Arc flash protective material

Abstract

The present disclosure relates to a relatively thin and lightweight multilayer fabric composite that can provide a high level of protection against thermal risks associated with arc flashes. The multilayer fabric composite comprises a laminated layer obtained by sewing one or more of laminated or flame-retardant fabric layers.

Description

Technical Field

[0001] The present invention relates to a protective multi-layer fabric composite. More specifically, the present invention relates to a lightweight fabric composite that provides protection against high-energy arc flashes and similar types of applied energy. Background Art

[0002] To reduce injuries, workers in hazardous environments where there may be short-term exposure to arc flashes (such as utility maintenance) require protective clothing. The protective equipment for workers exposed to these conditions should provide protection that allows the wearer to quickly and safely move away from the hazard rather than repair the hazard. The National Fire Protection Association (NFPA) has identified several levels of arc flash discharges. To rate a protective clothing as providing a certain level of protection for the wearer, there are minimum protection standards that the clothing must demonstrate to be sold as protective clothing. For example, clothing rated as Class 1 personal protective equipment (PPE) must be able to protect the wearer from a discharge of 4 calories per square centimeter (cal / cm 2 ). Class 2 PPE must be able to withstand an arc discharge of 8 cal / cm 2 , Class 3 PPE must withstand an arc discharge of 25 cal / cm 2 , Class 4 PPE must withstand 40 cal / cm 2 , and Class 5 arc discharges must withstand at least 75 cal / cm 2 of arc discharge. Generally, as the NFPA category rating increases from Class 1 to Class 5, the weight and volume of the PPE increase significantly.

[0003] Traditionally, arc-protective clothing has provided fire and heat protection. The clothing has always been made of the outermost layer of a full set of clothing (ensemble) containing non-flammable and non-melting fabrics, made of, for example: aramid, polybenzimidazole (PBI), poly-p-phenylene-2,6-benzobisoxazole (PBO), modified acrylic blends, polyamines, carbon, polyacrylonitrile (PAN), and their mixtures and combinations. These fibers can be inherently flame retardant, but can have several limitations. Specifically, to achieve the desired level of protection, relatively heavy, relatively thick, and bulky fabrics or multiple layers of these fabrics are required. Generally, the basis weight of these fabrics can exceed 400 grams per square meter 2For example, Class 5 clothing that can be hooked may have at least 3 layers, a thickness of about 4 mm, and an overall weight of greater than 800 g / m². The fibers used to form these textiles may also be very expensive, difficult to dye or factor, and may not have sufficient wear tolerance. In addition, compared to nylon or polyester-based fabrics, these fibers absorb more water and provide an unsatisfactory touch. To optimize user performance in an environment with occasional arc flash exposure, lightweight, breathable, and waterproof clothing with enhanced burn protection is needed. The cost of waterproof, arc flash-resistant protective clothing has been an important consideration in a large number of hazardous exposure applications, thus precluding the use of common, inherently flame-retardant textiles, such as the fabrics used in the fire community. Summary of the Invention

[0004] The present disclosure provides a relatively thin and lightweight multi-layer fabric composite that can provide a high level of protection from the thermal risks of arc flash. For example, the multi-layer fabric composite can provide protection from arc discharges ranging from 40 cal / cm 2 to over 100 cal / cm 2 In a first aspect, a multi-layer fabric composite is provided, the multi-layer fabric composite comprising: A) a first portion; and B) a second portion, wherein the first portion comprises a first laminate, the first laminate comprising: a1) a first fusible layer; a2) a first layer of a thermally reactive material comprising a polymer resin and expandable graphite; and a3) a first barrier layer; wherein the first portion and the second portion are attached to each other via one or more stitches. In a second aspect, the first laminate further comprises: a4) a first flame retardant (FR) fabric, wherein the first flame retardant fabric layer is adjacent to the first barrier layer and opposite to the first layer of the thermally reactive material.

[0005] In a third aspect, the multi-layer fabric composite as described in the first or second aspect comprises a second portion, wherein the second portion comprises: b) a second laminate, the second laminate comprising: b1) a second fusible layer; b2) a second layer of a thermally reactive material comprising a polymer resin and expandable graphite; and b3) a second barrier layer.

[0006] In a fourth aspect, the multi-layer fabric composite as described in any of the foregoing aspects, the second laminate further comprises: b4) a second flame retardant fabric, and the second flame retardant fabric is adjacent to the second barrier layer and opposite to the second layer of the thermally reactive material.

[0007] In a fifth aspect, the multi-layer fabric composite as described in the first or second aspect comprises a second portion, wherein the second portion comprises a third flame retardant fabric.

[0008] In aspect 6, the second part is adjacent to the first barrier layer of the first part.

[0009] In aspect 7, the second part is adjacent to the first flame retardant fabric of the first part.

[0010] In aspect 8, the second part comprises the second laminate, and the second fusible layer is adjacent to the first barrier layer of the first part.

[0011] In aspect 9, the second part comprises the second laminate, and the second fusible layer is adjacent to the first flame retardant fabric of the first part.

[0012] In aspect 10, the multi-layer fabric composite as described in any one of the foregoing aspects comprises a third part, wherein the third part is a fourth flame retardant fabric, and the third part is positioned between the first part and the second part.

[0013] In aspect 11, the multi-layer fabric composite as described in any one of the foregoing aspects comprises one or more stitches, wherein the stitches are: quilting stitches, a series of one or more sewing threads, a series of overlapping sewing threads, a series of sewn geometric shapes, a series of stitches in a grid pattern, a series of stitches that are substantially parallel to each other, a series of basting stitches, or a combination thereof.

[0014] In aspect 12, the multi-layer composite fabric as described in any one of the foregoing aspects comprises quilting stitches, wherein the quilting stitches are in the following sewing pattern: the sewing pattern comprises one or more horizontal pressure-bearing areas, wherein each horizontal pressure-bearing area is bounded by the quilting stitches, and wherein the horizontal pressure-bearing areas of the quilting pattern range from 1 centimeter 2 (cm 2 ) to 450 cm 2 .

[0015] In aspect 13, the first fusible fabric, the second fusible fabric, and the flame retardant fabric as described in any one of the foregoing aspects are each independently: a knitted fabric, a woven fabric, a non-woven fabric, or a combination thereof.

[0016] In aspect 14, the first fusible fabric and the second fusible fabric as described in any one of the foregoing aspects may independently comprise: polyamide fibers, polyester fibers, polyolefin fibers, acrylic fibers, polyurethane fibers, or a combination thereof.

[0017] In aspect 15, the flame-retardant fabric as described in any of the preceding aspects may comprise: aramid, p-aramid, m-aramid, polybenzimidazole, polybenzoxazole, polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modified acrylic resin, cellulose, FR cellulose, FR viscose, polyvinyl acetate, mineral fiber, protein fiber, or a combination thereof.

[0018] In aspect 16, the first layer of the thermally reactive material and the second layer of the thermally reactive material as described in any of the preceding aspects may be applied independently in a continuous or discontinuous manner.

[0019] In aspect 17, the weight of the multilayer fabric composite as described in any of the preceding aspects ranges from 250 to 800 grams per square meter (gsm).

[0020] In aspect 18, the first and / or second barrier layer as described in any of the preceding aspects may independently comprise: expanded polytetrafluoroethylene (ePTFE), polytetrafluoroethylene, polyurethane, polyethylene (PE), or a combination thereof.

[0021] In aspect 19, one or both of the first and second barrier layers as described in any of the preceding aspects independently comprise a multilayer film comprising two or more layers of ePTFE and polyurethane.

[0022] In aspect 20, the multilayer fabric composite as described in any of the preceding aspects, wherein the sewing connects at least a portion of the thickness of the first part to at least a portion of the thickness of the second part.

[0023] In aspect 21, the multilayer fabric composite as described in any of the preceding aspects, wherein the sewing connects the entire thickness of the first part to the entire thickness of the second part.

[0024] In aspect 22, the multilayer fabric composite as described in any of the preceding aspects, wherein the sewing is present on at least one surface of the multilayer fabric composite, or wherein the sewing is present on both surfaces of the multilayer fabric composite.

