(19) United States
`(12) Patent Application Publication (10) Pub. N0.2 US 2008/0299854 A1
`Hilleary et a].
`(43) Pub. Date:
`Dec. 4, 2008
`
`US 20080299854A1
`
`(54) FLAME RESISTANT SPACER FABRIC
`
`Publication Classi?cation
`
`(75) Inventors:
`
`Scott N. Hilleary, Spring City, TN
`(US); Howard Scroggins,
`Grandvlew, TN (US)
`
`Correspondence Address:
`ALSTON & BIRD LLP
`BANK OF AMERICA PLAZA, 101 SOUTH
`TRYON STREET, SUITE 4000
`CHARLOTTE, NC 28280-4000 (US)
`
`(73) Assignee:
`
`SSM Industries, Inc.
`
`(21) Appl. No.:
`
`11/756,850
`
`(22) Filed:
`
`Jun. 1, 2007
`
`(51) Int. Cl.
`2006.01
`B32B 5/02
`E200601g
`D02] 1/00
`(2006.01)
`D04B 1/00
`(52) US. Cl. ........................ .. 442/136; 264/103; 442/314
`(57)
`ABSTRACT
`The present invention provides a heat resistant spacer fabric
`comprising a ?rst and second fabric layers that are formed of
`a ?ame resistant material arranged in opposing face-to-face
`relation and are spaced apart from each other. The ?rst and
`second fabric layers are interconnected to each other With one
`or more spacer ?bers that interconnect the ?rst and second
`fabric layers and de?ne a space therebetWeen. The spacer
`?bers comprise at least one core ?ber having one or more
`Wrap ?bers of a ?ame resistant material Wrapped thereabout.
`The Wrap ?bers protect the core ?bers from direct contact
`With heat and ?ame. If the spacer fabric is exposed to heat/
`?ame, the ?ame resistant Wrap ?bers help to prevent any
`melted material of the core ?bers from ?oWing out of the
`spacer fabric. The spacer fabric can be used in protective
`garments such as coats, gloves, pants, cover-alls, suits, etc.
`
`IPR2017-00351
`Fredman EX1039 Page 1
`
`

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`IPR2017-00351
`Fredman EX1039 Page 2
`
`

`
`Patent Application Publication
`
`Dec. 4, 2008 Sheet 2 0f 4
`
`US 2008/0299854 A1
`
`FIG. 2A
`
`IPR2017-00351
`Fredman EX1039 Page 3
`
`

`
`Patent Application Publication
`
`Dec. 4, 2008 Sheet 3 0f 4
`
`US 2008/0299854 Al
`
`N
`N
`
`O
`
`4
`
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`
`%% gé
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`FIG. 2B
`
`IPR2017-00351
`Fredman EX1039 Page 4
`
`

`
`Patent Application Publication
`
`Dec. 4, 2008 Sheet 4 0f 4
`
`US 2008/0299854 A1
`
`FIG. 3
`
`IPR2017-00351
`Fredman EX1039 Page 5
`
`

`
`US 2008/0299854 A1
`
`Dec. 4, 2008
`
`FLAME RESISTANT SPACER FABRIC
`
`FIELD OF THE INVENTION
`
`[0001] The present invention relates generally to heat and
`?ame resistant fabrics and more particularly to a ?ame resis
`tant spacer fabric.
`
`BACKGROUND OF THE INVENTION
`
`[0002] Many Workers, such as ?remen, industrial Workers,
`forest ?re ?ghters, race car drivers and airplane pilots, have
`occupations that may expose them to environments and situ
`ations involving extreme heat and ?re. In such environments
`and/ or situations, safety is a paramount concern. Working in
`and around environments Wherein one is exposed to extreme
`heat and ?re continually subjects Workers to risks of being
`seriously burned or overcome by heat exposure, Which can
`cause heart attacks, strokes, dehydration and other injuries
`that very Well can be fatal. Accordingly, it is necessary to
`provide protective garments having a high degree of heat and
`?re resistance.
