims (12)

  1. 1 . A fabric comprising: a first yarn comprises a flame-resistant fiber or a blend of flame-resistant fibers, and a second yarn is an elastomeric yarn covered by a synthetic yarn, and wherein the fabric is constructed of two different yarns, the yarns being the first yarn and the second yarn plaited in a knitted construction, and wherein the fabric is rated for CAT 2 arc flash protection at a weight of 7 oz/yd 2 or less.
  2. 2 . The fabric according to claim 1 , wherein the fabric has elastic properties.
  3. 3 . The fabric according to claim 1 , wherein the fabric has a weight of 7 oz/yd 2 or less and is flame-resistant with elastic properties.
  4. 4 . The fabric according to claim 1 , wherein the fabric has a weight of 6.5 oz/yd 2 or less and is flame-resistant with elastic properties.
  5. 5 . The fabric according to claim 1 , wherein the fabric has a weight of 4 oz/yd 2 to 7 oz/yd 2 and is flame-resistant with elastic properties.
  6. 6 . The fabric according to claim 1 , wherein the first yarn is about 65% to 95% by weight of the fabric.
  7. 7 . The fabric according to claim 1 , wherein the second yarn is about 9% to 35% by weight of the fabric.
  8. 8 . The fabric according to claim 1 , wherein the flame-resistant fiber comprises at least one flame-resistant polymer selected from the group consisting of modacrylic, cellulosic derivatives, aramid fiber, fluoropolymer, polybenzimidazole, and a copolymer thereof, and a combination thereof.
  9. 9 . The fabric according to claim 1 , wherein the first yarn has about 5% to 20% by weight, based on total weight of the yarn blend, of at least one structural fiber component comprising at least one flame-resistant polymer selected from the group consisting of aramid fiber, melamine fiber, carbon fiber, and/or any combination thereof.
  10. 10 . The fabric according to claim 1 , wherein the first yarn comprising about 55 weight % to 75 weight % hydrophobic fiber.
  11. 11 . A method of making a flame-resistant elastic plaited fabric, the method comprising: plaiting two yarns in a knitted construction a first yarn comprising a flame-resistant fiber or a blend of flame-resistant fibers, and a second yarn is an elastomeric yarn covered by a synthetic yarn to form a plaited fabric, and wherein the plaited fabric is rated for CAT 2 arc flash protection at a weight of 7 oz/yd 2 or less.
  12. 12 . An article comprising: a two-yarn fabric construction comprising: a first yarn comprising a flame-resistant fiber or a blend of flame-resistant fibers, and a second yarn is an elastomeric yarn covered by a synthetic yarn, wherein the first yarn and the second yarn are plaited in a knitted construction, and wherein the two-yarn fabric construction is rated for CAT 2 arc flash protection at a weight of 7 oz/yd 2 or less.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority from U.S. Provisional Patent Application No. 63/154,376, filed on Feb. 26, 2021, in the United States Patent and Trademark Office. The disclosure of which is incorporated herein by reference in its entirety. FIELD OF THE INVENTION The present invention relates to a flame-resistant fabric, in particular to a flame-resistant elastic plaited fabric. BACKGROUND OF THE INVENTION Flame resistant and arc rated fabrics are commonplace within occupations that expose employees to hazardous situations involving open flames and arc faults. Most employees that work in such environments are required to wear approved flame/arc protective garments. Most inherently flame-resistant fabrics that meet standards such as ASTM F1506, NFPA 2112, and 70-E tend to be heavy (>7 oz/yd2) and have little to no elastic properties. There are lightweight flame-resistant fabrics on the market but most of them have a topical treatment applied that imparts flame-resistant properties to the fabric. Topical treatments deteriorate as the fabric is washed and therefore destroys the viability of the fabric's protective properties throughout the life of the garment. In addition to the hazardous work environment employees are often required to work in very warm weather with moderate to high physical activity. The markets current flame-resistant garments tend to increase the wearers body heat due to the bulk and weight of the fabric. Most flame-resistant fabrics with non-elastic properties create loose fitting garments that are prone to snagging. The flame-resistant garment marketplace needs a long lasting, light weight flame-resistant protective fabric that can be made into a form fitting garment that aids in mobility and comfortability of the wearer. Thus, there is a need for a light weight 7 oz/yd2 or less flame-resistant fabric with elastic properties on the market that is rated for CAT 2 arc flash protection. The fabric of the present invention addresses this need. SUMMARY OF THE INVENTION The present invention relates to a flame-resistant elastic plaited textile fabric, method of making, and articles made therefrom. In an aspect of the invention, a fabric is provided comprising a first yarn comprised of a flame-resistant fiber or a blend of flame-resistant fibers, and a second yarn comprised of an elastomeric yarn covered by a synthetic yarn, wherein the first yarn and the second yarn are plaited in a knitted construction. In an aspect of the invention, a method of making a flame-resistant elastic plaited fabric is provided. The method comprises plaiting in a knitted construction a first yarn comprised of a flame-resistant fiber or a blend of flame-resistant fibers, and a second yarn comprised of an elastomeric yarn covered by a synthetic yarn. In an aspect of the invention, an article is provided comprising a first yarn comprised of a flame-resistant fiber or a blend of flame-resistant fibers, and a second yarn comprised of an elastomeric yarn covered by a synthetic yarn, wherein the first yarn and the second yarn are plaited in a knitted construction. Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will become more fully understood from the detailed description and the accompanying drawings, which are not necessarily to scale, wherein: FIG. 1 illustrates a plaited knit construction (single-end/feed) (technical back view). FIG. 2 illustrates a plaited knit construction (fabric). DESCRIPTION OF THE PREFERRED EMBODIMENTS The following description of the embodiments of the present invention is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. The following description is provided herein solely by way of example for purposes of providing an enabling disclosure of the invention, but does not limit the scope or substance of the invention. Further, the term “or” as used in this disclosure and the appended claims is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form. Throughout the specification and claims, the following te