[0025] In aspect 23, the present disclosure relates to an article comprising the multilayer fabric composite as described in any of the preceding aspects.

[0026] In aspect 24, the article as described in the preceding aspect is: a blanket, clothing, a jacket, a coat, a vest, pants, work pants, a jumpsuit, leggings, a shirt, gloves, footwear, a headgear, a hood, a hat, or a combination thereof.

[0027] In aspect 25, the present disclosure relates to an article of clothing as described in aspect 24, wherein the article is an article of clothing and a first portion of the multi-layer fabric composite is positioned on an outer side of the article of clothing.

[0028] In aspect 26, the article as described in any of the foregoing aspects provides an arc thermal performance value of at least 40 cal / cm 2 (cal / cm 2 ) as measured according to ASTM F1959.

[0029] Multi-layer fabric composite

[0030] The present disclosure relates to a multi-layer fabric composite comprising: A) a first portion; and B) a second portion, wherein the first portion and the second portion are attached to each other via one or more sewings. The first portion comprises: a) a first laminate comprising: a1) a first meltable layer; a2) a first layer of a thermally reactive material comprising a polymer resin and expandable graphite; and a3) a first barrier layer. It is believed that the first portion is capable of dissipating a first portion of the energy of an arc flash exposure, thereby minimizing the amount of energy transmitted to the second portion. Optionally, the multi-layer fabric composite further comprises a third portion, wherein the third portion is located between the first and second portions and is attached to the multi-layer composite fabric via one or more sewings.

[0031] The first portion comprises a first laminate comprising: a1) a first meltable layer, a2) a first layer of a thermally reactive material comprising a polymer resin and expandable graphite, and a3) a barrier layer. The first portion may further comprise: a4) a first flame retardant fabric, wherein the first flame retardant fabric is adjacent to the first barrier layer. In some embodiments, the first meltable layer is a fabric that is the outermost layer on one side of the multi-layer fabric composite. The first meltable layer may be a woven fabric layer, a knitted fabric layer, or a non-woven fabric layer. The first meltable layer may be a meltable fabric. As used herein, the term "meltable" is a material that is meltable according to the melting and thermal stability tests described hereinafter.

[0032] In some embodiments, the second portion may be a second laminate comprising: b1) a second meltable layer, b2) a second layer of a thermally reactive material comprising a polymer resin and expandable graphite, and b3) a second barrier layer. In some embodiments, the second laminate may further comprise b4) a second flame retardant fabric.

[0033] In other embodiments, the second part may be a third flame retardant fabric. The third flame retardant fabric may be adjacent to the first barrier layer or adjacent to the first flame retardant fabric, if present. The first part is attached to the second part via one or more stitches.

[0034] The weight of the multi-layer fabric composite may range from 250 to 800 grams per square meter (gsm). In other embodiments, the weight of the multi-layer fabric composite may be in the range of: 250 to 750 gsm, or 250 to 700 gsm, or 250 to 675 gsm, or 250 to 650 gsm, or 250 to 625 gsm, or 250 to 600 gsm, or 275 to 800 gsm, or 275 to 750 gsm, or 275 to 700 gsm, or 275 to 675 gsm, or 275 to 650 gsm, or 275 to 625 gsm, or 375 to 600 gsm.

[0035] In further embodiments, the multi-layer fabric composite may be relatively thin, for example, having a thickness in the range of 1.25 millimeters (mm) to 3.0 mm. In other embodiments, the thickness of the multi-layer fabric composite may be in the range of: 1.3 mm to 2.9 mm, or 1.4 mm to 2.8 mm, or 1.4 mm to 2.75 mm, or 1.4 mm to 2.7 mm, or 1.4 mm to 2.6 mm.

[0036] The length and width of the multi-layer fabric composite are significantly greater than the thickness. For example, the multi-layer fabric composite may be 10 centimeters wide to about several meters wide. The length of the multi-layer fabric composite may be 10 centimeters to hundreds or thousands of meters long. In this way, the multi-layer fabric composite has a first major side and a second major side, with the second major side opposite the first side. The first side, i.e., the first major side, may be the first part, especially the first fusible layer forms the first side of the multi-layer fabric composite. The second side, i.e., the second major side of the multi-layer fabric composite, depends on the second part. In some embodiments, the second side may be the second barrier layer, the second flame retardant fabric, or the third flame retardant fabric.

[0037] Fusible layer

[0038] The multi-layer fabric composite includes a first meltable layer, and optionally a second meltable layer. Although the following description of the meltable layer is provided for the first meltable layer, it applies to both the first meltable layer and the second meltable layer, unless otherwise specified. The first meltable layer includes a fabric layer, where the fabric is a knitted fabric, a woven fabric, a non-woven fabric, or a combination thereof. The first meltable layer may include one or more meltable fibers, such as polyamide fibers, polyester fibers, polyolefin fibers, acrylic fibers, polyurethane fibers, or a combination thereof. The meltability of the meltable fabric layer can be determined using the melt and thermal stability tests provided herein.

[0039] The first meltable layer may include a relatively small amount of flame retardant fibers, non-meltable fibers, and / or antistatic fibers. If present, the presence of the flame retardant fibers, the non-meltable fibers, and / or the antistatic fibers causes the first meltable fabric to remain a meltable fabric when tested according to the melt and thermal stability tests described hereinafter. In some embodiments, the first meltable layer may be a meltable non-combustible fabric, such as: a phosphite / ester modified polyester (such as the material sold under the trade name CS by Trevira GmbH of Hattersheim, Germany, and the material sold under the trade name FR by RoseBrand of Secaucus (New Jersey, USA)).

[0040] The first meltable layer may include meltable fibers in an amount ranging from 50 wt% to 100 wt%. The first meltable layer may include meltable fibers in an amount ranging from 75 to 100 wt%. The first meltable layer may include meltable fibers in an amount ranging from 90 wt% to 100 wt%. The first meltable layer may include meltable fibers in an amount ranging from 95 wt% to 100 wt%. The remainder of the fibers may be antistatic fibers, meltable elastic fibers, non-meltable elastic fibers, or a combination thereof. For example, when the first meltable layer includes meltable fibers in an amount ranging from 95 to 99 wt%, the amount of the antistatic and / or elastic fibers may range from 1 to 5 wt%. All weight percentages are based on the total weight of the first meltable layer.

[0041] The weight of the first fusible layer may be less than or equal to about 250 gsm. In other embodiments, the weight of the first fusible layer may be from 30 gsm to 250 gsm, or the weight may be from 40 gsm to 200 gsm, or the weight may be from 40 gsm to 175 gsm, or the weight may be from 50 gsm to 200 gsm, or the weight may be about 60 gsm to 200 gsm, or the weight may be from 50 gsm to 180 gsm, or the weight may be about 60 gsm to 180 gsm, or the weight may be from 50 gsm to 175 gsm, or the weight may be about 60 gsm to 175 gsm, or the weight may be from 75 gsm to 200 gsm, or the weight may be about 75 gsm to 180 gsm.

[0042] The first fusible layer may be a combustible or non-combustible material. As used herein, a "combustible" material is combustible when tested in the Vertical Flame Test for Textile for determining whether a fabric is combustible or non-combustible as described below.

[0043] The first fusible layer may comprise: polyester fibers, polyamide fibers, polyolefin fibers, acrylic fibers, polyurethane fibers, or combinations thereof. Suitable polyesters may include, for example: polyethylene terephthalate, trimethylene terephthalate, polybutylene terephthalate, or combinations thereof. Suitable polyamides may include, for example: nylon 6, nylon 6,6, or combinations thereof. Suitable polyolefins may include, for example: polyethylene, polypropylene, or combinations thereof. In some embodiments, the first fusible layer comprises: polyamide fibers, polyester fibers, polyolefin fibers, or combinations thereof.

[0044] Fusible fabrics are not commonly used in arc-resistant laminates because the standards governing arc-resistant clothing require that the fabric or laminate be flame retardant in order to even meet the arc test (ASTM 1959). Unexpectedly, a multi-layer fabric composite comprising an outer fabric layer that is fusible can be used to provide protection from arc flash incidents.

