This invention relates to fire resistant textile materials and garments made from these materials. The invention relates particularly but not exclusively to articles of clothing for use by fire fighters and for textiles for manufacture of such clothing.

European legislation requires employers to provide garments which protect their employees against hazards to which they may be exposed. Clothing for protection against heat and flame must pass minimum performance requirements for flame, radiant heat, heat resistance, tensile and tear strength, abrasion resistance and penetration by water and liquid chemicals. The assembled garments must achieve levels of resistance to heat transfer by both flame and radiant heat.

One of the most effective ways to reduce second and third degree burns is to make sure that the barrier of protective clothing between the heat source and the skin remains intact during exposure. This is referred to as the break open resistance or non-break open protection.

US 6699802 discloses a fire resistant textile material comprising a woven face fabric composed of meta-aramid fibres including a woven mesh of low thermal shrinkage fibres, for example para-aramid fibres.

An object of the present invention is to provide a fire resistant textile material with reduced weight, increased drape and improved comfort in use.

According to the present invention a fire resistant textile material is composed of woven fabric having a face surface and a back surface, the fabric comprising:

polyparaphenylene isophthalamide (meta-aramid) fibres; and

a blend of cellulose fibres and wool fibres.

wherein the meta-aramid fibres are predominantly located on the face surface and the blend of cellulose fibres and wool fibres is predominantly located on the back surface. The term "predominantly" refers to an amount of 60% or more, preferably 75% or more, by yarn count.

A preferred polyparaphenylene isophthalamide (meta-aramid) is Nomex (Registered Trade Mark). A particularly preferred fibre comprises 95% Nomex, 3% Kevlar (Registered Trade Mark) and 2% antistatic (P 140) fibres. Alternatively, meta/para aramid blends such as TypeT450 (DuPont) may be employed.

A preferred polyparaphenylene isophthalamide (meta-aramid) fibre may comprise Nomex (Registered Trade Mark). Alternative fibres may comprise polybenzimidazole (PBI), poly(paraphenylenbenzobisoxazole) (PBO) or blends thereof.

A preferred cellulose fibre is a fire retardant viscose fibre. This may be manufactured from wood pulp treated with a fire retardant. Lenzing FR. 2.2 Decitex fibres are preferred.

Preferred wool fibres are shrink resistant wool fibres preferably with a thickness about 15.5 μηι to about 29.5 μιτι, more preferably 20.8 μιτι. The blend may comprise from 25% wool and 75% cellulose to 75% wool and 25% cellulose, preferably about 50% wool and about 50% cellulose.

Preferred fabric materials consist of a face and a back, wherein the face of the fabric consists of meta-aramid and optional further fibres and the back of the fabric consists of cellulose fibres and wool fibres and optional meta-aramid fibres.

The fabric is preferably a woven twill ripstop.

A preferred fabric may be a 2 x 1 twill ripstop, a 3 x 1 twill ripstop or a 4 x 1 twill ripstop. Alternatively, a satin fabric, having the warp on the surface, may be employed. A fabric in accordance with this invention is particularly suited for use in a single layer or in direct contact with a wearer's skin in a multilayer garment, that is in garments wherein a lining is not present.

The use of meta-aramid, generally having thicker yarns on the back, raises the fabric structure from the skin to provide an air layer, thereby increasing comfort and thermal protection for a wearer. The fabric creates a microclimate utilising the benefits of the hygrophilic properties of wool to help regulate temperature and humidity against a wearer's skin.

Preferred fabrics have more than 50% meta-aramid fibres on the face, more preferably more than 75% on the face.

The number of threads or the weight of the warped yarns in relation to the weft yarns may be adjusted to achieve a desired percentage of meta-aramid on the face surface. Either the warp or weft may predominate, as convenient.

In a preferred embodiment, the fabric may comprise a ripstop, preferably a 2 x 1 ripstop twill having a warp comprising meta-aramid or a blend thereof with other fibres, for example Nomex T450 with a warp count of Nm 60/2.

In a preferred fabric the weft may comprise a wool-cellulose blend with a weft count of Nm 60/2 (that is, two 60 Nm yarns twisted together) and Nm 40/2/2 (two 40 Nm yarns twisted together and two of the resultant yarns twisted together) Nomex, with maximum weft mixing. Use of such a yarn affords minimal contact with a wearer's skin.

