FORM-2
THE PATENT ACT,1970
(39 OF 1970)
AND
THE PATENT RULES, 2003
(As Amended)
COMPLETE SPECIFICATION (See section 10;rule 13)
"MOLTEN METAL PROTECTIVE FABRIC AND GARMENT THEREFROM"
Arvind Limited, a corporation organized and existing under the laws of India, of Naroda road, Ahmedabad, Gujarat – 382345, India.
The following specification particularly describes the invention and the manner in which it is to be performed:

MOLTEN METAL PROTECTIVE FABRIC AND GARMENT THEREFROM
Field of Invention
The present invention relates to molten metal protective wear fabric. More particularly, present invention relates to method of making molten metal protective fabric.
Background of Invention
Metals can be broadly classified as ferrous and non-ferrous based on the iron content. In order to obtain different compound or alloys, other metals can be added into said metal. The wide varieties of alloys can be used to obtain required metal and all the metals have different physical and chemical behaviour.
The flame retardant fabrics are available which can protect against metal. Iron and their alloys derived as steel, stainless steel etc. acquires a melting temperature ranging from 1200°C to almost 1700°C and when these metal splash into the garment and/or protective fabrics, they causes an increase of temperature. Molten ferrous alloys when they impact on non-protective fabrics, they cause immediate destruction due to contact in a high temperature. Rarely there are cases where the metal substance adheres to the protective fabric.
The iron is highly destructive when contacted with the flame retardant fabrics that have light weights and fibres that do not support high peak temperature, causing a break of the fabric.
The colour alloys such as copper, zinc, lead, tin, aluminium, nickel, or magnesium, with the exception of copper, these metals tend to stick easily in non-protective fabrics. The working temperatures are somewhat lower and the cooling capacity is very high. All these facts, causes that molten metal splash sticks in the fabric and allow immediate heat transfer to the operator himself as well as the fabric destruction.
In these types of fabrics protection splash of origin Non-Ferrous metals, it is essential to choose fibres capable of repelling the most of the adhesion of these metals in the fabric. Whatever their nature if the nonferrous metal (mainly Aluminium, Cryolite) remains stuck to the tissue, the consequences are severe but not so much with the lead, tin or zinc metals.

It is well known that Aluminium is the main non-ferrous alloy and is mostly used in the foundries, and is taken as one of the most critical for its “staying stuck” easy behaviour in the clothes of the smelters. Molten aluminium (secondary production process) has an operating temperature of 700/800°C, and is enough to cause severe burns too. In both the production processes, i.e. primary and secondary smelting, the Aluminium is the metal alloy that poses more danger when smelters and foundry men meet their liquid splashing. Alloys such as tin, zinc or lead, which are almost always remain adhered to the fabric and in these cases, seek the maximum repellence while it is true that the temperatures of these metals are lower than the Aluminium primary production.
Ferrous metals have a high destructive power on the protective clothing while nonferrous metals tend to stick causing a dangerous damage. The protective fabrics for ferrous metals such as iron or steel, must withstand high thermal shock splashes of these metals, to avoid being destroyed by this effect and maintain its structure so as to prevent metal from entering into the ‘wearer’ clothing. The use of flame retardant clothing, always working together to minimize the damage if the outer layers of tissue, may come to fail.
Woven fabrics for protection nonferrous metals mainly aluminium, must allow full and absolute repellence to these; and when sticks to the fabric is when the damage they cause are very high. These types of protective fabrics are the most technical one in this sector and it is very important to select the appropriate one.
Currently Wool/ Fire Retardant Viscose fabric are used for molten aluminium protection and tested as per ISO 11612 “D” Code. Due to the sticky behaviour of molten aluminium than molten iron many inherently flame retardant fabric fail in “D” code but Pass “E” code though the temperature is less in case of molten aluminium around 816 0C whereas molten iron is 1594°C.
Due to this wool/FR viscose blended fabric is used for molten aluminium protection. This yarn is produce by worsted spinning system and fabric made from this yarn is not comfortable to be and give itch due to wool fibres. The garment made from this fabric has a problem of shrinkage, pilling and not having an appealing look.
Thus, there is a need of a fabric that can overcome the limitations of existing protective fabrics.

Object of the Invention:
The primary object of the present invention is to provide a molten metal protective fabrics.
Further object of the present invention is to provide a molten metal protective fabrics which are soft and comfortable.
Yet another object of the present invention is to provide a molten metal protective fabrics which does not shrink, pill and has an appealing look.
Yet another object of the present invention is to provide a garments prepared from the molten metal protective fabrics.
Summary of the Invention:
In order to achieve the afore-said objectives, the present invention provides a molten metal protective fabric.
A According to one aspect, provided herein is a molten metal protective fabric of the present invention comprising from about 40% to about 50% w/w of wool; from about 40% to about 50% w/w of flame retardant cellulosic fibre; and from about 3% to about 10% w/w of Polyamide fibre.
The molten metal protective fabric according to the invention comprises ta woven structure of Twill or Satin weave.
The fabric is a flame retardant fabric as it comprises the flame retardant cellulosic fibre preferably FR Viscose.
The fabric is breathable having MVTR (Moisture Vapour Transmission Rate) as per ASTM E-96-05 more than 1000 gm/M2/Day. The fabric as per as per ISO11612 has achieved D3 and E3 at 365 gsm.
According to another aspect, provided herein is a process for manufacturing the molten metal protective fabric, comprising the steps of:

- spinning the fibres consisting of Flame retardant cellulosic fibre from about 80% to about 90% w/w, polyamide from about 10% to 20% w/w, wherein the yarn count varied from about 16s Ne to about 24s Ne (double yarn), to obtain 100% wool yarn;
- the yarns of two fibers are wound and twisted in doubling machine;
- weaving the yarns interlaced together in textile weave and obtained a woven fabric with twill weave;
- burning the protruding fibers by singeing machine through gas burner to improve the resistance to pilling and imparts lustre to the fabric;
- washing the fabric with hot water to remove impurities;
- dyeing the fabric with low affinity reactive dye with dye fixing to provide the fabric excellent fastness properties;
- optionally the dyed flame retardant cellulosic fibre is dyed with acid dye for wool and polyamide part;
- treating the fabric with hydrophilic softener;
- optionally, treating the fabric with anti-microbial, water and oil repellents, and stain release agents;
- allowing the fabric to shrink in length as well as width, to provide a permanent dimension to obtain the ready to use fabric.
Detailed Description of Invention:
The following description is provided to assist in a comprehensive understanding of exemplary embodiment of the invention. It includes various specific details to assist the understanding but these are to be regarded as merely exemplary.
Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, description of well-known functions / constructions is omitted for clarity and consciousness.
The terms and words used in the following description and claim 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 and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way or more other embodiment and/or in combination with or instead of the features of other embodiments.
It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the preference of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps or components or groups thereof.
Those skilled in the art will be aware that the invention described herein is subject to variations and modifications, other than those specifically described. It is to be understood that the invention described herein includes all such variations and modifications. The invention also includes all such steps, features, compositions and compounds referred to or indicated in this specifications, individually or collectively, and any and all combinations of any two or more of said steps or features.
The present invention is not to be limited in scope by the specific embodiments described herein, which is intended for the purposes of exemplification only. Functionally-equivalent products, compositions, and methods are clearly within the scope of the invention, as described herein.
The present invention provides molten metal protective fabric with wool, FR viscose and polyamide fibres.
According to one aspect, provided herein is a metal protective fabric comprising from about 40% to about 50% by weight of total fabric weight of wool; from about 40% to about 50% by weight of total fabric weight of flame retardant cellulosic fibre such as FR Viscose; and from about 3% to about 10% by weight of total fabric weight of Polyamide fibre.
According to an embodiment, the fabric comprises a woven structure of Twill or Satin weave.
According to another embodiment, the fabric is a flame retardant fabric. Because the fabric

comprises flame retardant fibre, the fabric is flame resistant substantially through the life of the garment made from the fabric.
According to another embodiment, the fabric is breathable (air permeable, moisture vapour permeable) which helps reduce perspiration and provides greater comfort to the user for longer periods of time. The MVTR (Moisture Vapour Transmission Rate) as per ASTM E-96-05 is more than 1000 gm/M2/Day.
According to another embodiment, the metal protective-wear is typically used when there is a risk of molten metal such as iron/ aluminium or cryolite in the working area and tested as per ISO 11612, in which sub category as ISO 9185 where Code “D” for aluminium and Code “E” for iron. The fabric according to the invention has achieved D3 and E3 at 365 gsm.
Performance Standard: ISO 11612: 2015, Clause 7.5 Molten iron splash ISO 9185:
2007,
Metal: Iron (>97% purity), Pouring Temperature: 1400 ± 20°C
Pouring Height: 225mm, Specimen angle to the horizontal: 75°

Property ISO 11612 Requirements
7.5 Molten iron Level Fe
splash E1 ≥ 60g
(Code letter E) E2 ≥ 120g
E3 ≥ 200g
Performance Standard: ISO 11612: 2015, Clause 7.4 Molten aluminium Splash, Test Method: ISO 9185: 2007, Metal: Aluminium, Pouring Temperature: 780 ± 20°C Pouring Height: 225mm, Specimen angle to the horizontal: 60°

Property ISO 11612 Requirements
7.4 Molten aluminium Level Al
splash D1 ≥ 100g
(Code letter D) D2 ≥ 200g
D3 ≥ 350g

