Flame resistant fabric having intermingles flame resistant yarns

A flame resistant fabric comprising:

• a plurality of warp elements comprising warp flame resistant (FR) yarns and intermingled FR yarns extending in a warp direction, wherein the warp FR yarns comprise a blend of nylon and FR-treated cotton fibers, and wherein the warp elements comprise between about 30 and 80% by number of yarns of intermingled FR yarns, and wherein the intermingled FR yarns and the warp FR yarns are arranged in an intermingled FR yarn:warp FR yarn alternating repeating pattern in the warp direction selected from the group consisting of 1:1, 2:1, 1:2, 2:2, 3:1, 2:3, 3:2, 3:3, 4:2, and 2:4;
• a plurality of filling elements comprising filling FR yarns extending in the fill direction transverse to the warp direction in interwoven relation to the warp elements and wherein the filling FR yarns comprise FR-treated cellulosic fibers;
• wherein the intermingled FR yarns comprise a length and at least three plies, wherein the first ply comprises continuous multifilament fibers, the second ply comprises staple FR fibers, and the third ply comprises staple FR fibers, wherein the first ply and the second ply have differential thermal shrinkage, wherein the intermingled FR yarns comprise distinct and discrete entanglement regions and non-entanglement regions along the length of the yarn, wherein in the entanglement regions the three plies are intermingled together where the staple fibers of the second and third plies are entangled in the continuous multifilaments of the first ply.

A flame resistant fabric comprising:

• a plurality of warp elements comprising warp flame resistant (FR) yarns and intermingled FR yarns extending in a warp direction, wherein the warp FR yarns comprise a blend of nylon and FR-treated cotton fibers, and wherein the warp elements comprise between about 30 and 80% by number of yarns of intermingled FR yarns, and wherein the intermingled FR yarns and the warp FR yarns are arranged in an intermingled FR yarn:warp FR yarn alternating repeating pattern in the warp direction selected from the group consisting of 1:1, 2:1, 1:2, 2:2, 3:1, 2:3, 3:2, 3:3, 4:2, and 2:4;
• a plurality of filling elements comprising filling FR yarns extending in the fill direction transverse to the warp direction in interwoven relation to the warp elements and wherein the filling FR yarns comprise FR-treated cellulosic fibers;
• wherein the intermingled FR yarns comprise a length and two plies, wherein the first ply comprises continuous multifilament fibers, and the second ply comprises staple FR fibers, wherein the first ply and the second ply have differential thermal shrinkage, wherein the intermingled FR yarns comprise distinct and discrete entanglement regions and non-entanglement regions along the length of the yarn, wherein in the entanglement regions the two plies are intermingled together where the staple fibers of the second ply are entangled in the continuous multifilaments of the first ply.