`[0003] To provide protection against heat and ?re, protec
`tive garments, such as ?re?ghter’s turnout coats, trousers,
`jackets, gloves, boots, hats, head coverings, masks, etc. have
`been developed that comprise fabrics formed of ?ame resis
`tant materials. Generally, these ?ame resistant fabrics com
`prise multilayers of fabric that are formed of ?ame resistant
`yarns that can be thick, heavy, and stiff. As a result, the
`protective garments can also be relatively heavy, bulky and
`someWhat in?exible.
`[0004] The Weight of ?ame resistant garments contributes
`to the stress to Which the Wearers are subjected, as the heavier
`the garment the more exertion that is required from the Wearer
`to move and Work in the garment. In general, manufacturers
`of ?ame resistant garments have tried to strike a balance
`betWeen providing a high a degree of ?ame and heat resis
`tance protection While limiting the Weight of such a garment
`so that a Worker can maintain an adequate level of mobility.
`[0005] Further, While such conventional ?ame and heat or
`thermal resistant fabrics generally have been adequate for
`protecting Workers against exposure to ?re and extreme heat,
`the stiffness and general in?exibility of such fabrics tends to
`cause another signi?cant problem, Which is the restriction of
`freedom of movement of a Worker While Wearing garments
`made from such fabrics. By restricting the freedom of move
`ment of the Wearer, further stress is placed upon and greater
`exertion is required from the Wearer in order to move and
`Work in the protective garments. This increased exertion fur
`ther increases the risk of injury to the Worker.
`[0006] Thus, there still exists a need for a ?ame resistant
`fabric that is relatively lightWeight and ?exible, While still
`providing adequate protection from heat and ?ame.
`
`BRIEF SUMMARY OF THE INVENTION
`
`[0007] The present invention provides a heat resistant
`spacer fabric that helps overcome many of the problems asso
`ciated With previous ?ame resistant fabrics. In particular, the
`present invention provides a ?ame resistant spacer fabric
`comprising at least a ?rst and second fabric layers that are
`formed of a ?ame resistant material and are arranged in an
`opposing back-to-back, spaced apart relationship With each
`other. The ?rst and second fabric layers are interconnected to
`each other With one or more spacer ?bers that interconnect the
`?rst and second fabric layers and de?ne a space therebetWeen.
`
`The spacer ?bers comprise a resilient material that is able to
`maintain the space betWeen the fabric layers, While still per
`mitting the layers to be reversibly compressed together. As a
`result, the spacer fabric provides a relatively light Weight and
`?exible fabric, While maintaining adequate protection to the
`Wearer from heat and ?ame.
`[0008] The spacer ?bers comprise at least one core ?ber
`having one or more Wrap ?bers of a ?ame resistant material
`Wrapped thereabout. The core ?bers generally comprise a
`resilient material that is capable of maintaining the space
`betWeen the ?rst and second fabric layers. Generally, the core
`?bers comprise a material that may not have a desired level of
`?ame resistance. To protect the core ?bers from direct contact
`With heat and ?ame, one or more ?ame resistant Wrap ?bers
`are Wrapped about the cores ?bers to substantially surround
`and encapsulate the core ?ber. The Wrapping of the ?ame
`resistant Wrap ?bers about the core ?ber forms a protective
`sheath or covering about the core ?bers. If the spacer fabric is
`exposed to heat/ ?ame that is in excess of the core ?ber’s
`melting temperature, the ?ame resistant Wrap ?bers help to
`prevent the melted material of the core ?bers from ?oWing out
`of the spacer fabric. This may be particularly useful in ?ame
`resistant articles, such as coats, pants, gloves, head coverings,
`race car driver jump suits, etc. Where the spacer fabric may be
`in close proximity to the Wearer.
