DESC:TECHNICAL FIELD
[001] The present invention relates to a method of manufacturing a diamond weaved flame-retardant protective textile material for example a fabric, a garment, and an apparel. Particularly, the invention relates to a fibre blend flame-retardant protective diamond weave woven fabric to provide protection against heat and flame, welding and allied processes, electric arc, electrostatic discharge and simultaneously provide an improved modern aesthetic appearance.

BACKGROUND
[002] Generally, in industries like oil refineries, petrochemicals, electrical industries, and utility sector typically personnel work in environments where hazards due to flame and electric arc are possible and therefore personnel require wearing flame-retardant protective clothing to protect from hazards. The existing flame-retardant protective clothing is mainly focused on flame resistant property of the clothing and has limitations regarding functionality, comfort, breathability, and aesthetic property provided to wearer. Also, the existing flame-retardant protective clothing is typically worn only during a 9 to 5 workday and limitedly does not provide comfortable feel, a smart stylish fashionable appearance when worn after a workday.
[003] Therefore, there is a need for a flame-retardant protective textile material to overcome one or more of the aforementioned problems.

SUMMARY
[004] Accordingly, an exemplary first aspect of the present invention discloses a flame-retardant protective woven fabric comprising a plurality of warp and weft yarns interlaced for forming a diamond weave woven fabric and each said warp and weft yarn is blended yarn having a configuration of 50%-60% cellulosic fibres, 30%-40% meta-aramid fibres, 10%-15% polyamide fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric.
[005] According to an exemplary second aspect, the present invention discloses a flame-retardant protective woven fabric comprising a plurality of warp and weft yarns interlaced for forming a diamond weave woven fabric and each said warp and weft yarn is blended yarn having a configuration of 90%-95% meta-aramid fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric.
[006] According to still another aspect, the present invention discloses methods for manufacturing a flame-retardant protective woven fabric according to the first and the second aspect of the present invention comprising the steps of: a) blending fibres in a blend proportion comprising 50%-60% cellulosic fibres, 30%-40% meta-aramid fibres, 10%-15% polyamide fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric or blending fibres in a blend proportion comprising 90%-95% meta-aramid fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric to form a plurality of warp and weft yarns; b) spinning the plurality of blended warp and weft yarns; c) warping, weaving by interlacing said blended warp and weft yarns to form a diamond weave woven fabric; d) a wet processing treatment comprising pre-treating woven greige fabric in a washer, dyeing of pre-treated woven greige fabric followed by washing and finishing of the dyed diamond weave woven fabric; and e) garmenting the flame-retardant protective diamond weave woven fabric.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[007] The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:
[008] Figure 1 illustrates a diamond weave structure of a flame-retardant protective woven fabric, according to an exemplary aspect of the present invention; and
[009] Figure 2 illustrates a method of manufacturing the diamond weave structure of a flame-retardant protective woven fabric, according to another exemplary aspect of the present invention.
[010] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to the other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that reference signs are used to depict the same or similar elements, features, and structures.

