Comfortable air layer three-dimensional structure flame-retardant arc-proof fabric

Abstract

The present application relates to a kind of comfortable air layer three-dimensional structure flame-retardant heat-insulating anti-arcing fabric, including outer layer, middle layer and inner layer;Wherein, the outer layer yarn is high-performance protective yarn, including at least 2 kinds of fiber in modacrylic, flame-retardant viscose, aramid 1414, aramid 1313, polyimide, polyphenylene sulfide fiber composition;The middle layer uses high-temperature resistant monofilament or multifilament;The inner layer is processed using flame-retardant comfort yarn, including at least 2 kinds of fiber in modacrylic, flame-retardant viscose, aramid 1414, aramid 1313, polyimide, polyphenylene sulfide fiber composition.The present application flame-retardant heat-insulating anti-arcing fabric production is efficient and simple, structure is realized conveniently and concisely, three-dimensional structure is complete and clear, fabric hand feeling is soft, comfortable and breathable, with high thermal resistance and high dielectric properties, protect human body from the impact of external heat and arc, effectively protect the life safety of wearing personnel.

Description

Technical Field

[0001] This invention relates to the field of safety protective textiles, specifically to a comfortable warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric. Background Technology

[0002] Near high-voltage electric fields, air ionization and conduction can cause arc discharge, posing a high risk of injury to individuals. The primary form of injury from an electric arc is heat; the instantaneous high temperature released by the arc can cause explosive impacts, burns, and carbonization. Therefore, protection against electric arcs and protection against heat in personal protective equipment are essentially the same, achieving the same goal through different means. Heat transfer occurs through convection, radiation, and conduction. In situations requiring heat protection, these three pathways are typically used to block heat and thus protect personnel. In situations where clothing provides heat protection, the commonly used methods are reducing convective heat and blocking radiative heat.

[0003] In practical operation, by utilizing the low thermal conductivity of air, various methods can be employed to increase the air content in clothing, reducing the efficiency of heat conduction to the human body. Thicker air layers or aerogel layers can also be incorporated into protective fabrics to directly form a low-thermal-conductivity insulation layer, thereby reducing the harm caused by heat to the human body and buying more escape time for those in fire situations. Besides its simple and efficient use as an insulation layer, air, due to its dielectric properties, can also enhance the performance of arc flash protection clothing by adding air layers or using materials with excellent dielectric properties. The dielectric constants of various high-performance fiber materials used in clothing are shown in Table 1.

[0004] Table 1 Dielectric coefficients of fabric-related materials

[0005]

[0006] Patent CN115216877A describes a double-layered fabric designed with a unique structure and special composition. When the fabric is burned, the inner and outer layers shrink differentially, forming a thicker air layer that effectively blocks heat. Patent CN112030307A utilizes a special fabric structure, adding a thick double-layered fabric as an insulation layer. Aerogel is coated on both sides of the insulation layer, effectively improving the fabric's heat insulation properties. The designed fabric achieves a thermal protection rating of 36.76 cal / cm². 2Patent CN218521390U utilizes specific fiber components and a special double-layer fabric structure design to form alternating three-dimensional air tubes in the warp direction of the fabric. This significantly increases the air content in the protective fabric, allowing it to contain more still air and thus improving the thermal protection performance of the welding fabric. Patent CN216032992U uses acrylonitrile and other fiber components, ensuring the fabric's flame retardancy and good arc resistance. Combined with a special double-layer structure design, it has a good three-dimensional structure, increasing the overall thickness of the fabric and forming a thicker air layer, effectively improving its arc resistance and thermal protection performance.