`[0009] In one embodiment, the Wrap ?bers and the ?rst and
`second fabric layers comprise a ?ame resistant material that is
`able to Withstand elevated temperatures. Suitable ?ame resis
`tant materials for the Wrap ?bers and ?rst and second fabric
`layers may include aramids, ?ame resistant polynosic rayon,
`?ame resistant cotton, ?ame resistant polyester, polybenZimi
`daZole, polyvinyl alcohol, polytetra?uoroethylene, ?ame
`resistant Wool, poly(vinyl chloride), polyetheretherketone,
`polyetherimide, polyethersulfone, polychlal, polyimide,
`polyamide, polyimide-amide, polyole?n, polybenZoxaZole,
`?ame resistant acetone, carbon, graphite modacrylic, acrylic,
`melamine, polyoxodiaZole and combinations thereof.
`[0010] In one embodiment, the ?rst and second fabric lay
`ers may comprise a Warp pile fabric in Which one set of ?bers
`(e.g., Warp ?bers) interlace With a second set of ?bers (e.g.,
`?lling ?bers) to form the fabric. In this embodiment, the
`spacer fabric of the invention can be prepared in a double
`Weave process in Which the spacer ?bers are interlaced With
`one set of Warp ?bers and one set of ?lling ?bers Which form
`the ?rst fabric layer. The spacer ?bers are then interlaced With
`a second set of Warp ?bers and ?lling ?bers to form the second
`fabric layer. The spacer ?bers interconnect the ?rst and sec
`ond fabric layers together and de?ne the space therebetWeen.
`[0011] Thus, the present invention provides a ?ame resis
`tant spacer fabric that is ?exible and relatively lightWeight,
`While still maintaining adequate heat and ?ame resistance.
`
`BRIEF DESCRIPTION OF THE SEVERAL
`VIEWS OF THE DRAWING(S)
`[0012] Having thus described the invention in general
`terms, reference Will noW be made to the accompanying
`draWings, Which are not necessarily draWn to scale, and
`Wherein:
`[0013] FIG. 1 is a perspective vieW of a ?ame and heat or
`thermal resistant spacer fabric that is in accordance With the
`invention;
`[0014] FIG. 2A is a perspective vieW of a spacer ?ber that
`can be used in the construction of the spacer fabric depicted in
`FIG. 1;
`
`IPR2017-00351
`Fredman EX1039 Page 6
`
`

`
`US 2008/0299854 A1
`
`Dec. 4, 2008
`
`[0015] FIG. 2B is a perspective vieW of an alternative
`embodiment of a spacer ?ber that can be used in the construc
`tion of the spacer fabric depicted in FIG. 1;
`[0016] FIG. 3 is an illustration of a protective garment
`utilizing the spacer fabric depicted in FIG. 1.
`
`DETAILED DESCRIPTION OF THE INVENTION
`
`[0017] The present invention noW Will be described more
`fully hereinafter With reference to the accompanying draW
`ings, in Which some, but not all embodiments of the inven
`tions are shoWn. Indeed, these inventions may be embodied in
`many different forms and should not be construed as limited
`to the embodiments set forth herein; rather, these embodi
`ments are provided so that this disclosure Will satisfy appli
`cable legal requirements. Like numbers refer to like elements
`throughout.
`[0018] With reference to FIG. 1, a ?ame resistant spacer
`fabric in accordance With the invention is illustrated and
`broadly designated by reference number 1 0. As shoWn, spacer
`fabric 10 includes a ?rst fabric layer 12 and a second fabric
`layer 14 that are disposed opposite each other in a back-to
`back relationship and are spaced-apart from each other to
`form a three dimensional fabric. The spacer fabric includes
`one or more spacer ?bers 16 interconnecting tWo or more
`fabric layers and de?ning a space 18 therebetWeen. The one or
`more spacer ?bers are integrated With and extend betWeen the
`?rst and second fabric layers so that the ?rst and second fabric
`layers are maintained in a spaced apart parallel relation, While
`still permitting the layers to be reversibly compressible
`toWards each other.
`[0019] Although the illustrated embodiment, shoWs only
`tWo fabric layers, it should be recogniZed that the spacer
`fabric can include three or more fabric layers that are each
`interconnected to an adjacent fabric layers With one or more
`spacer ?bers. For example, the spacer fabric can include a
`three-layered structure in Which an interior fabric layer is
`interconnected to tWo opposing outer fabric layers With one or
`more spacer ?bers to de?ne a spacer fabric having a space
`disposed on opposite sides of the interior fabric layer.