DETAILED DESCRIPTION
[011] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail, a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspects of the invention to the embodiment illustrated. Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention. Embodiments of the present disclosure will now be described with reference to the accompanying drawings. Embodiments are provided to convey the scope of the present disclosure thoroughly and fully to a person skilled in the art. Numerous details are set forth relating to specific components to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
[012] In general, the present invention discloses a flame-retardant protective woven fabric and method for manufacturing the same comprising a plurality of warp and weft yarns interlaced for forming a diamond weave woven fabric with a blended configuration. The diamond weave is formed by an interlacement of a plurality of blended warp and weft yarns diagonally extending at a right-hand side (R) and at a left-hand side (L) of said woven fabric.
[013] The exemplary flame-retardant protective woven fabric provides protection against hazards occurring due to heat and flame, welding and allied process, electric arc, and electrostatic discharge. The woven fabric provides strength, durability along with the incorporation of better comfort, feel, functionality, breathability, and improved stylish aesthetic appearance. Garment and apparels may be manufactured using the exemplary flame-retardant protective woven fabric.
[014] In an exemplary implementation of the present invention, the weight of the woven fabric may be in the range that include but not limited to 150 gsm to to 300 gsm, and the yarn count of the plurality of blended warp and weft yarns may be in the range that include but not limited to 2/24 Ne to 2/40 Ne. The diamond-weaved woven fabric is breathable and comfortable in nature.
[015] According to the exemplary implementation of the present invention, the diamond weaved flame-retardant woven fabric provides resistance to flammability along with the incorporation of better comfort, feel, improved aesthetic appearance without compromising the strength and durability of fabric. The flame-retardant fabric may comprise cellulosic and inherently flame-retardant fibres that provides good performance, feel and comfort and the diamond weave design provide a stylish outlook.
[016] The terminology used in the present disclosure is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results. As used in the present disclosure, the forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated elements, units and/or components, but do not forbid the presence or addition of one or more other elements, components, and/or groups thereof.
[017] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. Accordingly, it should be apparent to those skilled in the art that the following description of the diamond weaved flame-retardant woven fabric referred in the description for the purpose of the understanding and nowhere limit the invention. The skilled person will be able to devise various compositions, patterns of the diamond weaved flame-retardant woven fabric that, although not explicitly described herein, embody the principles of the present invention. All the terms and expressions in the description are only for the purpose of understanding and nowhere limit the invention. Terms like at least plurality, first, second, left, right, are used to differentiate between objects having the same terminology and are in no way intended to represent a chronological order, unless where explicitly stated otherwise. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass equivalents thereof. Thus, while specific type, patterns, composition of the structure of the diamond weaved flame-retardant woven fabric with desired configuration, shape, heights, dimensions, lengths, widths, manufacturing methods, have been disclosed, nowhere limit the invention, and are provided for understanding of the invention. It will be appreciated those of ordinary skill in the art that various changes and modifications of the embodiments manufactured with other design parameters and configurations as well and are not limited to those described herein above may be as per operational requirements by making necessary changes without departing from the scope of the invention.
[018] Figure 1 to 2 illustrate a flame-retardant woven fabric / diamond weave woven fabric (100), diamond weaved structure (D), left (L), right (R), and method (200).
[019] Referring Figure 1 illustrates an exemplary diamond weave structure (D) of a flame-retardant protective woven fabric (100) of the present invention. The diamond weave structure (D) is a derivative of a twill weave, which is formed by an interlacement of plurality of blended warp and weft yarns. The combination of diagonally extended twill lines at a right-hand side (R) and at a left-hand side (L) forms the diamond weave structure (D). The right-hand side (R) and the left-hand side (L) diagonal twill lines are extended to form the diamond shaped weave design. The woven fabric has a sheen and lustrous look due to the presence of the diamond weave.
[020] According to a first exemplary aspect, the present invention discloses the flame-retardant protective woven fabric (100) a plurality of warp and weft yarns interlaced for forming a diamond weave woven fabric (100) and each said warp and weft yarn is blended yarn having a configuration of 50%-60% cellulosic fibres, 30%-40% meta-aramid fibres, 10%-15% polyamide fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100). The cellulosic fibre of blended yarn is selected from a group of fibres that includes but not limited to cotton, or a flame- resistant viscose, or a tencel, or a rayon, or a modal or a combination thereof.
[021] According to a second exemplary aspect, the present invention discloses the flame-retardant protective woven fabric (100) comprising a plurality of warp and weft yarns interlaced for forming a diamond weave woven fabric (100) and each said warp and weft yarn is blended yarn having a configuration of 90%-95% meta-aramid fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100). However, it is understood that the weight percentage of the fibres may vary as per alternative embodiments of the present invention.
[022] According to exemplary embodiments of the present invention, the weight of the diamond weave woven fabric (100) is in the range of 150 gsm to 300 gsm, and a yarn count of the plurality of blended yarns is in the range of 2/24 Ne to 2/40 Ne. The double count imparts good lustre and strength while maintaining the same resultant count as the single count.
[023] According to exemplary embodiments of the present invention, the diamond weaved flame-retardant protective woven fabric (100) complies with requirements of EN ISO 15025, EN ISO 11612, EN ISO 11611, EN ISO 1149-5 and EN ISO 61482-2. The diamond weaved flame-retardant protective woven fabric (100) has a moisture vapour transmission rate (MVTR) of more than 1500 gm/m2 /day complying with requirements of ASTM E-96-05 and an arc thermal performance value (ATPV) of more than 5 cal/cm2 complying with requirements of EN ISO 61482-1-1 and EN ISO 61482-1-2.
[024] According to another exemplary aspect, referring Figure 2, the present invention discloses a method (200) for manufacturing a flame-retardant protective woven fabric (100). The manufacturing method comprises the steps of blending (210), spinning process (220), weaving process (230), wet processing (240), and garment making (250). According to an exemplary embodiment of the present invention, in the step of blending (210) process, various types of fibres in anyone of the following blend proportions are configured to form a plurality of warp and weft yarns i.e., a first blend proportion (210a) comprising of: 50%-60% cellulosic fibres, 30%-40% meta-aramid fibres, 10%-15% polyamide fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100) or a second blend proportion (210b) comprising of: 90%-95% meta-aramid fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100).