[0007] Because woven fabrics use a warp-weft interlacing method, forming a double-layer structure with a high air content requires twice the amount of weft yarn. At the same loom speed, the resulting fabric length is only half of the normal length. Therefore, even with high-speed looms, the weaving efficiency is relatively low. Secondly, the use of warp-weft interlacing to achieve a three-dimensional structure results in a complex design and a difficult loom operation, also leading to low efficiency. Furthermore, woven fabrics are formed by warp and weft yarns interlacing in a planar surface, resulting in a very limited fabric thickness. The air layer is relatively thin and cannot be easily adjusted; hence, this structure is also known as a "2.5D" structure. Even in some solutions using materials with differential heat shrinkage properties to form a thicker double-layer structure, the fabric thickness is limited to 1 cm due to the material's rigidity at high temperatures, and thickness variations are uncontrollable. Therefore, forming fabrics of a certain thickness using woven fabrics is inherently difficult and yields unsatisfactory results, limiting its development. In order to improve the thermal protection performance of fabrics, the thickness of the fabric is generally increased. However, the fabric produced by this method has a large weight, is thick and heavy, and its breathability and flexibility are affected by the protection performance requirements and cannot be improved. Therefore, the wearing comfort is poor, and the wearer often feels stuffy and uncomfortable.

[0008] Based on this, the present invention provides a comfortable warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric. Summary of the Invention

[0009] In view of the shortcomings of the prior art, the purpose of this invention is to provide a comfortable warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating and arc-proof fabric, which solves the problems of low weaving efficiency, complex weaving structure, high production difficulty, inconvenient air-layer structure adjustment, limited thickness, and thick, heavy fabric with poor flexibility and breathability of existing woven fabrics.

[0010] This invention provides a comfortable warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric, comprising an outer layer, a middle layer, and an inner layer;

[0011] The outer yarn is a high-performance protective yarn, comprising at least two fibers selected from acrylic fiber, flame-retardant viscose, aramid 1414, aramid 1313, polyimide, and polyphenylene sulfide fiber.

[0012] The intermediate layer is made of high-temperature resistant monofilament or multifilament;

[0013] The inner layer is made of flame-retardant and comfortable yarn, comprising at least two fibers selected from acrylic fiber, flame-retardant viscose, aramid 1414, aramid 1313, polyimide, and polyphenylene sulfide fiber.

[0014] Furthermore, the outer yarn comprises 40-60 parts of acrylonitrile, 20-50 parts of flame-retardant viscose, 15-30 parts of aramid 13, 15-20 parts of aramid 14, 0-20 parts of polyimide, and 0-20 parts of polyphenylene sulfide fiber.

[0015] Furthermore, the outer yarn composition specifically comprises 40 parts of acrylonitrile chlorofiber, 30 parts of flame-retardant viscose, 131-320 parts of aramid fiber, 141-45 parts of aramid fiber, and 5 parts of polyphenylene sulfide.

[0016] Furthermore, the monofilament comprises high-temperature resistant monofilament polyphenylene sulfide and / or polyphenylene sulfide sulfone with a diameter between 0.15 and 0.50 mm.

[0017] Furthermore, the multifilament comprises at least one of the following: high-performance high-temperature resistant fiber aramid 1414 with a fineness between 70D and 600D, polyimide, and poly(p-phenylenebenzodioxazole) (PBO) fiber.

[0018] Furthermore, the inner layer yarn comprises 40-65 parts flame-retardant viscose, 15-25 parts acrylonitrile, 15-25 parts polyphenylene sulfide fiber, 5-20 parts polyimide, 14140-20 parts aramid, and 13130-20 parts aramid.

[0019] Furthermore, the inner layer yarn composition specifically comprises 50 parts flame-retardant viscose, 25 parts acrylonitrile, 15 parts polyphenylene sulfide, 5 parts polyimide, and 13135 parts aramid.

[0020] Furthermore, the fabric can form 6,000 to 50,000 independent supports per square meter along the fabric thickness direction.

[0021] Furthermore, the fabric thickness is 0.3cm-3cm.

