Fire resistant corespun yarn and fabric comprising same

A method of forming a fire resistant corespun yarn by air jet spinning, comprising:

• introducing a continuous core filament into an air jet spinning apparatus;
• introducing two or more different types of synthetic fibers into the air jet spinning apparatus, wherein a first type of the synthetic fibers is modacrylic fibers and a second type of the synthetic fibers is melamine fibers, and wherein the air jet spinning apparatus causes the synthetic fibers to wrap around the continuous core filament, thereby forming a first sheath surrounding the continuous core filament;
• and
• introducing staple fibers into the air jet spinning apparatus, wherein the air jet spinning apparatus causes the staple fibers to wrap around the synthetic fibers, thereby forming a second sheath surrounding the first sheath.

A method of forming a fire resistant corespun yarn by air jet spinning, comprising:

• introducing continuous multi-ply core filaments into an air jet spinning apparatus, wherein the filaments comprise a low temperature resistant continuous filament synthetic fiber selected from the group consisting of polyethylene, nylon, polyester and polyolefin, two-plied with a high temperature resistant fiberglass continuous filament;
• introducing two or more different types of synthetic fibers into the air jet spinning apparatus, wherein a first type of the synthetic fibers is effective to char and expand when exposed to open flame, and a second type of the synthetic fibers is a high temperature resistant, brittle fiber, and wherein the air jet spinning apparatus causes the synthetic fibers to wrap around the continuous core filament, thereby forming a first sheath surrounding the continuous core filament;
• and
• introducing staple fibers into the air jet spinning apparatus, wherein the air jet spinning apparatus causes the staple fibers to wrap around the synthetic fibers, thereby forming a second sheath surrounding the first sheath, wherein the second sheath staple fibers are of a material selected from the group consisting of cotton, wool, nylon, polyester, polyolefin, rayon, acrylic, silk, mohair, cellulose acetate, and blends thereof.

A method of forming a fire resistant corespun yarn by air jet spinning comprising:

• introducing a core comprising a high temperature resistant continuous filament fiberglass multi-plied with a low temperature resistant continuous filament synthetic fiber into an air jet spinning apparatus;
• introducing at least a first type of staple fiber which chars and expands when exposed to open flame and a second type of staple fiber which is a high temperature resistant, unstable brittle fiber to said air jet spinning apparatus so as to form a staple fiber blended sheath surrounding said core;
• and
• introducing a chopped staple fiber into said air jet spinning apparatus so as to form a chopped staple fiber sheath surrounding the staple fiber blended sheath.