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  Blended outer shell fabricsUSPTO Application #: 20060084337Title: Blended outer shell fabrics Abstract: The present disclose relates to blended outer shell fabrics. In one embodiment, an outer shell fabric for use in firefighter turnout gear includes a plurality of yarns that comprise at least three different types of inherently flame resistant fibers. In another embodiment, a fabric includes a blend of inherently flame resistant fibers, the blend including a plurality of para-aramid fibers, a plurality of meta-aramid fibers, and a plurality of polybenzoxazole (PBO) fibers. (end of abstract) Agent: Thomas, Kayden, Horstemeyer & Risley, LLP - Atlanta, GA, US Inventors: Christopher Garrington Frank Corner, Stan Jewell USPTO Applicaton #: 20060084337 - Class: 442203000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material), Woven Fabric Is Characterized By A Particular Or Differential Weave Other Than Fabric In Which The Strand Denier Or Warp/weft Pick Count Is Specified The Patent Description & Claims data below is from USPTO Patent Application 20060084337. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND [0001] Firefighters typically wear protective garments commonly referred to in the industry as turnout gear. Turnout gear normally comprises various garments including, for instance, coveralls, trousers, and jackets. These garments usually include several layers of material including, for example, an outer shell that protects the wearer from flames, a moisture barrier that prevents the ingress of water into the garment, and a thermal barrier that insulates the wearer from extreme heat. [0002] Turnout gear outer shells typically comprise woven fabrics formed of one or two types of flame resistant materials. In addition to shielding the wearer from flames, the outer shells of firefighter turnout gear further provide abrasion resistance and protection from sharp objects. In that the outer shell must withstand exposure to flame and excessive heat, and must be resistant to abrasion and tearing, it must be constructed of a flame resistant material that is both strong and durable. [0003] The selection process for the materials used to construct outer shell fabrics, as with the selection process for other fabrics, often involves balancing various factors. Such factors include fabric performance as well as cost. For instance, outer shell fabrics that primarily comprise lower-performance fibers are normally less expensive than fabrics that include higher-performance fibers. Although the fabrics that comprise higher-performance fibers may provide greater protection, that protection comes at a greater cost, both to the manufacturer and the consumer. [0004] In view of the above, it would be desirable to be able to provide relatively inexpensive outer shell fabrics having performance that approaches or even exceeds that of more expensive outer shell fabrics. SUMMARY [0005] The present disclosure relates to blended outer shell fabrics. In one embodiment, an outer shell fabric for use in firefighter turnout gear includes a plurality of yarns that comprise at least three different types of inherently flame resistant fibers. [0006] In another embodiment, a fabric includes a blend of inherently flame resistant fibers, the blend including a plurality of para-aramid fibers, a plurality of meta-aramid fibers, and a plurality of polybenzoxazole (PBO) fibers. BRIEF DESCRIPTION OF THE DRAWINGS [0007] The disclosed fabrics can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. [0008] FIG. 1 is a rear view of an example protective garment that includes a blended outer shell fabric. [0009] FIG. 2 is a schematic representation of a blended outer shell fabric that can be used in the construction of the garment of FIG. 1. [0010] FIG. 3 is a schematic representation of an alternative blended outer shell fabric that can be used in the construction of the garment of FIG. 1. DETAILED DESCRIPTION [0011] As is described in the foregoing, it would be desirable to be able to provide relatively inexpensive outer shell fabrics having improved performance. As is described in the following, such a result can be achieved with certain blends of inherently flame resistant fibers. One such blend, for example, includes a blend of para-aramid, meta-aramid, and polybenzoxazole (PBO) fibers. As is described in greater detail below, such a blend provides unexpectedly desirable physical properties at a relatively low cost. [0012] FIG. 1 illustrates an example protective garment 100. More particularly, FIG. 1 illustrates a firefighter turnout coat that can