[0022] Furthermore, the method for preparing the fabric includes:

[0023] (1) Warping: Prepare warp beams 1, 2 and 3 for the outer layer of the fabric, which are required for the weaving of the fabric;

[0024] (2) Weaving: S1, the yarn on the warp beam 1 is fully threaded through the guide bar 1 and woven into the outer layer of the fabric by warp knitting on the needle bed 1; S2, the yarn on the warp beam 2 is fully threaded through the guide bar 2 and woven into the inner layer of the fabric by warp knitting on the needle bed 2; S3, the yarn padding guide bar alternately pads the yarn on the warp beam 3 on the needle bed 1 and needle bed 2 at a set interval. The interval between the needle bed 1 and needle bed 2 is adjusted according to the designed thickness of the fabric. The yarn padding interval of the yarn padding guide bar is 2-10 loop heights and 1-4 loop widths, which can form yarn support perpendicular to both sides of the fabric;

[0025] (3) Finishing: The process is carried out by washing, dyeing, stretching and setting.

[0026] Furthermore, in step S1, the weaving structure is a heavy warp weave, the padding yarn number is 2-0 / 1-3 / / , the loop height is 60-110 loops / 10cm, and the loop width is 40-80 loops / 10cm.

[0027] Furthermore, in step S2, the weaving structure is a three-needle warp satin weave, with the padding yarn number being 0-1 / 2-1 / 3-2 / 1-2 / / , the loop height being 60-110 loops / 10cm, and the loop width being 40-80 loops / 10cm. 。

[0028] The beneficial effects of this invention are as follows:

[0029] Compared to woven fabrics, under the same weight conditions, the fabric in this invention is thicker, reaching over 0.3 cm in its natural state. This allows it to contain more still air, resulting in superior thermal protection and arc-proof performance. The knitted structure makes the fabric soft and breathable, offering better ventilation, flexibility, and higher moisture permeability. The warp-knitted 3D structure provides a three-dimensional, elastic, stable, and deformation-free fabric, preventing the air layer from collapsing due to processing, compression, or use. Furthermore, compared to multi-layered woven fabrics, the knitted 3D structure offers higher processing efficiency and controllable thickness, allowing for the design and weaving of thermal arc-proof fabrics of varying thicknesses to meet specific needs.

[0030] This invention utilizes warp knitting to design and develop a three-dimensional air-layer structure fabric with flame-retardant, heat-insulating, and arc-resistant functions. It solves the problems of low weaving efficiency, complex weaving structures, high production difficulty, inconvenient air-layer structure adjustment, limited thickness, and the resulting thick, heavy fabrics with poor flexibility and breathability. The invention achieves high-efficiency and simple production, convenient and concise structural realization, a complete and clear three-dimensional structure, a soft hand feel, comfortable breathability, and high flexibility of wear. It also allows for greater fabric thickness, more static air layers, a dielectric constant exceeding 3.5, and a thermal protection factor (TPP) reaching 36 cal / cm². 2In this way, it protects the human body from the impact of external heat and electric arcs, effectively protecting the life safety of the wearer. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 Diagram showing the movement of the outer layer of knitting needles;

[0033] Figure 2 for Figure 1 The coil effect diagram;

[0034] Figure 3 Diagram showing the movement of the inner knitting needles;

[0035] Figure 4 for Figure 3 The coil effect diagram;

[0036] Figure 5 This is a schematic diagram of the finished product. Detailed Implementation

[0037] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example 1

[0039] The preparation method of the comfort warp-knitted air layer three-dimensional structure flame-retardant, heat-insulating and arc-proof fabric in this embodiment specifically includes three steps: warping, weaving and finishing.

[0040] (1) Warping:

[0041] According to the process design requirements, warp beam 1 is prepared according to the required head count of the yarn used for the outer layer of the fabric, warp beam 2 is prepared according to the required head count of the yarn used for the inner layer of the fabric, and warp beam 3 is prepared according to the required head count of the monofilament used for the middle layer of the fabric.

[0042] The outer yarn component consists of 45 parts acrylic chlorofiber, 25 parts flame retardant viscose, 131315 parts aramid, 10 parts polyphenylene sulfide, and 14145 parts aramid.