`[0020] In some embodiments, the space 18 betWeen the ?rst
`and second fabric layers can help improve the thermal insu
`lating properties of the spacer fabric. For example, the space
`in the spacer fabric can be used to prevent heat from ingress
`ing into the interior surface of the fabric as Well as preventing
`heat, such as body heat, from escaping out of the fabric. As a
`result, the spacer fabric can be used to prepare articles that
`provide insulating properties for exposure to both heat and
`cold. Further, the space Within the fabric layer may permit the
`overall Weight of the spacer fabric to be reduced, While still
`maintaining a desired level of heat and ?ame resistance and
`insulating properties. Further, the resiliently compressible
`nature of the spacer fabric provides improvements in ?exibil
`ity, reduction in bulk, and overall improvements in comfort to
`the Wearer.
`[0021] The distance betWeen the ?rst and second fabric
`layers can be selected based on the desired properties of the
`resulting spacer fabric, for example, ?ame resistance, resil
`iency, bulk, stiffness, compressibility, softness, liveliness,
`?exibility, drapeability, comfort, and the like. Further, the
`distance betWeen the ?rst and second fabric layers can also be
`selected based, at least in part, on the intended use of the
`spacer fabric. For example, in apparel and protective garment
`applications the distance betWeen the ?rst and second fabric
`layers may range from about 1 mmto 80 mm, and inparticular
`
`from about 2 mm to 25 mm, and more particularly, from about
`4 to 10 mm. In some embodiments, the distance betWeen the
`?rst and second fabric layers is betWeen about 2 to 10 mm,
`and in particular betWeen about 3 to 8 mm. In other embodi
`ments, such as structural or industrial applications, the dis
`tance betWeen the ?rst and second fabric layers can be greater
`than 75 mm, and in particular, greater than 150 mm. It should
`be understood that the spacing distance betWeen the ?rst and
`second layers is not limited to any particular distance pro
`vided that the spacer fabric maintains the desired properties.
`[0022] The basis Weight of the spacer fabric may also be
`selected based on the intended use and desired properties of
`the fabric. In apparel and protective garment applications, the
`basis Weight of the spacer fabric may range from about 4.5 to
`20 oZs./yd2, and in particular from about 6 to 18 oZs./yd2. In
`structural and industrial applications, the spacer fabric may
`have a higher basis Weight, such as from about 6 to 50 oZs./
`yd2, and in particular from about 8 to 40 oZs./yd2.
`[0023] The orientation of the spacer ?bers With respect to
`the opposing inner surfaces of the ?rst and second fabric
`layers is generally selected so that the spacer ?bers are
`capable of reversibly maintaining the space betWeen the ?rst
`and second fabric layers. For example, the angle betWeen the
`spacer ?bers and the inner surfaces of the ?rst and second
`fabric layers can generally vary betWeen about 30° and 150°,
`With an average angle of about 45° to 135° betWeen someWhat
`more typical. In the embodiment illustrated in FIG. 1, the
`spacer ?bers 16 are generally oriented so that they are about
`90° With respect to the inner surfaces 26, 28 of the ?rst and
`second fabric layers 12, 14, respectively.
`[0024] As can best be seen in FIG. 2, spacer ?ber 16
`includes at least one core ?ber 20 about Which one or more
`Wrap ?bers 22 are Wrapped. Generally, the core ?ber com
`prises a material having su?icient resilience and stiffness so
`that the space betWeen the tWo fabric layers is maintained
`When the spacer fabric is in an uncompressed state. In one
`embodiment, the core ?ber may be made of a resilient mate
`rial such as mono?lament or multi?lament ?ber. In particular,
`the use of mono?lament ?bers has been shoWn to enhance the
`desirable characteristics of compressibility and resiliency in
`the spacer fabric. Suitable materials for the core ?ber may
`include polyester, nylon, acrylic, polypropylene, and the like.