[0045] Thermally reactive material

[0046] The first part of the multi-layer fabric composite further comprises a first layer of thermally reactive material, the first layer of thermally reactive material comprising a polymeric resin and expandable graphite. The first layer of thermally reactive material may be positioned between the first meltable layer and the first barrier layer. The first layer of this thermally reactive layer may act as an adhesive to attach or bond the first meltable layer to the first barrier layer. The second layer of thermally reactive material may be positioned between the second meltable layer and the second barrier layer of the second part. The second layer of thermally reactive material may also act as an adhesive to attach or bond the second meltable layer to the second barrier layer. Unless otherwise specified, the description of the thermally reactive material hereinafter applies to both the first and second layers of the thermally reactive material.

[0047] The thermally reactive material layer may act as an adhesive to fix the first meltable layer to the first barrier layer or the second meltable layer to the second barrier layer. In some embodiments, the thermally reactive material layer may be applied as a continuous layer. In other embodiments, the thermally reactive material may be applied as a discontinuous layer. The thermally reactive material may be applied in a discontinuous manner to form a thermally reactive material layer with a surface coverage of less than 100%. The thermally reactive material may be applied in a pattern of discontinuous form. The thermally reactive material may be applied in a dot pattern, a grid pattern, a line pattern, a corrugated pattern, or any other pattern, or a combination thereof.

[0048] The thermally reactive material may comprise expandable graphite. The thermally reactive material may comprise a polymeric resin. The thermally reactive material may comprise a mixture of expandable graphite and a polymeric resin.

[0049] In the TMA expansion test described herein, when heated to about 240 °C, the expandable graphite may expand by at least about 400 microns. In the TMA expansion test described herein, when heated to about 240 °C, the expandable graphite may expand by at least about 500 microns. In the TMA expansion test described herein, when heated to about 240 °C, the expandable graphite may expand by at least about 600 microns. In the TMA expansion test described herein, when heated to about 240 °C, the expandable graphite may expand by at least about 700 microns. In the TMA expansion test described herein, when heated to about 240 °C, the expandable graphite may expand by at least about 800 microns. In the TMA expansion test described herein, when heated to about 280 °C, the expandable graphite may expand by at least about 900 microns.

[0050] The average expansion of the expandable graphite at 300 °C can be at least about 4 cubic centimeters per gram (cc / g), or at least about 5 cc / g, or at least about 6 cc / g, or at least about 7 cc / g, or at least about 8 cc / g, or at least about 9 cc / g, or at least about 10 cc / g, or at least about 11 cc / g, or at least about 12 cc / g, or at least about 19 cc / g, or at least about 20 cc / g, or at least about 21 cc / g, or at least about 22 cc / g, or at least about 23 cc / g, or at least about 24 cc / g, or at least about 25 cc / g, which is tested using the in-furnace expansion test described herein. For example, the average expansion of the expandable graphite at 300 °C can be about 19 cc / g, which is tested using the in-furnace expansion test described herein.

[0051] The endotherm of the expandable graphite can be greater than or equal to about 50 J / g, or greater than or equal to about 75 J / g, or greater than or equal to about 100 J / g, or greater than or equal to about 125 J / g, or greater than or equal to about 150 J / g, or greater than or equal to about 175 J / g, or greater than or equal to about 200 J / g, or greater than or equal to about 225 J / g, or greater than or equal to about 250 J / g. Differential scanning calorimetry (DSC) can be used to determine the endotherm value of the expandable graphite material.

[0052] The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 4 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 6 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 8 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 9 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 10 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 12 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 14 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 16 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 18 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 19 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 20 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 100 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.

[0053] The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 4 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 6 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 8 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 9 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 10 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 12 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 14 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 16 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.The thermally reactive material can include expandable graphite having the property that the average expansion at 300 °C is at least about 18 cubic centimeters per gram (cc / g), which is tested using the in-furnace expansion test described herein; and the endotherm is at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the property that the average expansion at 300 °C is at least about 19 cubic centimeters per gram (cc / g), which is tested using the in-furnace expansion test described herein; and the endotherm is at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the property that the average expansion at 300 °C is at least about 20 cubic centimeters per gram (cc / g), which is tested using the in-furnace expansion test described herein; and the endotherm is at least about 150 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.

[0054] The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 4 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 6 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 8 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 9 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 10 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 12 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 14 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material can include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 16 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 18 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 19 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 20 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 200 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.

[0055] The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 4 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 6 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 8 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 9 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 10 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 12 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 14 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may comprise expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 16 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 18 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 19 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein. The thermally reactive material may include expandable graphite having the following properties: the expandable graphite has an average expansion of at least about 20 cubic centimeters per gram (cc / g) at 300 °C, which is tested using the in-furnace expansion test described herein; and an endotherm of at least about 250 joules per gram (J / g), which is tested according to the DSC endotherm test method described herein.

[0056] The size of the expandable graphite particles may be selected such that the thermally reactive material can be applied by the selected application method. For example, if the thermally reactive material is applied by a gravure printing technique, the expandable graphite particle size should be small enough to fit into the gravure cells.

[0057] The thermally reactive material may include a polymer resin. The melting or softening temperature of the polymer resin may be lower than about 280 °C. The polymer resin may be sufficiently fluid or deformable to allow the expandable graphite to expand significantly upon thermal exposure at or below about 300 °C. The polymer resin may be sufficiently fluid or deformable to allow the expandable graphite to expand significantly upon thermal exposure at or below about 280 °C. The polymer resin may allow the expandable graphite to expand sufficiently at a temperature below the pyrolysis temperature of the first and / or second molten layers. The tensile viscosity of the polymer resin may be low enough to allow the expandable graphite to expand and high enough to maintain the structural integrity of the thermally reactive material after the mixture of the polymer resin and the expandable graphite expands. These factors can be quantified by the storage modulus and tanΔ of the polymer.

[0058] The storage modulus of the polymer resin may be at least about 103 dynes / cm 2 . The storage modulus of the polymer resin may be from 103 to 108 dynes / cm 2 . The storage modulus of the polymer resin may be from 103 to 107 dynes / cm 2 . The storage modulus of the polymer resin may be from 103 to 106 dynes / cm 2 . The storage modulus of the polymer resin may be from 103 to 105 dynes / cm2 The storage modulus of the polymer resin may be from 103 to 104 dynes / cm 2 The storage modulus is a measure of the elastic behavior of the polymer and can be measured using dynamic mechanical analysis (DMA). The TanΔ of the polymer resin at 200 °C may be from about 0.1 to about 10. TanΔ is the ratio of the loss modulus to the storage modulus and can also be measured using DMA techniques.

[0059] The modulus and elongation of the polymer resin at around or below about 300 °C may be suitable to allow the expandable graphite to expand. The polymer numerical value may be elastomeric. The polymer resin may be cross-linkable, such as cross-linkable polyurethane. The polymer may be thermoplastic.

[0060] The polymer resin may comprise polymers including but not limited to: polyester, polyether, polyurethane, polyamide, acrylic, vinyl polymer, polyolefin, silicone, epoxide, or combinations thereof.

[0061] The thermally reactive material and / or the polymer resin may comprise a flame retardant material. The flame retardant material may comprise: melamine, phosphorus, metal hydroxides such as aluminum trihydrate (ATH), borates / esters, or combinations thereof. The flame retardant material may comprise: brominated compounds, chlorinated compounds, antimony oxide, organophosphorus-based compounds, zinc borate, ammonium polyphosphate, melamine cyanurate, melamine polyphosphate, molybdenum compounds, magnesium hydroxide, triphenyl phosphate, resorcinol bis-(diphenyl phosphate), bisphenol A-(diphenyl phosphate), tricresyl phosphate, organophosphonates / esters, phosphonates, or combinations thereof. If present, the flame retardant material may be used in a proportion of 1% to 50% by weight, based on the total weight of the polymer resin.