be donned by firefighter personnel when exposed to flames and extreme heat. It is noted that, although a firefighter turnout coat is shown in the figure and described herein, embodiments of this disclosure pertain to protective garments and fabrics generally. Accordingly, the identification of firefighter turnout gear is not intended to limit the scope of the disclosure. [0013] As is indicated in FIG. 1, the garment 100 generally comprises an outer shell 102 that forms the exterior surface of the garment, a moisture barrier 104 that forms an intermediate layer of the garment, and a thermal liner 106 that forms the interior surface (i.e., the surface that contacts the wearer) of the garment. In that it forms the exterior surface of the garment 100, the outer shell 102 preferably is constructed so as to be flame resistant to protect the wearer against being burned. In addition, the outer shell 102 preferably is strong and durable so as to be resistant to abrasion and tearing during use in hazardous environments. [0014] FIG. 2 is a schematic detail view of an example blended outer shell fabric 200 that can be used in the construction of the protective garment 100, and more particularly the outer shell 102 shown in FIG. 1. It is noted, however, that the fabric 200 could be used in the construction of other protective garments either by itself or in combination with other fabrics. The example fabric 200 illustrated in FIG. 2 is a rip stop fabric that comprises a plurality of body yarns 206, including picks 202 and ends 204, and a plurality of rip stop yarns 208. Although a rip stop weave is illustrated in FIG. 2 and is described herein, it will be appreciated that other configurations could be used including, for instance, a plain weave, a twill weave, or a variation on a conventional rip stop weave (see, e.g., FIG. 3). [0015] Generally speaking, the fabric 200 comprises a blend of different inherently flame resistant materials. Typically, at least three different inherently flame resistant materials are used to construct the fabric 200 so as to obtain the distinct benefits of each, whether they be performance or cost benefits. By way of example, the yarns of the fabric 200, including one or more of the picks 202, ends 204, and rip stop yarns 208, comprise a blend of para-aramid fibers, meta-aramid fibers, and PBO fibers. [0016] Example para-aramid fibers include those that are currently available under the trademarks KEVLAR.RTM. (DuPont), and TECHNORA.RTM. and TWARON.RTM. (Teijin). Example meta-aramid fibers include those sold under the tradenames NOMEX T-450.RTM. (100% meta-aramid), NOMEX T-455.RTM. (a blend of 95% NOMEX.RTM. and 5% KEVLAR.RTM.), and NOMEX T-462.RTM. (a blend of 93% NOMEX.RTM., 5% KEVLAR.RTM., and 2% anti-static carbon/nylon), each of which is produced by DuPont. Example meta-aramid fibers also include fibers that are currently available under the trademarks CONEX.RTM. and APYEIL.RTM., which are produced by Teijin and Unitika, respectively. Example PBO fibers include ZYLON.RTM. from Toyobo.RTM.. [0017] It is noted that, for purposes of the present disclosure, when a material name is used herein, the material referred to, although primarily comprising the named material, may not be limited to only the named material. For instance, the term "meta-aramid fibers" is intended to include NOMEX.RTM. T-462 fibers, which, as is noted above, comprise relatively small amounts of para-aramid fiber and anti-static fiber in addition to fibers composed of meta-aramid material. [0018] While a tri-blend of para-aramid, meta-aramid, and PBO fibers has been explicitly identified, other inherently flame resistant materials can be added to the blend, if desired. Such other materials may, for example, include one or more of polybenzimidazole (PBI), melamine, polyamide, polyimide, polyimideamide, and modacrylic. [0019] Moreover, non-inherently flame resistant materials can be added to the blend, if desired. Examples of such materials include cellulosic fibers, such as rayon, acetate, triacetate, and lyocell. These cellulosic materials, although not naturally resistant to flame, can be rendered flame resistant, if desired. [0020] In cases in which para-aramid, meta-aramid, and PBO fibers are used to construct the fabric 200, the fabric can, for example, comprise about 40% to about 70% para-aramid, about 10% to about 40% meta-aramid, and about 5% to about 30% PBO. As is described below, one example blend is an approximately 60/20/20 blend of para-aramid fibers, meta-aramid fibers, and PBO fibers, respectively. Continue reading... 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