`It should be understood that the term ?ber is used in its
`generic sense and may include ?bers, ?laments, yarns, and
`the like.
`[0025] The Wrap ?ber comprises a ?ame resistant material
`that is capable of Withstanding elevated temperatures and/or
`?ames Without melting or catching ?re. The Wrap ?ber sur
`rounds the core ?ber so that the core ?ber is substantially
`encapsulated Within the Wrap ?ber. The Wrapping of the ?ame
`resistant Wrap ?bers about the core ?ber forms a protective
`sheath or covering about the core ?bers. Generally, the mate
`rial comprising the core ?bers is selected based on the desired
`resiliency of ?bers and the ability of the ?bers to maintain the
`spaced-apart relation betWeen the ?rst and second fabric lay
`ers. Typically, such ?bers are selected based on a desired
`resiliency and may not have a desired level of ?ame resis
`tance. Since the core ?bers generally have a loWer resistance
`to heat and ?re than the Wrap ?bers and tend to degrade or
`melt from exposure to extreme temperatures and ?re, the
`Wrap ?bers protect the core ?ber from direct exposure to heat
`and ?ame and may prevent melting of the core ?ber in some
`situations.
`
`IPR2017-00351
`Fredman EX1039 Page 7
`
`

`
`US 2008/0299854 A1
`
`Dec. 4, 2008
`
`[0026] In the event the spacer fabric is exposed to heat/
`?ame that is in excess of the core ?ber’s melting temperature,
`the ?ame resistant Wrap ?bers help to prevent the melted
`material of the core ?bers from ?owing out of the spacer
`fabric. This may be particularly useful in ?ame resistant
`articles, such as coats, pants, gloves, head coverings, race car
`driver jump suits, etc. Where the spacer fabric may be in close
`proximity to the Wearer. With conventional spacer fabrics, a
`melted core ?ber can cause melt burns that can be more
`damaging to the Wearer than the initial heat source due to the
`enduring heat of the molten polymer and its proximity to the
`skin of the Wearer. The spacer ?bers can comprise a core spun
`?ber that is prepared using conventional methods such as ring
`spinning, rotor spinning, air jet spinning, and the like.
`[0027] The Wrap ?bers are Wrapped tightly about the core
`yarn at about 20 to 60 turns per inch, and in particular, about
`25 to 30 turns per inch. It also is possible for the Wrap ?bers
`to be Wrapped about the core ?bers in feWer or greater turns
`per inch as desired as long as the Wrap ?ber covers the core
`?bers to prevent exposure of the core ?bers to heat and ?ame.
`The number of Wraps generally depends on the siZe of the
`Wrap ?bers as the larger the Wrap ?ber, the feWer Wraps or
`tWists per inch are needed to ensure complete coverage. Fur
`ther, the number of turns per inch may also be dictated by the
`desired characteristics of the resulting spacer fabric, such as
`the characteristics discussed above. In some embodiments,
`tWo or more Wrap ?bers may be Wrapped about the core ?ber
`in a side-by-side relationship. In this regard, FIG. 2B illus
`trates an embodiment Wherein tWo Wrap ?bers 22, 22' are
`Wrapped about a core ?ber 20 in a side-by-side relation With
`respect to each other. In the illustrated embodiment, the tWo
`Wrap ?bers are shoWn as being Wrapped about the core ?ber
`in the same direction (e. g., clock Wise). In other embodi
`ments, the Wrap ?bers can be Wrapped in opposite directions
`With respect to each other, such as a counter-Wrap orientation.
`In a further embodiment, tWo or more layers of Wrap ?bers
`can be Wrapped about a core ?ber to produce a multi-layered
`spacer ?ber. Use of multiple layers can be used to further
`enhance the ability of the Wrap ?bers to contain molten mate
`rial from the core ?bers Within the spacer ?ber structure. In
`addition, the Wrap ?bers in such a multilayered spacer thread
`can be comprised of the same or a different composition With
`respect to each other.
`[0028] The siZe of the core ?bers is typically from about 15
`to 300 denier, and in particular from about 15 to 100 denier.