[025] According to the exemplary embodiment of the present invention, after blending process (210), the method includes spinning process (220). In the process of spinning (220), yarn formation occurs from fibres. According to the end requirement, different types of polymers are blended to provide various properties. The spinning process (220) produces a plurality of intimate blended warp and weft yarns with a yarn count of about 2/24 Ne to 2/40 Ne, and then the blended warp and weft yarns are passed to weaving process (230). The weaving process (230) includes (230a) warping and (230b) weaving by interlacing said blended warp and weft yarns to form a diamond weave woven fabric (100) at a weight of about 150 gsm to 300 gsm. After the weaving process (230), the diamond weave woven fabric undergoes a wet processing treatment (240) comprising (240a) pre-treatment, dyeing (240b), and finishing (240c) to make flame-retardant garments at garment making (250) process. The fabric is breathable and comfortable in nature.
[026] According to the exemplary embodiment of the present invention, the weaving step (230) includes two processes such as warping (230a) and weft preparation process and weaving (230b). The warping and weft preparation process (230a) of plurality of blended yarn produces warp and weft yarn. These warp and weft yarns are interlaced and weaved by weaving process (230b) in an air jet loom to produce a woven fabric in diamond weave structure (D) of woven fabric (100).
[027] According to the exemplary embodiment of the present invention, the diamond weaved woven fabric (100) is then passed to a wet processing step (240) that includes three processes such as pre-treatment (240a), dyeing (240b), and finishing (240c). In the pre-treatment process (240a) the woven greige fabric is pre-treated in a washer which removes the impurities and improves absorbency property of woven fabric to make it suitable for dyeing (240b) followed by a finishing (240c) process of the dyed woven diamond weaved fabric (100). After pre-treatment (240a), in the next step, the pre-treated greige woven fabric (100) is passed into dyeing (240b) process using cold pad batch machine followed by washing, if dyeing is required. In the next step, the dyed diamond weave woven fabric (100) is passed into finishing process (240c). Finishing (240c) of dyed diamond weave woven fabric (100) is done using at least any one of the chemical finishes that include not limited to an oil repellent, a water repellent, an antimicrobial finish, and a stain release finish as per the requirement. Then the finished diamond weave fabric (100) is passed to the final garmenting making (250) process that includes the preparation of flame-retardant garments or apparels from the finished diamond weave woven fabric (100).
[028] The present invention provides flame-retardant fabric/garment/apparel which protect against heat, flame, welding, reduces static charge generation, and consequent fire hazards associated with static build up. The flame-retardant fabric/garment/apparel of the present invention resists the transfer of energy when exposed to the intense thermal stress of an electrical arc. The flame-retardant fabric/garment/apparel reduces energy transfer by absorbing a portion of the incident energy and through charring which allows for a reduction in transmitted energy.
[029] In general, “Arc Thermal Protective Value” (ATPV) refers to the maximum incident energy (in calories per centimetre squared) that protective equipment can be exposed to and prevents onset of a second-degree burn. A Hazard Risk Category (HRC) level is determined by the minimum number of calories per square centimetre (ATPV or cal/cm2). Any protective garment must pass through with a 50% probability of a 2nd or 3rd degree burn occurring, through which the protective level of the protective clothing is determined. The higher the ATPV, the higher the HRC level attained and greater is the protection that is needed. Typical HRCs are given below:
HRC 1: 4 cal/cm2 = ATPV < 8 cal/cm2
HRC 2: 8 cal/cm2 = ATPV < 25 cal/cm2
HRC 3: 25 cal/cm2 = ATPV < 40 cal/cm2
HRC 4: 40 cal/cm2 = ATPV
[030] According to the exemplary embodiment of the present invention, the diamond weaved flame-retardant protective woven fabric (100) described herein complies with standards such as EN ISO 15025 (Limited Flame Spread test), EN ISO 11612 (Heat and Flame), EN ISO 11611 (Welding and allied processes), EN ISO 1149-5 (Electrostatic Discharge), EN ISO 61482-2 (Electric Arc (Open Arc and Box Method)).
[031] According to the exemplary embodiment of the present invention, the diamond weave (D) provides better strength to the fabric. The tear and tensile strength properties of diamond weave (D) flame-retardant fabrics are better when compared to plain weave flame-retardant fabric of similar blend and gsm.
[032] According to the exemplary embodiment of the present invention, the protective fabric/garment/apparel is air permeable as well as moisture vapour permeable. The protective fabric/garment/apparel may reduce the perspiration and provide greater comfort to a user for longer period of time. The protective diamond weave woven fabric (100) has a MVTR (Moisture Vapour Transmission Rate) of more than 1500 gm/m2 /day when tested pursuant to ASTM E-96-05. The present invention satisfies the requirement of fabric for fire protective clothing so that heat can be dissipated easily.
[033] Example 1: The diamond-weave (D) flame-retardant woven fabric for providing protection against heat and flame, electric arc, and electrostatic discharge was manufactured. The diamond weave woven fabric had 93% meta-aramid fibres by weight of the total weight of the fabric, 5% para-aramid by weight of the total weight of the fabric, and 2% anti-static fibres by weight of the total weight of the fabric. The fabric was woven in a diamond weave at 150 gsm. According to EN ISO 11612 (A1, A2, B1, C1, F1), EN ISO 1149-5(3), and EN ISO 61482-1-2 Class 1, the performance testing of flame-retardant woven fabric was carried out, and the results are presented in Table 1, Table 2. The protective diamond weave woven fabric had an ATPV of more than 5 cal/cm2 when tested pursuant to EN ISO 61482-1-1.
Table 1: Results of performance test as per EN ISO 11612: 2015 done on the fabric.
EN ISO 11612:2015- Test results for example 1
Clause Test Method Requirement and Performance levels Results Pass/Fail
Heat Resistance
(at 180° C, 5 min) ISO 17493: 2016 Shall not ignite, melt or shrink > 5% Did not ignite or melt,
Shrinkage
Warp = 0%
Weft = 0% Pass
Tensile Strength EN ISO 13934-1:2013 Class 1 & Class 2:
Min of 300 N in the warp and weft direction Warp: 940 N
Weft: 690 N Class 1 &
Class 2
Tear Strength EN ISO 13937-2:2000 Class 1 & Class 2: Min of 10 N in the warp and weft direction Warp: 85 N
Weft: 61 N Class 1 &
Class 2
Dimensional Change EN ISO 5077: 2008 Class 1 & Class 2:
Max ± 3% Warp: -1%
Weft: -1% Pass
Limited Flame spread EN ISO 15025: 2016 (Procedure A and B) No specimen must ignite towards the top or towards the edge No flaming to the top or side edge Class 1 &
Class 2
No specimen shall give hole formation of 5 mm or greater in any direction No hole formation
No specimen shall give flaming or molten debris No flaming or molten debris
After flame time = 2 sec No after flame
After glow time = 2 sec No after glow
Convective Heat (Code Letter B) ISO 9151: 2016 Level- HTI24 Specimen HTI24 Level B1
B1 = 4 sec 1 7.0
B2 = 10 sec 2 5.5
B3 = 20 sec 3 6.1
Average 6.2
Radiant Heat
(Code Letter C) EN ISO 6942: 2002 Level - HTI24 Specimen HTI24 Level C1
C1 = 7 sec 1 13.6
C2 = 20 sec 2 13.0
C3 = 50 sec 3 13.1
C4 = 95 sec Average 13.2
Contact Heat
(Code Letter F) EN ISO 12127-1: 2015 (TC = 260° C) Level - t1 Specimen t1 Level F1
F1 = 5 sec 1 8.76
F2 = 10 sec 2 8.71
F3 = 15 sec 3 8.62
Average 8.6