[0062] The thermally reactive material may form a plurality of tendrils containing graphite that expands when exposed to heat from an electric arc. The total surface area of the thermally reactive material may increase significantly compared to before expansion of the mixture. For example, the surface area of the thermally reactive material may increase by at least 2 times, or at least 3 times, or at least 4 times, or at least 5 times, or at least 6 times, or at least 7 times, or at least 8 times, or at least 9 times, or at least 11 times, or at least 12 times, or at least 13 times, or at least 14 times, or at least 15 times after expansion.

[0063] Tendrils may extend outward from the expanded thermally reactive material. When the thermally reactive material is located on the layer in a discontinuous form, the tendrils may extend so as to at least partially fill the open area between the discontinuous domains of the thermally reactive material. The tendrils may elongate and the aspect ratio of length to width may be at least 5 to 1.

[0064] In an embodiment where the thermally reactive material comprising the polymer resin - expandable graphite mixture is applied in a pattern in a discontinuous form, the thermally reactive material is expandable and, upon expansion, forms loosely packed tendrils with voids therebetween and spaces between the patterns of the thermally reactive material. Without wishing to be bound by theory, upon exposure to heat from an electric arc, each of the first and second fusible layers melts and generally departs from the open areas between the thermally reactive material in the discontinuous form.

[0065] The thermally reactive material can act as an adhesive material between the first fusible layer and the first barrier layer and between the second fusible layer and the second barrier layer.

[0066] The thermally reactive material can be prepared by a method that provides an intimate blend of the polymer resin and expandable graphite without causing significant expansion of the expandable graphite. The polymer resin and expandable graphite can be blended to form a mixture that can be applied in a continuous or discontinuous pattern to a surface interface (i.e., at least one surface of the first fusible layer and the first barrier layer; and at least one of the surfaces of the second fusible layer and the second barrier layer). In this way, the layers of the first and second thermally reactive materials can act as adhesives to attach or bond the layer of the first fusible layer to the first barrier layer and attach the second fusible layer to the second barrier layer. The polymer resin and expandable graphite mixture can be mixed by any suitable mixing method. Suitable mixing methods include but are not limited to: paddle mixers, blending, and other low - shear mixing techniques.

[0067] The thermally reactive material comprising the polymer resin and expandable graphite can be prepared by mixing the expandable graphite with a monomer or prepolymer prior to polymerizing the polymer resin. In other embodiments, the thermally reactive material can be prepared by blending the expandable graphite with a polymer resin dissolved in a solvent, wherein at least a portion of the solvent is removed after mixing. In other embodiments, the thermally reactive material can be prepared by mixing expandable graphite with a polymer melted at a temperature below the expansion temperature of the graphite and above the melting temperature of the polymer. Without wishing to be bound by theory, the mixtures prepared by these methods can comprise an intimate blend of polymer resin and expandable graphite particles.

[0068] In a method of providing a intimate blend of a polymeric resin and expandable graphite particles or an agglomerate of expandable graphite, the expandable graphite is coated or encapsulated by the polymeric resin prior to graphite expansion. An intimate blend of the polymeric resin and expandable graphite can be prepared prior to applying the thermally reactive material to the first or second meltable layer or the first or second barrier layer.

[0069] The thermally reactive material can comprise less than or equal to about 50 wt% expandable graphite, based on the total weight of the thermally reactive material. In other embodiments, the thermally reactive material can comprise less than or equal to about 40 wt%, or less than or equal to about 30 wt%, or less than or equal to about 20 wt%, or less than or equal to about 10 wt%, or less than or equal to about 5 wt%, or greater than or equal to about 1 wt% of the expandable graphite, based on the total weight of the thermally reactive material, with the balance essentially comprising the polymeric resin. Generally, from about 5 wt% to about 50 wt% expandable graphite, based on the total weight of the thermally reactive material, is desirable. However, desired flame retardant properties can be achieved with even lesser amounts of expandable graphite. In some embodiments, loadings as low as 1 wt% can be used. Other levels of expandable graphite may be suitable for other embodiments, depending on the desired properties and construction of the resulting laminate structure. Other additives, such as colorants, fillers, antimicrobial agents, processing aids, and stabilizers, can also be added to the thermally reactive material.

[0070] The first laminate comprises a first meltable layer and a first barrier layer, with a layer of the first thermally reactive material therebetween acting as an adhesive. The first layer of the thermally reactive material can be applied to one side of the first meltable layer and / or one side of the first barrier layer. The second layer of the thermally reactive material can be applied to one side of the second meltable layer and / or one side of the second barrier layer.

[0071] The first and / or second layer of the thermally reactive material can be applied independently in a continuous or discontinuous manner. For example, when enhanced breathability and / or hand is desired, both layers of the thermally reactive material can be applied in a discontinuous manner, resulting in a thermally reactive material layer with a surface coverage of less than 100%. Applying the thermally reactive material layer discontinuously can result in a surface coverage of less than 100% on the meltable fabric and the barrier layer.

[0072] A layer of heat-reactive material can be applied in a discontinuous manner in one or more patterns. The heat-reactive material can be applied to the first fusible layer or the first barrier layer, and to the second fusible layer, or to the second barrier layer, to form each layer of heat-reactive material in the form of a plurality of discrete pre-expanded structures. Upon expansion, the discrete pre-expanded structures can form a plurality of expanded structures having structural integrity. The plurality of discrete expanded structures having structural integrity can provide sufficient protection for the multi-layer fabric composite to achieve the enhanced properties described herein. Structural integrity means that after expansion, the heat-reactive material withstands flexure or bending without substantially disintegrating or flaking off, and withstands compression when measuring the thickness, which is measured according to the Thickness Change Test described herein.

[0073] A layer of heat-reactive material can be applied in a discontinuous manner in a pattern that includes a plurality of discrete pre-expanded structures that include the heat-reactive material. The pattern can include shapes such as dots, circles, diamonds, ellipses, stars, rectangles, squares, triangles, pentagons, hexagons, octagons, lines, ripples, etc., and combinations thereof.

[0074] The average distance between adjacent regions of the discontinuous pattern of the heat-reactive material can be less than the size of an impinging flame. The average distance between adjacent regions of the discontinuous pattern can be equal to or less than about 10 millimeters (mm), or equal to or less than about 9 mm, or equal to or less than about 8 mm, or equal to or less than about 7 mm, or equal to or less than about 6 mm, or equal to or less than about 5 mm, or equal to or less than about 4 mm, or equal to or less than about 3.5 mm, or equal to or less than about 3 mm, or equal to or less than about 2.5 mm or equal to or less than about 2 mm, or equal to or less than about 1.5 mm, or equal to or less than about 1 mm, or equal to or less than about 0.5 mm, or equal to or less than about 0.4 mm, or equal to or less than about 0.3 mm, or equal to or less than about 0.2 mm. For example, in a dot pattern of the heat-reactive material printed out, the spacing between the edges of two adjacent dots of the heat-reactive material will be measured. Depending on the application, the average distance between adjacent regions of the discontinuous pattern can be equal to or greater than about 40 microns, or equal to or greater than about 50 microns, or equal to or greater than about 100 microns, or equal to or greater than about 200 microns. In some patterns described herein, an average dot spacing of equal to or greater than about 200 microns and equal to or less than about 500 microns has been found useful.

[0075] The pitch can be used, for example, in conjunction with the surface coverage as a way to describe the laydown of a printed pattern. Generally, the pitch is defined as the average center-to-center distance between adjacent forms of the printed pattern, such as dots, lines, or grid lines. This average value is used, for example, to account for a printed pattern with irregular spacing. A pattern having the following pitch and surface coverage can be applied in a discontinuous manner to the thermally reactive material: the pitch and surface coverage provide superior flame retardant properties as compared to a thermally reactive mixture having the same weight of the thermally reactive material deposited continuously. The pitch can be defined as the average of the center-to-center distances between adjacent shapes of the thermally reactive material. For example, the pitch can be defined as the center-to-center distance between adjacent dots or grid lines of the thermally reactive material. The pitch can be: equal to or greater than about 500 microns, equal to or greater than about 600 microns, equal to or greater than about 700 microns, equal to or greater than about 800 microns, equal to or greater than about 900 microns, equal to or greater than about 1000 microns, equal to or greater than about 1200 microns, equal to or greater than about 1500 microns, equal to or greater than about 1700 microns, equal to or greater than about 1800 microns, equal to or greater than about 2000 microns, equal to or greater than about 3000 microns, equal to or greater than about 4000 microns, or equal to or greater than about 5000 microns, or equal to or greater than about 6000 microns, or any value therebetween. The pitch of a preferred pattern of the thermally reactive material can be from about 500 microns to about 6000 microns.