`The siZe of the Wraps ?bers in typically from about 20 to 400
`denier, and in particular from about 50 to 100 denier. Gener
`ally, the spacer ?bers have a siZe that is from about 30 to 500
`denier, and in particular from about 70 to 200 denier. In one
`particular embodiment, the spacer ?bers have a siZe that is
`about 167 denier and are comprised of tWo Wrap ?bers that
`each have a siZe that is about 50 denier and a core ?ber having
`a siZe that is about 30 denier.
`[0029] The ?rst and second fabric layers can comprise a
`Woven, knit or nonWoven fabric. The ?rst and second fabric
`can be Woven using a variety of different Weaving techniques,
`such as plain Weaving, tWill Weaving, satin Weaving, leno
`Weaving, pile Weaving, etc. In one particular embodiment, the
`?rst and second fabric layers can comprise a Woven fabric
`comprising a series of longitudinally extending ?bers (e.g.,
`Warp ?bers or yarns) and a series of laterally extending ?bers
`(e. g., ?lling or Weft ?bers or yarns). Generally, the longitudi
`nal and lateral ?bers are interWoven to form a lattice-like
`structure. As noted above, the ?bers comprising the ?rst and
`
`second fabric layer comprise a ?ame resistant material so that
`the resulting fabric layers are also ?ame resistant. The ?bers
`comprising the ?rst and second fabric layers may be the same
`or different from each other. Further, the longitudinal and
`lateral ?bers may be the same or different from each other.
`[0030] In one embodiment, the fabric layers (e.g., the ?rst
`and second fabric layers) comprise a Warp pile fabric in Which
`one set of ?bers (e.g., Warp ?bers) interlace With a second set
`of ?bers (e. g., ?lling ?bers) to form the fabric. Representative
`methods of forming Warp pile fabrics include Wire-cut pile,
`looped pile, and double Weave. As discussed in greater detail
`beloW, the spacer fabric of the invention can be prepared in a
`double Weave process in Which the spacer ?bers are interlaced
`With one set of Warp ?bers and one set of ?lling ?bers Which
`form the ?rst fabric layer. The spacer ?bers are then interlaced
`With a second set of Warp ?bers and ?lling ?bers to form the
`second fabric layer. The spacer ?bers interconnect the ?rst
`and second fabric layers together.
`[0031] Spacer fabrics in accordance With the invention can
`be prepared using conventional methods for preparing such
`fabrics. For instance, in one embodiment, the spacer fabric
`can be prepared by knitting a three-dimensional knit fabric on
`a double-needle bar Warp knitting machine, such as a Raschel
`Warp knitting machine. Generally, double needle bar Raschel
`Warp knitting machines are equipped With tWo independently
`operated needle bars fed With multiple Warps of yarn from a
`plurality of respective Warp beams through a corresponding
`plurality of yarn guide bars. In one embodiment, the spacer
`fabric can be prepared from ?ve or more sets of ?bers sepa
`rately Wound on individual Warp beams and fed to the tWo
`needle bars through a corresponding set of yarn guide bars,
`normally With at least tWo sets of ?bers fed through tWo
`corresponding guide bars exclusively to one of the needle
`bars to fabricate one of the fabric layers, at least tWo other sets
`of ?bers fed through other corresponding guide bars exclu
`sively to the other needle bar to fabricate the other fabric
`layer, and the remaining sets of ?bers (i.e., spacer ?bers) fed
`through one or more of the remaining available guide bars
`alternately to the tWo needle bars to extend betWeen and
`interknit With the tWo fabric layers and thereby to intercon
`nect and maintain the fabric layers in a spaced-apart essen
`tially parallel relation. In a further embodiment, the spacer
`fabric can be prepared using a double needle bar Raschel
`Warp knitting machines having 2 Warp beams and three guide
`bars.