Table 2: Results of performance test as per EN ISO 1149-5: 2018 done on the fabric.
EN ISO 1149-5: 2018 Test results for example 1
Clause Test Method Requirement and Performance levels Results Pass/Fail
Charge Decay EN 1149-3: 2004 Decay Half Time t50 < 4 s Decay Half Time t50 < 0.1 s Pass
Shielding Factor > 0.2 Shielding Factor: 0.8

[034] Example 2: The diamond-weaved (D) flame-retardant woven fabric for providing protection against heat and flame, welding and allied processes, electric arc, and electrostatic discharge was manufactured. The diamond weave woven fabric had 50% cellulosic fibres by weight of the total weight of the fabric, 33% meta-aramid fibres by weight of the total weight of the fabric, 10% polyamide fibre by weight of the total weight of the fabric, 5% para-aramid by weight of the total weight of the fabric, and 2% anti-static fibres by weight of the total weight of the fabric. The fabric was woven in a diamond weave (D) at 185 gsm. According to EN ISO 11612 (A1, A2, B1, C1, F1), EN ISO 11611 Class 1, EN ISO 1149-5(3), and EN ISO 61482-1-2 Class 1, the performance testing of flame-retardant woven fabric was carried out, and the results are presented in Table 3, 4 and Table 5. The protective fabric had an ATPV of more than 6 cal/cm2 when tested pursuant to EN ISO 61482-1-1.
Table 3: Results of performance test as per EN ISO 11612: 2015 done on the fabric
EN ISO 11612:2015- Test results for example 2
Clause Test Method Requirement and Performance levels Results Pass/Fail
Heat Resistance
(at 180° C, 5 min) ISO 17493: 2016 Shall not ignite, melt or shrink > 5% Did not ignite or melt,
Shrinkage
Warp = -2%
Weft = -1% Pass
Tensile Strength EN ISO 13934-1:2013 Class 1 & Class 2:
Min of 300 N in the warp and weft direction Warp: 700 N
Weft: 580 N Class 1 &
Class 2
Tear Strength EN ISO 13937-2:2000 Class 1 & Class 2: Min of 10 N in the warp and weft direction Warp: 22 N
Weft: 21 N Class 1 &
Class 2
Dimensional Change EN ISO 5077: 2008 Class 1 & Class 2:
Max ± 3% Warp: -3%
Weft: -2% Pass
Limited Flame spread EN ISO 15025: 2016 (Procedure A and B) No specimen must ignite towards the top or towards the edge No flaming to the top or side edge Class 1 &
Class 2
No specimen shall give hole formation of 5 mm or greater in any direction No hole formation
No specimen shall give flaming or molten debris No flaming or molten debris
After flame time = 2 sec No after flame
After glow time = 2 sec No after glow
Convective Heat (Code Letter B) ISO 9151: 2016 Level- HTI24 Specimen HTI24 Level B1
B1 = 4 sec 1 6.0
B2 = 10 sec 2 6.0
B3 = 20 sec 3 6.1
Average 6.0
Radiant Heat
(Code Letter C) EN ISO 6942: 2002 Level - HTI24 Specimen HTI24 Level C1
C1 = 7 sec 1 13.1
C2 = 20 sec 2 13.5
C3 = 50 sec 3 13.3
C4 = 95 sec Average 13.3
Contact Heat
(Code Letter F) EN ISO 12127-1: 2015 (TC = 260° C) Level - t1 Specimen t1 Level F1
F1 = 5 sec 1 7.23
F2 = 10 sec 2 7.29
F3 = 15 sec 3 7.21
Average 7.2