[0076] In embodiments where properties such as hand feel, breathability, and / or fabric weight are important, a surface coverage of equal to or greater than about 25% and equal to or less than about 90%, or equal to or greater than about 25% and less than about 80%, or equal to or greater than about 25% and less than about 70%, or equal to or greater than about 25% and less than about 60%, or equal to or greater than about 25% and less than about 50%, or equal to or greater than about 25% and less than about 40%, or equal to or greater than about 25% and less than about 30% can be used. When exposed to an electric arc, the first fusible layer can be exposed to sufficient energy to burn. In those embodiments, and if higher flame retardant properties are desired, a surface coverage of the thermally reactive material on the surface of the first or second fusible layer of about 30% to about 100% can be desired. If higher flame retardant properties are desired, then a surface coverage of the thermally reactive material with a pitch of about 500 microns to about 6000 microns can be desired. For example, the surface coverage of the thermally reactive material can be: about 30% to about 80% of the thermally reactive material on the surface of the first or second fusible layer or on the first or second barrier layer, where the pitch is from about 500 microns to about 6000 microns.

[0077] A method of depositing the thermally reactive material in a discontinuous manner on the first or second meltable layer, or the first or second barrier layer, such that the surface coverage is less than 100% may include: applying the thermally reactive material by printing onto the layer. Depositing the thermally reactive material on the first or second meltable layer and / or the first or second barrier layer may be achieved by any suitable method, such as: gravure printing, screen printing, spray or scatter coating, knife coating, and any similar method that enables the thermally reactive material to be applied in a manner such that the desired properties are achieved upon exposure to heat from an electric arc.

[0078] The thermally reactive material may be applied to achieve an add-on weight of from about 10 gsm to about 100 gsm per thermally reactive material layer. The thermally reactive material may be applied to achieve an add-on weight of the thermally reactive material that is equal to or less than about 100 gsm, or equal to or less than about 75 gsm, or equal to or less than about 50 gsm, or equal to or less than about 25 gsm.

[0079] A method of manufacturing the first and second laminates as described herein may include: applying a layer of thermally reactive material to the first or second meltable layer and / or the first or second barrier layer in an amount that provides good bonding between the barrier layer and the corresponding meltable layer. The role of the thermally reactive material layer may be that of an adhesive. For example, the thermally reactive material may bond one side of the first meltable layer to one side of the first barrier layer, thereby forming a thermally reactive material layer between the first meltable layer and the first barrier layer. Similarly, a second layer of the thermally reactive material may bond one side of the second meltable layer to one side of the second barrier layer, thereby forming a second layer of thermally reactive material between the second meltable layer and the second barrier layer.

[0080] During the formation of the first and / or second laminate, layers of the first and / or second thermally reactive material may be applied independently, either continuously or discontinuously, to the fusible layer and / or to the barrier layer. The first fusible layer and the first barrier layer may then adhere to each other, and the second fusible layer and the second barrier layer may then adhere to each other. Optionally, each of the first and / or second laminates may then be kneaded by two or more rollers to apply pressure and / or heat to help ensure a strong bond. If heating is employed, the temperature should be low enough such that the heat does not cause the exfoliated graphite to expand. Applying pressure (e.g., pressure from rollers) may cause at least the polymer resin in the thermally reactive material to enter at least partially into surface pores, surface voids, or the voids or spaces between fibers in one or both of the layers. At least the polymer resin in the thermally reactive material may penetrate into the voids or spaces between the fibers and / or fibrils of the fusible layer. In some embodiments, at least the polymer resin in the thermally reactive material may penetrate into the barrier layer. In yet further embodiments, at least the polymer resin in the thermally reactive material may penetrate into the voids or spaces between the fibers of the fusible layer and may also penetrate into the barrier layer.

[0081] Barrier layer

[0082] The multilayer fabric composite further comprises the first barrier layer and, if present, the second barrier layer. The following description of the barrier layer is for the first barrier layer but may also apply to the second barrier layer. In some embodiments, the barrier layer is in the form of a film. Each of the barrier layers may independently comprise a layer of: polyimide, silicone, polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyolefin, polyethylene, polypropylene, or a combination thereof. In some embodiments, the first and the second barrier layers may comprise expanded polytetrafluoroethylene (ePTFE).

[0083] The first and / or the second barrier layer may independently be a single-layer film, a double-layer film, a triple-layer film, or a multi-layer film. Suitable single-layer films may comprise a layer of a microporous expanded polytetrafluoroethylene film, a polyimide film, a silicone film, or a polytetrafluoroethylene film. In some embodiments, the barrier layer may be a multi-layer film comprising: a microporous expanded polymer film comprising micropores, and an additional polymer that fills at least a portion of the pores of the expanded polymer film, and optionally a caplayer or film layer formed on one or both sides of the microporous expanded polymer film.

[0084] In some embodiments, the double-layer barrier layer may include a first layer of microporous expanded polytetrafluoroethylene and a second layer of microporous expanded polytetrafluoroethylene. In other embodiments, the double-layer barrier layer may include: a first layer of microporous expanded polytetrafluoroethylene, and a polyurethane coating on the microporous expanded polytetrafluoroethylene layer, wherein the polyurethane layer is a coating on the microporous ePTFE surface and / or the polyurethane fills at least a portion of the pores of the microporous ePTFE layer. In other embodiments, the three-layer barrier layer may include a polyurethane layer between two layers of microporous ePTFE. In some three-layer embodiments, the polyurethane layer at least partially penetrates the pores of one or both of the microporous ePTFE layers. In other embodiments, the first and / or second barrier layer may be a microporous expanded polyolefin film layer, wherein the polyurethane layer is coated on the microporous expanded polyolefin film. The polyurethane may penetrate at least a portion of the pores of the microporous expanded polyolefin film and / or may form a capping layer on top of the polyolefin film. In other embodiments, the first and / or second barrier layer may be a microporous expanded polyethylene film layer, wherein the polyurethane layer is coated on the microporous expanded polyethylene film. The polyurethane may penetrate at least a portion of the pores of the microporous expanded polyethylene film and / or may form a capping layer on top of the microporous expanded polyethylene film.

[0085] The barrier layer may be a film having a thickness equal to or less than 1 millimeter (mm) and a handle equal to or less than about 100, the thickness and handle being tested by the flexibility or handle measurements described herein.

[0086] The barrier layer may be a thermally stable barrier layer. In some embodiments, the barrier layer is a thermally stable barrier layer as measured by the barrier thermal stability test described herein. The barrier layer may have a higher thermal stability compared to the first and / or second meltable layer and / or any of the first, second, third, or fourth flame retardant fabrics that may be present. The thermally stable barrier layer may help prevent heat transfer from one side (outer side) to the other side (inner side) of the multi-layer fabric composite during exposure to an electric arc, such as heat transfer from the first part to the second part. The thermally stable barrier layer used as the barrier layer in the embodiments described herein has a maximum air permeability of about 50 liters per meter 2 / second (l / m 2 / sec) as tested according to the air permeability test ISO 9237 (1995). The thermally stable barrier layer used as the barrier layer in the embodiments described herein also has the property of preventing pore formation (diameter greater than or equal to 5 millimeters) after exposure to an electric arc. In other embodiments, the maximum air permeability of the barrier layer after thermal exposure is less than about 25 l / m 2 / sec, or less than about 15 l / m 2 / sec, as measured according to the air permeability test for the thermally stable barrier layer described herein. When the barrier layer comprises a film, the maximum air permeability of the film after thermal exposure may be equal to or less than about 25 l / m 2 / sec, as measured according to the melting and thermal stability tests described herein. When the barrier layer comprises a film, the air permeability of the film after arc exposure sufficient to expand the expandable graphite may be equal to or less than about 15 l / m 2 / sec, as measured according to the air permeability test for the thermally stable barrier disclosed herein.

