Stretchable flame resistant fabric

DETAILED DESCRIPTION Briefly described, the present invention comprises a stretchable flame resistant fabric and garments made therefrom, so that the garments have thermal and flame resistance capabilities and also have an inherent stretch-ability and flexibility.
The fabric is formed from a series of warp yarns interwoven with a series of stretchable weft or filling yarns.
The warp yarns are formed of a flame and/or thermal resistant material, typically a blend of KEVLAR.
RTM.
, or similar aromatic polyamide fiber, and poly-benzimidazole (PBI).
For example, a KEVLAR.
RTM.
/PBI blend in a ratio of approximately 60% KEVLAR.
RTM.
to approximately 40% PBI has been found to provide heat and fire resistance properties in compliance with National Fire Protection Association safety standards for firefighter's bunker gear.
The warp yarns also can be formed from other types of flame resistant materials which, when woven into fabrics, comply with current national fire protection safety standards.
The weft or filling yarns each comprise a stretchable core yarn spirally wrapped or overspun with a series of wrap yarns or fibers.
The core yarns are formed from elastic materials such as spandex or rubber so as to enable the filling yarns to stretch along their lengths.
The wrap threads spun about the core yarns generally are formed from the same flame and/or heat resistant material as the warp yarns, i.
e.
a KEVLAR.
RTM.
/PBI or similar flame resistant material and protect the elastic core yarns from degradation or melting, when exposed to extreme temperatures and fire.
The wrap yarns/fibers are wrapped tightly about the core yarns, with the tightness of the wrapping being dependent upon the size of the core yarn, so as to leave substantially no space between the adjacent segments of the warp yarns, so as to shield the core yarn from exposure to the exterior atmosphere.
Typically, multiple plies/layers of wrap yarns/fibers are spun about the core yarn although a single wrap yarn can be spun about each core yarn if so desired