FIRE RETARDANT AND HEAT RESISTANT YARNS AND FABRICS TREATED FOR INCREASED STRENGTH AND LIQUID SHEDDING

Abstract

Fire retardant and heat resistant yarns and fabrics include an inner core comprised of oxidized polyacrylonitrile encapsulated by an outer shell comprised of a liquid-resistant and strengthening polymer material. The liquid-resistant and strengthening polymer material includes one or more types of cured silicone polymer resin. A fluorchemical may be at least partially impregnated into the inner core prior to applying the liquid-resistant and strengthening polymer material in order to further enhance the liquid shedding properties of the yarns or fabric. Because the silicone polymer resin only encapsulates the yarn, but does not form a continuous coating over the whole fabric, the treated fabric is still able to breath through pores and spaces between individual yarn strands that make up the fabric. The liquid-resistant and strengthening polymer material increases the strength, abrasion resistance, durability and liquid and gel shedding capability of the fire retardant heat resistant yarn or fabric.

Description

Claims

1. A liquid-shedding fire retardant and heat resistant yarn, comprising: a fire retardant and heat resistant inner core comprised of: one or more types of fire retardant and heat resistant polymer fibers and/or filaments having an LOI of at least about 50 and that do not burn when exposed to heat or flame having a temperature of about 3000° F.; andone or more types of strengthening fibers and/or filaments; andan outer liquid-shedding and strengthening shell encapsulating at least a portion of the inner core comprised of a liquid-resistant and strengthening polymer coating,wherein the liquid-shedding fire retardant and heat resistant yarn has increased strength, abrasion resistance, durability and liquid shedding ability compared to a yarn consisting exclusively of the fire retardant and heat resistant inner core.

2. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the fire retardant and heat resistant polymer fibers and/or filaments comprise oxidized polyacrylonitrile.

3. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the fire retardant and heat resistant inner core includes oxidized polyacrylonitrile in an amount in a range of about 25% to about 99.9% by weight of the inner core.

4. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the fire retardant and heat resistant inner core includes oxidized polyacrylonitrile in an amount in a range of about 40% to about 95% by weight of the inner core.

5. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the fire retardant and heat resistant inner core includes oxidized polyacrylonitrile in an amount in a range of about 50% to about 90% by weight of the inner core.

6. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the strengthening fibers and/or filaments comprise at least one of p-aramid, m-aramid, polybenzimidazole, polybenzoxazole, polyphenylene-2,6-benzobisoxazole, modacrilic, polyvinyl halide, wool, fire resistant polyester, nylon, rayon, cotton, or melamine.

7. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the inner core comprises at least one metallic strengthening filament selected from steel, stainless steel, steel alloy, titanium, titanium alloy, aluminum, aluminum alloy, copper, or copper alloy.

8. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the inner core further comprises at least one ceramic strengthening filament selected from silicon carbide, graphite, or a high strength ceramic that includes at least one oxide of Al, Zr, Ti, Si, Fe, Co, Ca, Nb, Pb, Mg, Sr, Cu, Bi, or Mn.

9. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the liquid-resistant and strengthening polymer coating comprises at least one type of cured silicone polymer resin.

10. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, further comprising at least one fluorochemical at least partially impregnated within the inner core that further imparts liquid shedding capability to the liquid-shedding fire retardant and heat resistant yarn.

11. A liquid-shedding fire retardant and heat resistant yarn as defined in claim 1, wherein the yarn also has flammable gel shedding ability.

12. A liquid shedding fire retardant and heat resistant fabric comprising: a plurality of liquid shedding fire retardant and heat resistant yarns (according to claim 1 that have been woven, knitted, or otherwise joined together into a fabric.

13. A liquid shedding fire retardant and heat resistant article of manufacture formed from the liquid shedding fire retardant and heat resistant fabric according to claim 11.

14. A liquid shedding fire retardant and heat resistant article of manufacture as defined in claim 12, wherein the article of manufacture is selected from the group consisting of clothing, jump suit, glove, sock, welding bib, fire blanket, padding, protective head gear, lining, undergarment, bedding, and drape.

15. A liquid-shedding fire retardant and heat resistant yarn, comprising: a fire retardant and heat resistant inner core comprised of polyacrylonitrile fibers and/or filaments;at least one fluorochemical at least partially impregnated within the inner core; andan outer liquid-shedding and strengthening shell encapsulating at least a portion of the inner core comprised of a liquid-resistant and strengthening silicone polymer coating,wherein the liquid-shedding fire retardant and heat resistant yarn has increased strength, abrasion resistance, durability and liquid shedding ability compared to a yarn consisting exclusively of the fire retardant and heat resistant inner core.

16. A liquid shedding fire retardant and heat resistant yarn as defined in claim 15, the fire retardant and heat resistant inner core further comprising one or more types of strengthening fibers and/or filaments selected from the group consisting of p-aramid, m-aramid, polybenzimidazole, polybenzoxazole, polyphenylene-2,6-benzobisoxazole, modacrilic, polyvinyl halide, wool, fire resistant polyester, nylon, rayon, cotton, and melamine.

17. A liquid-shedding fire retardant and heat resistant fabric, comprising: a plurality of liquid-shedding fire retardant and heat resistant yarn strands woven, knitted or otherwise joined together to form the fabric, wherein the fire retardant and heat resistant yarn strands are comprised of polyacrylonitrile fibers and/or filaments, wherein the fabric includes spaces between the yarn strands; anda liquid-shedding and strengthening shell encapsulating at least a portion of the yarn strands, wherein the liquid-shedding and strengthening shell is comprised of a liquid-resistant and strengthening polymer coating that is applied so that the fabric maintains spaces between the yarn strands and remains porous and breathable,wherein the liquid-shedding fire retardant and heat resistant fabric has increased strength, abrasion resistance, durability and liquid shedding ability compared to a fabric consisting exclusively of the fire retardant and heat resistant yarn strands.

18. A liquid shedding fire retardant and heat resistant fabric as defined in claim 17, the fire retardant and heat resistant yarn strands further comprising one or more types of strengthening fibers and/or filaments selected from the group consisting of p-aramid, m-aramid, polybenzimidazole, polybenzoxazole, polyphenylene-2,6-benzobisoxazole, modacrilic, polyvinyl halide, wool, fire resistant polyester, nylon, rayon, cotton, and melamine.

19. A liquid-shedding fire retardant and heat resistant fabric as defined in claim 17, wherein the liquid-resistant and strengthening polymer coating comprises at least one type of cured silicone polymer resin.

20. A liquid-shedding fire retardant and heat resistant fabric as defined in claim 17, further comprising at least one fluorochemical at least partially impregnated within the fire retardant and heat resistant yarn strands that further imparts liquid shedding capability to the liquid-shedding fire retardant and heat resistant yarn strands.

21. A liquid shedding fire retardant and heat resistant fabric as defined in claim 17, wherein the fabric forms at least part of an article of manufacture selected from the group consisting of clothing, jump suit, glove, sock, welding bib, fire blanket, padding, protective head gear, lining, undergarment, bedding, and drape.