[0087] The maximum air permeability of the barrier layer after thermal exposure may be equal to or less than about 50 l / m 2 / sec, or equal to or less than about 45 l / m 2 / sec, or equal to or less than about 40 l / m 2 / sec, or equal to or less than about 35 l / m 2 / sec, or equal to or less than about 30 l / m 2 / sec, or equal to or less than about 25 l / m 2 / sec, or equal to or less than about 20 l / m 2 / sec, or equal to or less than about 15 l / m 2 / sec, or equal to or less than about 10 l / m 2 / sec, or equal to or less than about 5 l / m 2 / sec, as measured according to the air permeability test for the thermally stable barrier layer described herein.

[0088] The weight of the barrier layer can be in the range of 4 grams per square meter (gsm) to 60 gsm, or in the range of 5 gsm to 55 gsm, or in the range of 6 gsm to 50 gsm, or in the range of 8 gsm to 50 gsm, or in the range of 10 gsm to 50 gsm, or in the range of 10 gsm to 45 gsm, or in the range of 10 gsm to 40 gsm, or in the range of 10 gsm to 35 gsm, or in the range between 30 gsm and 40 gsm, or in the range between 20 gsm and 30 gsm, or in the range between 15 gsm and 35 gsm, or in the range between 20 gsm and 35 gsm, or in the range between 25 gsm and 35 gsm, or in the range between 30 gsm and 35 gsm, or in the range between 15 gsm and 30 gsm, or in the range between 25 gsm and 30 gsm, or in the range between 15 gsm and 25 gsm, or in the range between 20 gsm and 25 gsm, or in the range between 15 gsm and 20 gsm, or in the range between 21 gsm and 23 gsm, or in the range between 29 gsm and 31 gsm, or any value therebetween, or approximately 22 gsm, or approximately 30 gsm.

[0089] Flame-retardant fabric

[0090] The present disclosure describes a first flame retardant fabric, a second flame retardant fabric, a third flame retardant fabric, and a fourth flame retardant fabric. Each of these flame retardant fabrics is a separate layer that can be present in the multi-layer fabric composite, and the following description of the flame retardant fabrics applies to describe each flame retardant fabric that can be used in any part. Each flame retardant fabric can be selected independently relative to the other flame retardant fabrics (if present). Thus, each flame retardant fabric can be the same or different.

[0091] The first part may include a first flame retardant fabric. The first flame retardant fabric may be adjacent to the first barrier layer. Suitable flame retardant fabrics may include fibers or yarns made from materials that are inherently flame retardant, materials that have been treated with one or more flame retardants to make them flame retardant, or combinations thereof. Suitable materials may include, for example: aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymers, polytetrafluoroethylene, modified acrylics, cellulose, FR cellulose, FR viscose, polyvinyl acetate, polyacrylonitrile, carbon, minerals, protein fibers, or combinations thereof. In some embodiments, a small proportion (e.g., less than 10 wt% antistatic fibers or filaments) may be added to the fabric, wherein the weight percentage of the antistatic fibers or filaments is based on the total weight of the flame retardant fabric. Suitable antistatic fibers / filaments are known in the art and may include, for example: conductive metals, copper, nickel, stainless steel, steel, gold, silver, titanium, carbon fibers.

[0092] The weight of the flame retardant fabric may range from 100 grams per square meter (gsm) to about 300 gsm. In other embodiments, the weight of the flame retardant fabric may range from 100 gsm to about 275 gsm, or 100 gsm to about 250 gsm, or 100 gsm to about 240 gsm, or 100 gsm to about 230 gsm, or 100 gsm to about 225 gsm, or 100 gsm to about 220 gsm.

[0093] When the first flame retardant fabric is part of the first laminate, it may be attached to the first barrier layer with a flame retardant adhesive. The flame retardant adhesive may be any fabric adhesive known in the art. Typically, one or more flame retardants may be added to the adhesive to provide flame retardancy. Typical flame retardants include, for example: phosphorus-based flame retardants, amine-based flame retardants, other known flame retardants, or combinations thereof.

[0094] Second part

[0095] The multi-layer fabric composite further includes a second part. In some embodiments, the second part is adjacent to the first part and is attached to the first part via one or more sewings. In other embodiments, a third part is located between the first part and the second part, wherein at least a portion of the first, second, and third parts are attached via one or more sewings.

[0096] The second part may comprise: b) the second laminate, wherein the second laminate comprises: b1) the second fusible layer; b2) the second layer of the thermally reactive material; b3) the second barrier layer; and optionally b4) the second flame retardant fabric; or the second part may comprise the third flame retardant fabric. In some preferred embodiments, the second part may be adjacent to the first barrier layer of the first part. In embodiments where the second part is the third flame retardant fabric, the third flame retardant fabric is adjacent to the first barrier layer. In embodiments where the second part is a second laminate, the second fusible layer of the second part is adjacent to the first barrier layer of the first part. The second flame retardant fabric may be adhered to the second barrier layer by one or more of the flame retardant adhesives described above.

[0097] When the second part is the third flame retardant fabric, the third flame retardant fabric may be: a woven, knitted, or non-woven fabric comprising, for example, fibers such as: aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modified acrylic, cellulose, FR cellulose, FR viscose, polyvinyl acetate, polyacrylonitrile, carbon, mineral, protein fiber, or a combination thereof. In some embodiments, a small proportion (e.g., less than 10 wt%) of antistatic fibers or filaments may be added to the third flame retardant fabric, wherein the weight percentage of the antistatic fibers or filaments is based on the total weight of the third flame retardant fabric. Suitable antistatic fibers / filaments are known in the art and may include, for example: conductive metals, copper, nickel, stainless steel, steel, gold, silver, titanium, carbon fiber.

[0098] When the second part is the second laminate, the second fusible layer, the second layer of the heat-reactive material, and the second barrier layer can each independently use any of the materials described with respect to the first fusible layer, the first layer of the heat-reactive material, and / or the first barrier layer. For example, the first fusible layer can be a polyester woven fabric, and the second fusible layer can be another layer of the same polyester woven fabric, or the second fusible layer can be a polyamide knitted fabric. In other words, any of the materials described with respect to the first fusible layer can be independently used for the second fusible layer; any of the materials described with respect to the first layer of the heat-reactive material can be independently used for the second layer of the heat-reactive material; and any of the materials described with respect to the first barrier layer can be independently used for the second barrier layer. In some embodiments, the first and second fusible layers are the same. In some embodiments, the first and second layers of the heat-reactive material are the same. In some embodiments, the first and second barrier layers are the same. In some embodiments, the first and second fusible layers are different. In some embodiments, the first and second layers of the heat-reactive material are different. In some embodiments, the first and second barrier layers are different.

[0099] If desired, the second laminate can further comprise: b4) the second flame-retardant fabric. Any of the materials described with respect to the first flame-retardant fabric can be employed. For example, the second flame-retardant fabric can comprise one or more of the following: aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modified acrylic, cellulose, FR cellulose, FR viscose, polyvinyl acetate, mineral, protein fiber, or combinations thereof. One or more of the antistatic fibers described previously can be present in the second flame-retardant fabric in an amount of 10 wt% or less, based on the total weight of the second flame-retardant fabric. If present, the first and second flame-retardant fabrics can be the same or different.

[0100] As described previously, the second flame-retardant fabric can be adhered to the second barrier layer via an adhesive (preferably an adhesive containing a flame-retardant additive). Suitable fabric adhesives and adhesives containing flame retardants are known in the art and can include, for example: polyurethane adhesives, polyester adhesives, acrylic adhesives, or combinations thereof.