Use of a 2 x 1 twill allows an excess of meta-aramid, for example Nomex or blends thereof, in the warp to be provided on the fabric face. A ripstop is provided in the warp & weft combination. Use of a ripstop affords good tear resistance and reduced surface contact in comparison to other fabrics. Dimensional stability is enhanced. Increased durability to washing may also be obtained. Double twisted yarns may be employed. The warp may have a yarn count in the range of Nm 20/2 to 100/2, preferably Nm 30/2 to 80/2, more preferably Nm 40/2 to 60/2, especially Nm 60/2. When using Nm 60/2 the number of warp ends may be 4500 to 5600, typically 5168.

A preferred fabric weight may be 200 to 300, typically 240g/m .

A fabric in accordance with the present invention confers several advantages. The water absorbing or hydrophilic properties of wool combined with excellent working properties of the cellulose fibres ensures efficient transfer of moisture away from a wearer's skin. The moisture is retained by the buffering effect of the wool by absorption and desorption before evaporation to maintain cool and dry wearing conditions during use. Lenzing (FR) and wool affords excellent thermal protection by absorption of heat energy with break open protection provided by the meta-aramid fibres. Wool also provides inherent antimicrobial and antistatic properties to make the garment comfortable even after prolonged wearing or repeated washing or laundering.

Water is released during thermal decomposition of a meta-aramid surface layer upon exposure to high heat energy. This water may be absorbed by the underlying wool fibres. Evaporation of this moisture may enhance thermal protection of a user's skin.

Thermal regulation is improved in warm dry conditions due to the unique blend of wool / Lenzing and para-aramid fibres. The natural hydrophilic properties of wool facilitate vapour or moisture absorption and desorption in low relative humidity climates. The hygrophilic properties of Lenzing fibres serve to push moisture away. The fabric therefore serves as a heat exchanger and regulator.

The unique blend of the fibres and yarns gives the fabric breathable buffer and thermal barrier properties which assist in keeping the wearer comfortable and avoids a liability to suffer from heat fatigue as commonly encountered with previously used products.. The primary use of the fabric is a moisture management system coupled with a barrier to both radiant and convective heat extremes. These fabrics are particularly suited for use during wildland fire fighting. Other uses include Level 1 stationware and high voltage electrical engineering applications.

Tear Strength is increased due to the unique network of meta aramid fibres (which may be referred to as "tram lines") acting as strengthening support beams in the fabric structure and making it more durable and stable dimensionally.

When the face of the fabric is exposed to extreme heat and a consolidation occurs due to the nature of the aromatic fibres the heavier weft yarns (tram lines) act as a support to the fabric not only in providing dimensional stability but assists in the crimping effect of the structure thus getting volume into the structure. This property creates an increase in the thermal barrier protection by absorbing some of the energy on exposure and has less surface contact with the wearer.

The invention is further described by means of example, but not in any limitative sense, with reference to the accompanying drawings, of which:

Figure 1 is a weaving plan of a fabric in accordance with this invention; and Figure 2 is a plan view of the fabric in accordance with this invention.

Example 1

The fabric comprises warp A consisting of meta-aramid (Nomex)/para- aramid (Kevlar) yarn). Weft A is a wool/Lenzing yarn and Weft B is a meta-aramid (Nomex) yarn. The Weft A (Kevlar) yarns are each located between two Weft B (Nomex) yarns. The Weft B yarns are separated by 6 Weft A wool/Lenzing yarns to form a 2x1 twill ripstop fabric.

Example 2

The fabric comprises warp A consisting of a PBI/para-aramid blend yarn. Weft A is a wool/Lenzing yarn and Weft B is a meta-aramid (Nomex) yarn. The construction is the same as for Example 1. Example 3

The fabric comprises warp A consisting of a PBI/para-aramid blend yarn. Weft A is a wool/Lenzing yarn and Weft B is a meta-aramid (Nomex) yarn. The construction is the same as for Example 1. Warp A consists of PBO/para-aramid blend yarns.

Example 4

The fabric comprises warp A consisting of meta-aramid (Nomex)/para- aramid (Kevlar) yarn). Weft A is a wool/Lenzing yarn and Weft B is a meta-aramid (Nomex) yarn. The Weft A (Kevlar) yarns are each located between two Weft B (Nomex) yarns. The Weft B yarns are separated by 6 Weft A wool/Lenzing yarns to form a 2x1 twill ripstop fabric. Warp A consists of a meta-aramid/para-aramid blend including 2% of anti-static carbon fibre.