Table 4: Results of performance test as per EN ISO 11611: 2015 done on the fabric.
EN ISO 11611:2015- Test results for example 1
Clause Test Method Requirement and Performance levels Results Pass/Fail
Tensile Strength EN ISO 13934-1:2013 Class 1 & Class 2:
Min of 400 N in the warp and weft direction Warp: 700 N
Weft: 580 N Class 1 &
Class 2
Tear Strength EN ISO 13937-2:2000 Class 1 & Class 2: Min of 15 N in the warp and weft direction Warp: 22 N
Weft: 21 N Class 1 &
Class 2
Dimensional Change EN ISO 5077: 2008 Class 1 & Class 2:
Max ± 3% Warp: -3%
Weft: -2% Pass
Limited Flame spread EN ISO 15025: 2016 (Procedure A and B) No specimen must ignite towards the top or towards the edge No flaming to the top or side edge Class 1 &
Class 2
No specimen shall give hole formation of 5 mm or greater in any direction No hole formation
No specimen shall give flaming or molten debris No flaming or molten debris
After flame time = 2 sec No after flame
After glow time = 2 sec No after glow
Radiant Heat EN ISO 6942: 2002 Level- RHTI24 Specimen RHTI24 Class 1
Class 1 = 7 1 13.1
Class 2 = 16 2 13.5
3 13.3
Average 13.3
Impact of Spatter EN ISO 9150: 1988 No Ignition No Ignition Class 1
Class 1: = 15 drops Average: 19

Class 2: = 25 drops
Electrical Resistance EN ISO 1149-2:1997 Class 1: > 105? Average: 2.58 x107? Pass
Class 2: > 105?