[0101] The second laminate is positioned and attached to the first portion such that the resulting first barrier layer is oriented adjacent to the second fusible layer. In some embodiments, there is no third portion between the first barrier layer and the second fusible layer. In some embodiments, there is a third portion between the first portion and the second portion. In some embodiments, sewing is used to attach at least one layer in the first portion to at least one layer in the second portion.

[0102] Third part

[0103] The multi-layer fabric composite may further comprise a third portion. In some embodiments of the multi-layer fabric composite, there is the third portion. In some embodiments of the multi-layer fabric composite, the third portion is not included. The third portion comprises a fourth flame retardant fabric positioned between the first portion and the second portion and attached to the multi-layer fabric composite via the one or more sewings.

[0104] The third portion comprises the fourth flame retardant fabric. The fourth flame retardant fabric can be a knitted fabric, a woven fabric, a non-woven fabric, or a multi-layer combination thereof. Suitable flame retardant fabrics can include, for example: aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modified acrylic, cellulose, FR cellulose, FR viscose, polyvinyl acetate, mineral, protein fiber, or a combination thereof. One or more of the antistatic fibers described previously can be present in the second flame retardant fabric in an amount of 10 wt% or less, based on the total weight of the second flame retardant fabric. If present, the first, second, third, and fourth flame retardant fabrics can be the same or different.

[0105] Sew (STICH)

[0106] The first portion, the second portion, and optionally the third portion are attached to each other via one or more sewings. The sewing is stitch sewing and can be machine sewn, hand sewn, or a combination thereof. The sewing comprises one or more of the following: quilting sewing, a series of one or more sewing threads, a series of overlapping sewing threads, a series of sewn geometric shapes, a series of sewing in a grid pattern, a series of sewings that are substantially parallel to each other, a series of basting stitches, or a combination thereof.

[0107] The sewing forms a connection or attachment between the parts, where one side of the first part (e.g., the first barrier layer) is connected to one side of the second part (e.g., the second fusible layer). In embodiments where there is a third part, the third part is located between the first part and the second part and is attached to the first and second parts via the sewing. In some embodiments (as Figure 4 exemplarily shown), one side of the third part contacts the first barrier layer of the first part, while the opposite side of the third part contacts the second part. The quilting sewing penetrates the first fusible layer, the first layer of the heat-reactive material, the first barrier layer, and both the third part and the second part. When the second part is a second laminate (as Figure 5 exemplarily shown), the first barrier layer contacts one side of the third part, while the opposite side of the third part contacts the second fusible layer of the second part. In other embodiments that include a third part, the first flame-retardant layer contacts one side of the third part, while the opposite side of the third part contacts the second part.

[0108] The sewing creates connection areas between the two parts and is spaced apart such that the horizontal pressure-bearing areas of the first and second parts are not tightly connected. The sewings should be spaced far enough apart from each other such that a horizontal pressure-bearing area in the range of about 1 centimeter 2 (cm 2 ) to about 1500 cm 2 is provided between the sewings. In other embodiments, the horizontal pressure-bearing area can be in the range of: 1 to 1400 cm 2 , or 1 to 1300 cm 2 , or 1 to 1250 cm 2 , or 1 to 1200 cm 2 , or 1 to 1150 cm 2 , or 1 to 1100 cm 2 , or 1 to 1050 cm 2 , or 1 to 1000 cm 2 , or 1 to 950 cm 2 , or 1 to 900 cm 2 , or 1 to 850 cm 2 , or 1 to 800 cm 2 , or 1 to 750 cm 2 , or 1 to 700 cm 2 , or 1 to 650 cm 2 , or 1 to 600 cm 2 , or 1 to 550 cm 2 , or 1 to 500 cm 2 , or 1 to 450 cm2 、 or 6 to 1250 cm 2 、 or 6 to 1200 cm 2 、 or 6 to 1150 cm 2 、 or 6 to 1100 cm 2 、 or 6 to 1050 cm 2 、 or 6 to 1000 cm 2 、 or 6 to 950 cm 2 、 or 6 to 900 cm 2 、 or 6 to 850 cm 2 、 or 6 to 800 cm 2 、 or 6 to 750 cm 2 、 or 6 to 700 cm 2 、 or 6 to 650 cm 2 、 or 6 to 600 cm 2 、 or 6 to 550 cm 2 、 or 6 to 500 cm 2 、 or 6 to 450 cm 2 。 The term "land area" means the area of the layer that forms an unattached area between the layers between the sewing lines. In some embodiments (e.g., quilting sewing), the land area is the area of the sewing bond. In other embodiments (e.g., a series of topstitch sewings), the land area can be determined by analyzing the repeating pattern or the pattern of the sewing and determining the area covered by each repeating unit (as exemplarily shown in Figure 7 ), Figure 7 shows a periodic repeating pattern of topstitch sewing (the pattern forms a series of rectangular land areas), and the distance between each positioning sewing having a land height and a land width. In this example, the land area is the land height multiplied by the land width.

[0109] The sewing can penetrate the entire thickness of the multi-layer fabric composite. For example, as exemplarily shown in Figure 1 、 2 、 and 3, the sewing can penetrate the entire thickness of the multi-layer fabric composite from the first fusible layer to the second part. For example, Figure 1 shows the sewing penetrating the entire thickness from the first fusible layer to the FR fabric layer. Figure 2 shows the sewing penetrating from the first fusible layer to the second barrier layer. Figure 3It shows that the sewing penetrates through the entire thickness of the second FR fabric of the second laminate from the first fusible layer. In other embodiments, the sewing may penetrate less than the full thickness of the multi-layer fabric composite, for example, only penetrate some of the layers in the multi-layer fabric composite, and generally connect at least the first barrier layer, and the second fusible fabric, or the second flame retardant fabric. As Figure 6 shown, the first barrier layer can be sewn to the second fusible fabric, and the remaining part of the multi-layer fabric composite is adhered via one or more adhesive layers. Once the first barrier layer and the second fusible fabric are sewn together, standard lamination techniques can be used to form the remaining part of the multi-layer fabric composite. In some embodiments, a part of the multi-layer fabric composite can be formed by applying the first layer or the second layer of the thermally reactive material to the first barrier layer or the second fusible fabric, and then applying the first fusible layer or the second barrier layer. This process can be repeated for the remaining layers to form the multi-layer fabric composite. Although this process is described for the first part and the second part, this process can be used for any combination of the first part, the second part, and the third part, sewing at least a part of the first part to at least a part of the second part, where there is or is not a third part between the first and the second parts.

[0110] The sewing itself can be any material commonly used for sutures. In some embodiments, the sewing can be one or more of the flame retardant fibers in the form of sutures. Any of the materials described as being useful for manufacturing flame retardant fabrics can be used to manufacture the sewing material. For example, the thread can be: aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modified acrylic, cellulose, FR cellulose, FR viscose fiber, polyvinyl acetate, mineral, protein fiber, or a combination thereof. The thread for sewing can also be a thread with a core / shell structure, which contains a core of any of the flame retardant fibers, and a shell of a fusible fiber, such as the fusible fiber shell being: polyamide, polyester, polyolefin, acrylic, polyurethane, or a combination thereof. In other embodiments, the core can be a fusible fiber, such as: polyester, or polyamide, and the shell can be a flame retardant fiber.

[0111] Method for manufacturing the fabric composite

[0112] The multi-layer fabric composite including the first part and the second part can be manufactured in various ways. The first part includes the first laminate, and the first laminate includes: the first fusible layer, the first layer of the thermally reactive material, the first barrier layer, and in some embodiments, the first flame-retardant fabric. In some embodiments, the second part includes the second laminate, and the second laminate includes: the second fusible layer, the second layer of the thermally reactive material, the second barrier layer, and optionally the second flame-retardant fabric layer. In other embodiments, the second part may include the third flame-retardant fabric. The first part including the first laminate can be produced by the following method: selecting the first fusible layer, the first thermally reactive material, and the first barrier layer. The first laminate can be manufactured using the following standard lamination techniques: applying the first layer of the thermally reactive material to one or both of the first fusible layer and / or the first barrier layer. The layer of the first thermally reactive material can be applied using printing and / or coating techniques such as gravure printing, screen printing, flow coating, knife coating, and so on. After applying the first layer of the thermally reactive material, the first fusible layer and the first barrier layer can be brought into contact with each other such that the first layer of the thermally reactive material is sandwiched between the first fusible layer and the first barrier layer, thereby causing the two layers to adhere to each other. Optionally, pressure and / or heat can be applied to form the first part including the first laminate. If desired, a similar lamination process can be used to form the second part including the second laminate. In some embodiments, the first laminate and the second laminate are exactly the same laminate. In other embodiments, the second laminate has at least one layer different from the first laminate.

