Flame Resistant Fiber Blends and Flame Resistant Yarns, Fabrics, and Garments Formed Thereof

A flame resistant fiber blend comprising:

• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the fiber blend;
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the fiber blend, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the fiber blend;
• wherein:
• the first weight percentage is 20 wt % to 45 wt % of modacrylic flame resistant fibers;
• the second weight percentage is 40 wt % to 75 wt % of non-flame resistant hydrophilic/absorbent fibers;
• and
• the third weight percentage is 5 wt % to 30 wt % of second flame resistant fibers.

A flame resistant yarn formed of a flame resistant fiber blend, the flame resistant fiber blend comprising:

• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the yarn;
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the yarn, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the yarn.

A flame resistant yarn formed of a flame resistant fiber blend, the flame resistant fiber blend comprising:

• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the yarn;
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the yarn, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the yarn;
• wherein
• the first weight percentage is 20 wt % to 45 wt % of modacrylic fibers;
• the second weight percentage is 40 wt % to 75 wt % of hydrophilic/absorbent fibers;
• and
• the third weight percentage is 5 wt % to 30 wt % of second flame resistant fibers.

A flame resistant fabric formed of a fiber blend, the fiber blend comprising:

• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the fabric;
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second percentage of the fabric, wherein the second weight percentage is greater than the first percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the fabric.

A flame resistant fabric formed of a fiber blend, the fiber blend comprising:

• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the yarn;
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the yarn, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the yarn;
• wherein
• the first weight percentage is 20 wt % to 45 wt % of modacrylic flame resistant fibers;
• the second weight percentage is 40 wt % to 75 wt % of hydrophilic/absorbent fibers;
• and
• the third weight percentage is 5 wt % to 30 wt % of second flame resistant fibers.

A flame resistant composite fabric comprising:

• a first flame resistant fabric layer;
• a second flame resistant fabric layer;
• and
• a barrier layer bonding the first flame resistant fabric layer to the second flame resistant fabric layer,
• wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of a fiber blend, the flame resistant fiber blend comprising:
• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the fiber blend,
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the fiber blend, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the fiber blend;
• and
• the composite layer is capable of withstanding temperature of 500° F. for at least 5 minutes without substantial change in the dimensional integrity of the flame resistant composite fabric.

A flame resistant composite fabric, the fabric comprising:

• a first flame resistant fabric layer;
• a second flame resistant fabric layer;
• and
• a barrier layer bonding the first flame resistant fabric layer to the second flame resistant fabric layer,
• wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of a flame resistant fiber blend comprising:
• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the fiber blend,
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the fiber blend, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the fiber blend;
• and
• the barrier layer is capable of withstanding temperature of 500° F. for at least 5 minutes without substantial change in the dimensional integrity of the flame resistant composite fabric;
• wherein:
• the first weight percentage is 20 wt % to 45 wt % of modacrylic flame resistant fibers;
• the second weight percentage is 40 wt % to 75 wt % of hydrophilic/absorbent fibers;
• and
• the third weight percentage is 5 wt % to 30 wt % of second flame resistant fibers.

A flame resistant composite fabric comprising:

• a first flame resistant fabric layer;
• a second flame resistant fabric layer;
• and
• a barrier layer bonding the first flame resistant fabric layer to the second flame resistant fabric layer,
• wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of a fiber blend, the flame resistant fiber blend comprising:
• a plurality of modacrylic fibers comprising a first weight percentage of the fiber blend,
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the fiber blend, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the fiber blend;
• and
• wherein the flame resistant composite fabric offers protection from electric arc flash hazards and/or from flash fire hazards in accordance with one or more of the following National Fire Protection Association standards:
• NFPA 70E (2012 Ed.), NFPA 1975 (2009 Ed.), NFPA 1977 (2011 Ed.), NFPA 1951 (2007 Ed.), and NFPA 2112 (2012 Ed.).

A flame resistant composite fabric of, comprising

• a first flame resistant fabric layer;
• a second flame resistant fabric layer;
• and
• a barrier layer bonding the first flame resistant fabric layer to the second flame resistant fabric layer,
• wherein at least one of the first flame resistant fabric layer and the second flame resistant fabric layer is formed of a fiber blend, the flame resistant fiber blend comprising:
• a plurality of modacrylic fibers comprising a first weight percentage of the fiber blend,
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the fiber blend, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the fiber blend;
• wherein:
• the first weight percentage is 20 wt % to 45 wt % of modacrylic fibers;
• the second weight percentage is 40 wt % to 75 wt % of hydrophilic/absorbent fibers;
• and
• the third weight percentage is 5 wt % to 30 wt % of second flame resistant fibers.

A flame resistant garment formed of a flame resistant fiber blend, the flame resistant fiber blend comprising:

• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the garment;
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the garment, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the garment.

A flame resistant garment formed of a flame resistant fiber blend, the flame resistant fiber blend comprising:

• a plurality of modacrylic flame resistant fibers comprising a first weight percentage of the garment;
• a plurality of non-flame resistant hydrophilic/absorbent fibers comprising a second weight percentage of the garment, wherein the second weight percentage is greater than the first weight percentage;
• and
• a plurality of second flame resistant fibers comprising a third weight percentage of the garment;
• wherein:
• the first weight percentage is 20 wt % to 45 wt % of modacrylic flame resistant fibers;
• the second weight percentage is 40 wt % to 75 wt % of hydrophilic/absorbent fibers;
• and
• the third weight percentage is 5 wt % to 30 wt % of second flame resistant fibers.