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  Simulated rip stop fabricsUSPTO Application #: 20060089069Title: Simulated rip stop fabrics Abstract: Disclosed are simulated rip stop fabrics. In one embodiment, a simulated rip stop fabric includes a plurality of body yarns that form a body of the fabric, and a plurality of pseudo rip stop yarns that are provided individually in discrete portions of the fabric body so as to form a grid pattern, the psuedo rip stop yarns comprising at least three individual yarns that are plied together. (end of abstract) Agent: John S. Pratt, Esq Kilpatrick Stockton, LLP - Atlanta, GA, US Inventors: Michael Bruce Allen, Mike Creech USPTO Applicaton #: 20060089069 - Class: 442189000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material), Including Strand Which Is Of Specific Structural Definition The Patent Description & Claims data below is from USPTO Patent Application 20060089069. 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] In addition to shielding the wearer from flames, the outer shells of firefighter turnout gear further provide protection from sharp objects. In that the outer shell must withstand exposure to flame and excessive heat and must be resistant to tearing, it must be constructed of a flame resistant material that is both strong and durable. [0003] One common method for increasing the strength or tear resistance of a fabric, including outer shell fabrics, is to form what is called a rip stop weave. A rip stop weave is a weave that includes a grid of multiple ends and picks that are woven side-by-side along the fabric to reduce the propagation of tears and, therefore, increase the fabric strength. Common rip stop weaves include two-end and three-end rip stop weaves in which two or three ends/picks, respectively, are woven along with each other intermittently throughout the fabric. [0004] Although the provision of such rips increases the strength of the fabric, the rips can adversely affect the appearance of the fabric. For example, the rips can be higher tensioned during the weaving processes relative to the other yarns of the fabric, resulting in undesired puckering. Furthermore, the fibers of the rips can "fibrillate" at the cross-over points, i.e., the points in the fabric at which the rips of one direction of the fabric cross over the rips of the other direction of the fabric. Such fibrillation results in small fibrils being formed that extend from the shafts of the fibers in the rips. Those fibrils can create a frosted appearance for the fabric along the rip stop grid and, therefore, a non-uniform color across the fabric. [0005] In view of the above, it would be desirable to be able to produce outer shell fabrics, and other fabrics, that are highly tear resistant, but which are not rip stop fabrics. SUMMARY [0006] Disclosed are simulated rip stop fabrics. In one embodiment, a simulated rip stop fabric includes a plurality of body yarns that form a body of the fabric, and a plurality of pseudo rip stop yarns that are provided individually in discrete portions of the fabric body so as to form a grid pattern, the psuedo rip stop yarns comprising at least three individual yarns that are plied together. 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 simulated rip stop fabric. [0009] FIG. 2 is a schematic representation of a simulated rip stop fabric that can be used in the construction of the garment of FIG. 1. [0010] FIG. 3 is a schematic representation of a body yarn that can be used to construct the fabric of FIG. 2. [0011] FIG. 4 is a schematic representation of a first embodiment of a pseudo rip stop yarn that can be used to construct the fabric of FIG. 2. [0012] FIG. 5 is a schematic representation of a second embodiment of a pseudo rip stop yarn that can be used to construct the fabric of FIG. 2. DETAILED DESCRIPTION [0013] As is described in the foregoing, it would be desirable to be able to provide fabrics that are highly resistant to tearing, but that are not rip stop fabrics. As is described in the following, such a result can be achieved by substituting individual pseudo-rip stop yarns for the multiple rip stop yarns (or "rips") that are provided in typical rip stop weaves. Through such substitution, problems that may be encountered with rip stop weaves, such as puckering and color non-uniformity, can be reduced or avoided completely. As is described in greater detail below, the pseudo rip stop yarn can comprise a plied yarn having from 3 to 7 single yarns that are twisted together. [0014] 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 is described herein, embodiments of this disclosure pertain to garments and fabrics generally. Accordingly, the identification of firefighter turnout gear is not intended to limit the scope of the disclosure. [0015] 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. [0016] 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 garments, either by itself or in combination with other fabrics. The example fabric 200 illustrated in FIG. 2 is a plain weave fabric that simulates rip stop fabrics. Accordingly, the fabric 200 may be referred to as a simulated rip stop fabric. [0017] The fabric 200 comprises a plurality of body yarns 206, including picks 202 and ends 204, and a plurality of pseudo rip stop yarns 208. In some embodiments, the fabric 200 comprises a blend of inherently flame resistant materials. This blend can comprise a single type of inherently flame resistant fibers, or a blend of two or more different types of inherently flame resistant fibers. By way of example, the yarns of the fabric 200, including one or more of the picks 202, ends 204, and pseudo rip stop yarns 208, comprise a blend of para-aramid fibers and meta-aramid fibers. Example blends of those materials include blends that comprise about 40% to about 60% para-aramid, and about 40% to about 60% meta-aramid. For instance, one preferred embodiment comprises a 50/50 blend of para-aramid and meta-aramid fibers. [0018] 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 trademark CONEX.RTM., which is produced by Teijin. [0019] 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. [0020] While para-aramid and meta-aramid fibers have been explicitly identified above, other inherently flame resistant fibers may be used to construct the fabric, including, for example, polybenzoxazole (PBO), polybenzimidazole (PBI), melamine, polyamide, polyimide, polyimideamide, and modacrylic. Continue reading... Full patent description for Simulated rip stop fabrics Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Simulated rip stop fabrics patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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