[0043] The intermediate layer uses high-temperature resistant monofilaments with a diameter of 0.20 mm made of polyphenylene sulfide monofilament.

[0044] The inner layer yarn consists of 45 parts flame-retardant viscose, 20 parts acrylonitrile chlorofiber, 15 parts polyphenylene sulfide, 10 parts polyimide, 13135 parts aramid, and 14145 parts aramid.

[0045] (2) Weaving:

[0046] The yarns on warp beam 1 are fully threaded through guide bar 1, and the outer layer of the fabric is woven on needle bed 1 using a warp knitting method. A heavy warp weave is used, with a padding yarn number of 2-0 / 1-3 / / , and the needle movement is as follows: Figure 1 As shown, the coil height is 90 coils / 10cm, the coil width is 60 coils / 10cm, and the coil effect is as follows. Figure 2 As shown.

[0047] Figure 1 In the diagram, black dots represent knitting needles, and black lines represent the movement trajectory of a single yarn. The movement of the yarn is driven by the guide bar, and it can form a loop by wrapping around the knitting needle.

[0048] Figure 2 for Figure 1 The diagram shows the coil's effect. Here, A represents the coil's height, and B represents its width, expressed as the number of coils of this length within a 10cm radius.

[0049] The yarns on warp beam 2 are fully threaded through guide bar 2, and the inner layer of the fabric is woven on needle bed 2 using a warp knitting method. The weaving structure is a three-needle warp satin weave, with padding yarn numbers of 0-1 / 2-1 / 3-2 / 1-2 / / , and the needle movement is as follows: Figure 3 As shown, the coil height is 85 coils per 10cm, and the coil width is 62 coils per 10cm. The coil effect is as follows. Figure 4 As shown.

[0050] The yarn-padding comb alternately pads the yarn on the warp beam 3 onto the needle bed 1 and needle bed 2 in a loop height of 6 loops and a width of 2 loops. The distance between the needle bed 1 and needle bed 2 is adjusted to 2.5cm, forming a yarn support perpendicular to both sides of the fabric.

[0051] The finished product's appearance is as follows Figure 5 As shown.

[0052] (3) Post-processing:

[0053] The process involves washing, dyeing, and drying to set the shape.

[0054] The finished fabric, after dyeing and finishing, has stable dimensions and structure. Calculations show that the effective independent supports formed between the inner and outer layers can reach 45,000 per meter. 2The fabric was tested and found to be 2.2 cm thick with a relative permittivity of 3.6. According to the direct method test in GB 8965.1-2024, its thermal protection value reaches 37.7 cal / cm². 2 .

[0055] Example 2

[0056] The preparation method of the comfort warp-knitted air layer three-dimensional structure flame-retardant, heat-insulating and arc-proof fabric in this embodiment specifically includes three steps: warping, weaving and finishing.

[0057] (1) Warping:

[0058] According to the process design requirements, warp beam 1 is prepared according to the required head count of the yarn used for the outer layer of the fabric, warp beam 2 is prepared according to the required head count of the yarn used for the inner layer of the fabric, and warp beam 3 is prepared according to the required head count of the monofilament used for the middle layer of the fabric.

[0059] The outer yarn component consists of 50 parts of acrylonitrile, 20 parts of flame-retardant viscose, 131315 parts of aramid, 10 parts of polyimide, and 14145 parts of aramid.

[0060] The intermediate layer uses high-temperature resistant monofilaments with a diameter of 0.30 mm made of polyphenylene sulfide monofilament.

[0061] The inner yarn component consists of 40 parts flame-retardant viscose, 15 parts acrylonitrile chlorofiber, 18 parts polyphenylene sulfide fiber, 7 parts polyimide, 141410 parts aramid, and 131310 parts aramid.

[0062] (2) Weaving:

[0063] The yarns on warp beam 1 are fully threaded through guide bar 1, and the outer layer of the fabric is woven on needle bed 1 using a warp knitting method. The weaving structure is a heavy warp structure, with padding yarn numbers of 2-0 / 1-3 / / , such as... Figure 1 As shown, the height of the circles is 60 per 10cm, and the width of the circles is 40 per 10cm.