The fabrics described herein are dimensionally stable (i.e., display reduced stretching or shrinking), and optionally further comprise other functional durable finishes such as an anti-microbial, water and oil repellent, stain release Finishes and the like, without affecting protective performance.
The protective wear described herein complies with standards such as ISO 11611 A1, ISO 11612 (Code “D”, Code “E”), ISO 15025-A1.
According to another aspect, provided herein is a process for manufacturing the molten metal protective fabric, comprising the steps of:
- spinning the fibres consisting of Flame retardant cellulosic fibre from about 80% to about 90% w/w, polyamide from about 10% to 20% w/w, wherein the yarn count varied from about 16s Ne to about 24s Ne (double yarn), to obtain 100% wool yarn;
- the yarns of two fibers are wound and twisted in doubling machine;
- weaving the yarns interlaced together in textile weave and obtained a woven fabric with twill weave;
- burning the protruding fibers by singeing machine through gas burner to improve the resistance to pilling and imparts lustre to the fabric;
- washing the fabric with hot water to remove impurities;
- dyeing the fabric with low affinity reactive dye with dye fixing to provide the fabric excellent fastness properties;
- optionally the dyed flame retardant cellulosic fibre is dyed with acid dye for wool and polyamide part;
- treating the fabric with hydrophilic softener;
- optionally, treating the fabric with anti-microbial, water and oil repellents, and stain release agents;

- allowing the fabric to shrink in length as well as width, to provide a permanent
dimension to obtain the ready to use fabric.
The present invention will now be explained with the help of the following examples, however; the scope of the invention should not be limited to said example. It is to be understood that the above described embodiments are merely illustrative principles of the present invention and that many variations may be devised by those skilled in the art without departing from the scope of the present invention. It is therefore, intended that such variations be included with the scope of the claims.
EXAMPLES
The Process Flow Chart is a follows:
Spinning ---- weaving ---- wet processing ---- garmenting
Spinning:
Spinning is a process of converting fibres into yarn. Different types of fibre blends/ polymer blends are selected in the spinning process according to the end use requirements for the yarn.
According to one example, fibers consisting of Flame retardant cellulosic fibre: from about 80% to about 90% by weight of the total weight of the fibers, Polyamide: 10% to 20% by weight of the total weight of the fibbers. The yarn count varied from about 16s Ne to about 24s Ne (double yarn). The spinning is conducted in a ring spinning system. 100% wool yarn is obtained from woollen spinning system. Then both yarns are wound and twisted in doubling machine (TFO).
In the woollen spinning system, shorter fibres are processed and obtained a yarn.
Double yarn gives good lustre and strength while having the same resultant count of single yarn.
In the weaving process, yarns are interlaced together in textile weave and obtained fabric. In the present invention, fabric is woven with twill weave.
Wet Processing:
Washing – Dyeing – Finishing – Sanforising

Washing: the fabric is washed with hot water to remove impurities.
Dyeing: the fabric is dyed with low affinity reactive dye with dye fixing to make the fabric with excellent fastness properties or if dyed flame retardant cellulosic fibre is used then the fabric is dyed with acid dyed for wool and polyamide part.
Finishing: Fabric is given a soft hand feel by hydrophilic softener.
Other durable features like anti-microbial finish, water and oil repellents, and stain release
agents are incorporated at this stage of the process.
Sanforising: The fabric is allowed to shrink in length as well as width, to provide a permanent dimension.
Garmenting: After sanforising the fabric, it is now ready for garment making with flame retardant trims.
Due to the doubling process and wet processing after making fabric the feel, touch enhance with the metal protection properties in addition to this the itching effect also solve. We can get limited colour with excellent fastness properties and the durability and resistance to pilling also enhance exponentially.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such modifications can be made without departing from the spirit or scope of the present invention as defined.

We claim:
1. A molten metal protective fabric comprising from about 40% to about 50% w/w of wool; from about 40% to about 50% w/w of flame retardant cellulosic fibre; and from about 3% to about 10% w/w of Polyamide fibre.
2. The fabric as claimed in claim 1, wherein the flame retardant cellulosic fibre is FR Viscose.
3. The fabric as claimed in claim 1, wherein the fabric comprises a woven structure of Twill or Satin weave.
4. The fabric as claimed in claim 1, wherein the fabric is a flame retardant fabric.
5. The fabric as claimed in claim 1, wherein the fabric is breathable having MVTR (Moisture Vapour Transmission Rate) as per ASTM E-96-05 more than 1000 gm/M2/Day.
6. The fabric as claimed in claim 1, wherein the fabric as per as per ISO 11612 has achieved D3 and E3 at 365 gsm.
7. A process for manufacturing the molten metal protective fabric as claimed in claim 1, comprising the steps of:

- spinning the fibres consisting of Flame retardant cellulosic fibre from about 80% to about 90% w/w, polyamide from about 10% to 20% w/w, wherein the yarn count varied from about 16s Ne to about 24s Ne (double yarn), to obtain 100% wool yarn;
- the yarns of two fibers are wound and twisted in doubling machine;
- weaving the yarns interlaced together in textile weave and obtained a woven fabric with twill weave;
- washing the fabric with hot water to remove impurities;
- dyeing the fabric with low affinity reactive dye with dye fixing to provide the fabric excellent fastness properties;

- optionally the dyed flame retardant cellulosic fibre is dyed with acid dye for wool and polyamide part;
- treating the fabric with hydrophilic softener;
- optionally, treating the fabric with anti-microbial, water and oil repellents, and stain release agents;
- allowing the fabric to shrink in length as well as width, to provide a permanent dimension to obtain the ready to use fabric.