`[0032] Spacer fabrics in accordance With the invention can
`comprise Weft knit fabrics including circular knit fabrics,
`?lling knit fabrics, ?at knit fabrics and the like. Weft knit
`fabrics can be formed on circular and ?at bed knitting
`machines. In one embodiment, the spacer fabric is formed
`from ?ame resistant ?bers that are interlooped to form the ?rst
`and second fabric layers. The ?ame resistant spacer ?bers
`may also be interlooped With the ?ame resistant ?bers of the
`fabric layers to form the spacer fabric.
`[0033] The siZe of the ?bers of the ?rst and second fabric
`layers are typically selected based on the desired level of heat
`and ?ame resistance of the spacer fabric, and the desired
`comfort, stiffness, and drapeability of the spacer fabric. For
`example, in apparel and protective garment applications the
`?bers comprising the fabric layer generally have a siZe
`betWeen about 20 to 600 denier, and in particular from about
`20 to 400 denier. In one particular embodiment, the ?bers
`comprising the fabric layer generally have a siZe betWeen
`about 80 to 200 denier. In structural and industrial applica
`
`IPR2017-00351
`Fredman EX1039 Page 8
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`

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`US 2008/0299854 A1
`
`Dec. 4, 2008
`
`tions, the ?bers comprising the fabric layer generally have a
`siZe between about 100 to 4,000 denier, and in particular from
`about 200 to 2,000 denier.
`[0034] Suitable ?ame resistant materials for the Wrap ?bers
`and ?rst and second fabric layers may include aramids, ?ame
`resistant cellulose rayon including ?ame resistant viscose
`rayon, such as polynosic rayon, ?ame resistant cotton, ?ame
`resistant cuprammonium, ?ame resistant lyocell, ?ame resis
`tant modal, ?ame resistant poly-lactic acid, ?ame resistant
`polyester, polybenZimidaZole, polyvinyl alcohol, polytet
`ra?uoroethylene, ?ame resistant Wool, poly(vinyl chloride),
`polyetheretherketone, polyetherimide, polyethersulfone,
`polychlal, polyimide, polyamide, polyimide-amide, polyole
`?n, polybenZoXaZole, ?ame resistant acetone, carbon, graph
`ite modacrylic, acrylic, melamine, polyoxodiaZole and com
`binations thereof. In one particular embodiment, the Wrap
`?bers and the ?rst and second fabric layers is formed from a
`?ame resistant material such as Kevlar® or Nomex® ?bers. A
`particularly useful ?ame resistant ?ber that may be used in the
`practice of the invention is described in Us. patent applica
`tion Ser. No. 11/389,783, entitled “FLAME RETARDANT
`TEXTILE FABRIC”, the contents of Which is hereby incor
`porated by reference in its entirety. The Wrap ?bers can be
`made of either the same or a different material from that of the
`?rst and second fabric layers. In one embodiment, the Wrap
`?bers and the ?bers of the ?rst and second layers comprise
`?ame materials, such as aramids and ?ame resistant cellulose
`?bers including cotton and viscose.
`[0035] The ?ame resistant spacer fabric of the present
`invention can be used to construct or form thermal/?ame
`protective garments, such as a ?re?ghters’ tum-out coat,
`pants, face shield, head-covering, gloves, one-piece coverall,
`race car driver jump suits, and the like. With reference to FIG.
`3 of a ?reman’s coat constructed in accordance With an
`embodiment of the present invention is illustrated and
`broadly designated as reference number 30. Fireman’s coat
`30 comprises an outer coat portion 32 Which forms an outer
`shell and an inner coat portion 34 that forms a detachable liner
`for the outer shell. The inner liner 34 typically comprises a
`thermal insulation material and the outer coat portion 32 is
`typically formed from the ?ame resistant spacer fabric of the
`present invention. The present invention can also be used to
`form either layer of the garment and also can be used to form
`single layer garments and other types of garments. In one
`embodiment, the coat 30 may also include one or more pock
`ets 36 disposed on opposite sides of the coat.
`[0036] The spacer fabric of the invention can also be used to
`prepare ?ame resistant fabrics for numerous applications,
`such as upholstery, mattress and pilloW ticking, mattress
`pads, bed spreads, pilloW covers, draperies or cubicle cur
`tains, Wall-coverings, WindoW treatments, and the like.