[0064] The yarns on warp beam 2 are fully threaded through guide bar 2, and the inner layer of the fabric is woven on needle bed 2 using a warp knitting method. The weaving structure is a three-needle warp satin weave, with the padding yarn numbers being 0-1 / 2-1 / 3-2 / 1-2 / / , such as... Figure 3 As shown, the height of the circles is 65 per 10cm, and the width of the circles is 43 per 10cm.

[0065] The yarn-padding comb alternately pads the yarn on the warp beam 3 onto the needle bed 1 and needle bed 2 in a loop height of 8 loops and a width of 4 loops. The distance between the needle bed 1 and needle bed 2 is adjusted to 3.0 cm, forming a yarn support perpendicular to both sides of the fabric.

[0066] (3) Post-processing:

[0067] The process involves washing and then drying to set the shape.

[0068] The finished fabric, after dyeing and finishing, has stable dimensions and structure. Calculations show that the effective independent supports formed between the inner and outer layers can reach 7500 per meter. 2 The fabric was tested and found to be 2.8 cm thick with a relative permittivity of 3.8. According to the direct method test in GB 8965.1-2024, its thermal protection value reaches 36.5 cal / cm². 2 .

[0069] Example 3

[0070] The preparation method of the comfort warp-knitted air layer three-dimensional structure flame-retardant, heat-insulating and arc-proof fabric in this embodiment specifically includes three steps: warping, weaving and finishing.

[0071] (1) Warping:

[0072] According to the process design requirements, warp beam 1 is prepared according to the required head count of the yarn used for the outer layer of the fabric, warp beam 2 is prepared according to the required head count of the yarn used for the inner layer of the fabric, and warp beam 3 is prepared according to the required head count of the monofilament used for the middle layer of the fabric.

[0073] The outer yarn component consists of 55 parts acrylic chlorofiber, 20 parts flame retardant viscose, 131320 parts aramid, and 14145 parts aramid.

[0074] The intermediate layer uses high-temperature resistant multifilament aramid 1414 filament with a fineness of 200D.

[0075] The inner yarn component consists of 50 parts flame-retardant viscose, 20 parts acrylonitrile chlorofiber, 15 parts polyphenylene sulfide fiber, 10 parts polyimide, and 13135 parts aramid fiber.

[0076] (2) Weaving:

[0077] The yarns on warp beam 1 are fully threaded through guide bar 1, and the outer layer of the fabric is woven on needle bed 1 using a warp knitting method. The weaving structure is a heavy warp structure, with padding yarn numbers of 2-0 / 1-3 / / , such as... Figure 1 As shown, the height of the circles is 100 pieces per 10cm, and the width of the circles is 80 pieces per 10cm.

[0078] The yarns on warp beam 2 are fully threaded through guide bar 2, and the inner layer of the fabric is woven on needle bed 2 using a warp knitting method. The weaving structure is a three-needle warp satin weave, with the padding yarn numbers being 0-1 / 2-1 / 3-2 / 1-2 / / , such as... Figure 3As shown, the height of the circle is 108 pieces / 10cm, and the width of the circle is 86 pieces / 10cm.

[0079] The yarn-padding comb alternately pads the yarn on the warp beam 3 onto the needle bed 1 and needle bed 2 in a loop height of 10 loops and a width of 4 loops. The distance between the needle bed 1 and needle bed 2 is adjusted to 1.8 cm, forming a yarn support perpendicular to both sides of the fabric.

[0080] (3) Post-processing:

[0081] The process involves washing, dyeing, and drying to set the shape.

[0082] The finished fabric, after dyeing and finishing, has stable dimensions and structure. Calculations show that the effective independent supports formed between the inner and outer layers can reach 20,000 per meter. 2 The fabric was tested and found to be 1.5 cm thick with a relative permittivity of 3.8. According to the direct method test in GB 8965.1-2024, its thermal protection value reaches 38.2 cal / cm². 2 .