Table 5: Results of performance test as per EN ISO 1149-5: 2018 done on the fabric.
EN ISO 1149-5-2018 Test results for example 2
Clause Test Method Requirement and Performance levels Results Pass/Fail
Charge Decay EN 1149-3: 2004 Decay Half Time t50 < 4 s Decay Half Time t50 < 0.1 s Pass
Shielding Factor > 0.2 Shielding Factor: 0.5

[035] Thus, the above-described diamond weave flame-retardant protective woven fabric and manufacturing method for diamond weave flame-retardant protective garment provides a flame-retardant garment which protects against heat and flame, welding and allied process, electric arc, and electrostatic discharge with an improved aesthetic appearance.
[036] There have been described and illustrated herein several embodiments of exemplary indicative implementation of the diamond weave flame-retardant protective woven fabric (100) and the method (200) for manufacturing the same. It will also be apparent to a skilled person that the embodiments described above are specific examples of a single broader invention, which may have greater scope than any of the singular descriptions taught. There may be many alterations made in the description without departing from the scope of the invention. While embodiments of the invention have been described, it is not intended that the invention be limited to said configuration disclosed thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise not restrictive to the terminology described herein above. Any discussion of embodiments included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
,CLAIMS:
1. A flame-retardant protective woven fabric (100), said woven fabric (100) comprising:
a plurality of warp and weft yarns interlaced for forming a diamond weave woven fabric (100) and each said warp and weft yarn is blended yarn having a configuration of 50%-60% cellulosic fibres, 30%-40% meta-aramid fibres, 10%-15% polyamide fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100).

2. A flame-retardant protective woven fabric (100), said woven fabric (100) comprising:
a plurality of warp and weft yarns interlaced for forming a diamond weave woven fabric (100) and each said warp and weft yarn is blended yarn having a configuration of 90%-95% meta-aramid fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100).

3. The woven fabric (100) as claimed in claim 1, wherein said cellulosic fibre of blended yarn is selected from a group of fibres including cotton, or a flame- resistant viscose, or a tencel, or a rayon, or a modal or a combination thereof.

4. The woven fabric (100) as claimed in claim 1 or 2, wherein said diamond weave is formed by a combination of diagonally extended twill yarns at a right-hand side (R) and at a left-hand side (L) of said woven fabric (100).

5. The woven fabric (100) as claimed in anyone of the preceding claims 1-4, wherein weight of the woven fabric (100) is in the range of 150 gsm to 300 gsm, and a yarn count of the plurality of blended yarns is in the range of 2/24 Ne to 2/40 Ne.

6. The woven fabric (100) as claimed in anyone of the preceding claims 1-5, wherein said woven fabric (100) complies with requirements of EN ISO 15025, EN ISO 11612, EN ISO 11611, EN ISO 1149-5 and EN ISO 61482-2.

7. The woven fabric (100) as claimed in anyone of the preceding claims 1-6, said woven fabric (100) has a moisture vapour transmission rate (MVTR) of more than 1500 gm/m2 /day complying with requirements of ASTM E-96-05 and an arc thermal performance value (ATPV) of more than 5 cal/cm2 complying with requirements of EN ISO 61482-1-1 and EN ISO 61482-1-2.

8. A method (200) for manufacturing a flame-retardant protective woven fabric (100), said method (200) comprising the step of:
a) blending (210) fibres in a blend proportion (210a) comprising 50%-60% cellulosic fibres, 30%-40% meta-aramid fibres, 10%-15% polyamide fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100) to form a plurality of warp and weft yarns.

9. A method (200) for manufacturing a flame-retardant protective woven fabric (100), said method (200) comprising the step of:
a) blending (210) fibres in a blend proportion (210b) comprising 90%-95% meta-aramid fibres, 5%-10% para-aramid fibres, and 1%-2% anti-static fibres by weight of the total weight of the woven fabric (100) to form a plurality of warp and weft yarns.

10. The method (200) as claimed in claim 8 or 9, wherein the method (200) includes the steps of:
b) (220) spinning the plurality of blended warp and weft yarns;
c) (230a) warping, (230b) weaving by interlacing said blended warp and weft yarns to form a diamond weave woven fabric (100);
d) a wet processing treatment (240) comprising (240a) pre-treating woven greige fabric (100) in a washer, (240b) dyeing of pre-treated woven greige fabric (100) followed by washing and (240c) finishing of the dyed diamond weave woven fabric (100); and
e) (250) garmenting the flame-retardant protective diamond weave woven fabric (100).