`[0037] Spacer fabrics in accordance With the invention can
`also be used in a Wide variety of industrial and/or structural
`applications. For example, the spacer fabric can be used in
`heat shield applications, insulation applications, such as ther
`mal insulation for automotive use, e. g., for insulating engine
`compartment, components, hoses and the like, as Well as
`fabric structures including architectural applications. The
`spacer fabric may also be used in body armor applications.
`[0038] Many modi?cations and other embodiments of the
`inventions set forth herein Will come to mind to one skilled in
`the art to Which these inventions pertain having the bene?t of
`the teachings presented in the foregoing descriptions and the
`associated draWings. Therefore, it is to be understood that the
`
`inventions are not to be limited to the speci?c embodiments
`disclosed and that modi?cations and other embodiments are
`intended to be included Within the scope of the appended
`claims.Although speci?c terms are employed herein, they are
`used in a generic and descriptive sense only and not for
`purposes of limitation.
`
`That Which is claimed:
`1. A ?ame resistant spacer fabric comprising:
`at least a ?rst and second fabric layers arranged in opposing
`back-to-back relation
`and spaced apart from each other, the ?rst and second fabric
`layers comprising a ?ame resistant material; and
`one or more spacer ?bers interconnecting the ?rst and
`second fabric layers and de?ning a space therebetWeen,
`the spacer ?bers comprising at least one core ?ber hav
`ing one or more Wrap ?bers of a ?ame resistant material
`Wrapped thereabout.
`2. The ?ame resistant spacer fabric of claim 1, Wherein the
`?rst and second layers each include an inner surface and
`Wherein the spacer ?bers are generally oriented at an average
`angle of about 45° to 1350 With respect to the inner surfaces.
`3. The ?ame resistant spacer fabric of claim 1, Wherein the
`distance betWeen the ?rst and second fabric layers is at least
`about 1 mm.
`4. The ?ame resistant spacer fabric of claim 1, Wherein the
`distance betWeen the ?rst and second fabric layers is betWeen
`about 2 to 8 mm.
`5. The ?ame resistant spacer fabric of claim 1, Wherein the
`core ?ber comprises a mono?lament comprising polyester,
`nylon, acrylic, polypropylene, or a combination thereof.
`6. The ?ame resistant spacer fabric of claim 1, Wherein the
`?ame resistant Wrap ?bers comprise aramids, ?ame resistant
`viscose rayon, ?ame resistant cotton, ?ame resistant polyes
`ter, polybenZimidaZole, polyvinyl alcohol, polytetra?uoroet
`hylene, ?ame resistant Wool, poly(vinyl chloride), poly
`etheretherketone,
`polyetherimide,
`polyethersulfone,
`polychlal, polyimide, polyamide, polyimide-amide, polyole
`?n, polybenZoXaZole, ?ame resistant acetone, carbon, graph
`ite modacrylic, acrylic, melamine, polyoxodiaZole, and com
`binations thereof.
`7. The ?ame resistant spacer fabric of claim 1, Wherein the
`?ame resistant Wrap ?bers comprise rayon, cuprammonium,
`lyocell, modal, viscose, cotton, aramid, or combinations
`thereof.
`8. The ?ame resistant spacer fabric of claim 1, Wherein the
`?rst and second layer comprise aramids, ?ame resistant vis
`cose rayon, ?ame resistant cotton, ?ame resistant polyester,
`polybenZimidaZole, polyvinyl alcohol, polytetra?uoroethyl
`ene, ?ame resistant Wool, poly(vinyl chloride), polyethere
`therketone, polyetherimide, polyethersulfone, polychlal,
`polyimide, polyamide, polyimide-amide, polyole?n, poly
`benZoXaZole, ?ame resistant acetone, carbon, graphite
`modacrylic, acrylic, melamine, polyoxodiaZole and combi
`nations thereof.
`9. The ?ame resistant spacer fabric of claim 1, Wherein the
`core ?bers are Wrapped With tWo or more of Wrap ?bers
`disposed in a side-by-side or counter