[0083] Finally, it should be noted that the above embodiments are only used to illustrate the present invention and are not intended to limit the technical solutions described in the present invention; those skilled in the art should understand that modifications or equivalent substitutions can still be made to the present invention; and all technical solutions and improvements that do not depart from the spirit and scope of the present invention should be covered within the scope of the claims of the present invention.

Claims

1. A comfortable warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric, characterized in that, Includes outer layer, middle layer and inner layer; The outer yarn is a high-performance protective yarn, comprising at least two fibers selected from acrylic fiber, flame-retardant viscose, aramid 1414, aramid 1313, polyimide, and polyphenylene sulfide fiber. The intermediate layer is made of high-temperature resistant monofilament or multifilament; The inner layer is made of flame-retardant and comfortable yarn, including at least two fibers selected from acrylic fiber, flame-retardant viscose, aramid 1414, aramid 1313, polyimide, and polyphenylene sulfide fiber. The monofilament comprises high-temperature resistant monofilament polyphenylene sulfide and / or polyphenylene sulfide sulfone with a diameter between 0.15-0.50 mm; The multifilament includes at least one of the following: high-performance, high-temperature resistant fiber aramid 1414 with a fineness between 70D and 600D; polyimide; and poly(p-phenylenebenzodioxazole) fiber. The fabric can form 6,000-50,000 independent supports per square meter along the thickness direction; The fabric thickness is 0.3cm-3cm.

2. The comfort-type warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric according to claim 1, characterized in that, The outer yarn comprises 40-60 parts of acrylonitrile, 20-50 parts of flame-retardant viscose, 15-30 parts of aramid 1313, 5-20 parts of aramid 1414, 0-20 parts of polyimide, and 0-20 parts of polyphenylene sulfide fiber.

3. The comfort-type warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric according to claim 1, characterized in that, The inner layer yarn comprises 40-65 parts flame-retardant viscose, 15-25 parts acrylonitrile, 15-25 parts polyphenylene sulfide fiber, 5-20 parts polyimide, 0-20 parts aramid 1414, and 0-20 parts aramid 1313.

4. The comfort-type warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric according to claim 1, characterized in that, The method for preparing the fabric includes: (1) Warping: Prepare warp beams 1, 2, and 3 for the outer layer of the fabric, which are required for the weaving of the fabric; (2) Weaving: Step S1, the yarn on the warp beam 1 is fully threaded through the guide bar 1 and woven into the outer layer of the fabric by warp knitting on the needle bed 1; Step S2, the yarn on the warp beam 2 is fully threaded through the guide bar 2 and woven into the inner layer of the fabric by warp knitting on the needle bed 2; Step S3, the yarn padding guide bar alternately pads the yarn on the warp beam 3 on the needle bed 1 and the needle bed 2 at a set interval. The interval between the needle bed 1 and the needle bed 2 is adjusted according to the designed thickness of the fabric. The yarn padding interval of the yarn padding guide bar is 2-10 loop heights and 1-4 loop widths, which can form yarn support perpendicular to both sides of the fabric; (3) Finishing: Washing, dyeing, stretching and setting are carried out.

5. The comfort-type warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric according to claim 1, characterized in that, In step S1, the weaving structure is a heavy warp weave, the padding yarn number is 2-0 / 1-3 / / , the loop height is 60-110 loops / 10cm, and the loop width is 40-80 loops / 10cm.

6. The comfort-type warp-knitted air-layer three-dimensional structure flame-retardant, heat-insulating, and arc-resistant fabric according to claim 1, characterized in that, In step S2, the weaving structure is a three-needle warp satin weave, with the padding yarn number being 0-1 / 2-1 / 3-2 / 1-2 / / , the loop height being 60-110 loops / 10cm, and the loop width being 40-80 loops / 10cm.

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