[0113] The first part can then be attached to the second part by sewing in one or more places such that the first barrier layer is in contact with the second part. In embodiments where the second part is the second laminate, the first barrier layer is adjacent to and in contact with the second fusible layer. In some embodiments, there is no third part between the first barrier layer and the second fusible layer. In embodiments where the second part is the flame-retardant fabric, the first barrier layer is adjacent to the flame-retardant fabric. In some embodiments, the third part is located between the first part and the second part. In some embodiments, the multi-layer fabric composite includes the third part, which is located between and in contact with the first barrier layer and the second fusible layer. In other embodiments, the multi-layer composite fabric includes the third part located between the first barrier layer and the second flame-retardant fabric.

[0114] The sewing process may include hand-sewn sewing, machine-sewn sewing, or a combination thereof. The sewing may be continuous sewing that uses various patterns to create a connection between the first and second parts, and includes a horizontal bearing area that encompasses the areas of the first and second parts between the sewings. In some embodiments, the sewing is: quilting sewing, a series of sewn geometric shapes, a series of sewings in a grid pattern, a series of sewings that are substantially parallel to each other, a series of basting stitches, or a combination thereof. Any quilting sewing may be used, provided that the quilting sewing provides the necessary dimensions of the horizontal bearing area as described herein. In other embodiments, the sewing may also be a tack stitch or non-continuous sewing. The tack stitch may include a series of periodically repeated sewings, where the sewings are not continuous (as exemplified in Figure 7 ). When using a tack stitch, the horizontal bearing area may be determined to be the area defined by the repeating pattern of the tack stitch. The horizontal bearing area may be determined by: analyzing the repeating pattern or sewing pattern and determining the area / extent covered by each repeating unit. Figure 7 Illustrated is a periodic repeating pattern of a tack stitch that forms a series of rectangular horizontal bearing areas, with the distance between each positioning sewing having a horizontal bearing height and a horizontal bearing width. In this example, the horizontal bearing area is the horizontal bearing height multiplied by the horizontal bearing width. In any embodiment, whether continuous or non-continuous sewing, the area of each horizontal bearing area may be in the range of 1 centimeter 2 (cm 2 ) to 1500 cm 2 . In some embodiments, the horizontal bearing area may be in the range of 6 cm 2 to approximately 1500 cm 2 . In other embodiments, the horizontal bearing area may be in the range of: 1 to 1400 cm 2 , or 1 to 1300 cm 2 , or 1 to 1250 cm 2 , or 1 to 1200 cm 2 , or 1 to 1150 cm 2 , or 1 to 1100 cm 2 , or 1 to 1050 cm 2 , or 1 to 1000 cm 2 , or 1 to 950 cm 2 , or 1 to 900 cm 2 , or 1 to 850 cm 2 , or 1 to 800 cm 2 , or 1 to 750 cm 2 , or 1 to 700 cm 2 , or 1 to 650 cm2 、 or from 1 to 600 cm 2 、 or from 1 to 550 cm 2 、 or from 1 to 500 cm 2 、 or from 1 to 450 cm 2 、 or from 6 to 1250 cm 2 、 or from 6 to 1200 cm 2 、 or from 6 to 1150 cm 2 、 or from 6 to 1100 cm 2 、 or from 6 to 1050 cm 2 、 or from 6 to 1000 cm 2 、 or from 6 to 950 cm 2 、 or from 6 to 900 cm 2 、 or from 6 to 850 cm 2 、 or from 6 to 800 cm 2 、 or from 6 to 750 cm 2 、 or from 6 to 700 cm 2 、 or from 6 to 650 cm 2 、 or from 6 to 600 cm 2 、 or from 6 to 550 cm 2 、 or from 6 to 500 cm 2 、 or from 6 to 450 cm 2 。

[0115] Use

[0116] The multi-layer fabric composite described herein can be used to form a garment, wherein the first portion (especially the first fusible layer) is positioned on the outer side of the garment, and the second portion is positioned on the inner side of the garment. In some embodiments, the garment can be a jacket, shirt, glove, pants, coverall, overall, footwear, hood, hat, or a combination thereof. Depending on the construction, the garment comprising the multi-layer fabric composite can protect the wearer from an arc discharge having an energy greater than or equal to 40 cal / cm 2 。 2 、 or greater than 75 cal / cm 2 、 or greater than 90 cal / cm 2 、 or greater than 100 cal / cm. The garment can provide protection from high-energy arc discharges while providing a relatively lightweight garment. Brief Description of the Drawings

[0117] Figure 1 Shows an embodiment of a multi-layer fabric composite in which the second portion is a flame-retardant fabric.

[0118] Figure 2An embodiment of a multi-layer fabric composite is shown in which the second part is a second laminate.

[0119] Figure 3 An embodiment of a multi-layer fabric composite is shown in which the second part is a second laminate.

[0120] Figure 4 An embodiment of a multi-layer fabric composite is shown having a second part and a third part, the third part being located between the first part and the second part.

[0121] Figure 5 An embodiment of a multi-layer fabric composite is shown having a first part, a second part, and a third part, wherein the second part is a second laminate.

[0122] Figure 6 An embodiment of a multi-layer fabric composite is shown having a first part and a second part, wherein the second part is a second laminate, and the quilting stitches connect a portion of the first part to a portion of the second laminate.

[0123] Figure 7 An embodiment of a multi-layer fabric composite using thick-stitch sewing is shown. Detailed Description

[0124] The present invention will be further described with reference to the accompanying drawings, in which like structures are denoted by like reference numerals throughout the several views. The drawings presented are not necessarily to scale, but rather are focused on illustrating the concepts of the present invention. Further, some features may be exaggerated to show details of particular components.

[0125] The drawings form a part of this specification and include illustrative embodiments of the present invention and illustrate its various objects and features. Further, the drawings are not necessarily to scale and some features may be exaggerated to show details of particular components. Additionally, any measurements, descriptions, etc. shown in the drawings are intended to be illustrative and not restrictive. Therefore, the specific structural and functional details disclosed herein should not be construed as restrictive, but rather should be construed only as a basis for teaching those skilled in the art to practice the present invention in various ways.

[0126] Among the benefits and improvements already disclosed, other objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings. Specific embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples of the present invention which may be embodied in various forms. Additionally, the examples provided in connection with the various embodiments of the present invention are intended to be illustrative and not restrictive.

[0127] Throughout the specification and claims, unless the context clearly indicates otherwise, the following terms have the meanings explicitly associated herein. As used herein, the phrases "in one embodiment" and "in some embodiments" do not necessarily refer to the same embodiment, although they may. Additionally, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, although they may. Thus, as described below, the various embodiments of the present invention can be readily combined without departing from the scope or spirit of the invention.

[0128] Unless the context clearly dictates otherwise, the term "based on" is not exclusive and allows for additional factors not described. Also, throughout the specification, the meanings of "a / an" and "the" include plural referents. The meaning of "in" includes "in" and "on".

[0129] As used herein, the terms "fiber" and "filament" may be used interchangeably. Fibers and filaments have a relatively small width and height compared to their length. The cross-section of fibers and filaments can be circular, square, or nearly any shape, including those with one or more lobes, and are well known in the art. Generally, fibers have a relatively short length, e.g., a length less than or equal to 30 centimeters, while filaments have a length greater than 30 centimeters and can be substantially infinite, e.g., several kilometers long.

[0130] As used herein, the term "meltable" when used in connection with a fiber, filament, yarn, or fabric means that the fiber melts at a temperature less than or equal to 280 °C, or less than or equal to 300 °C. In embodiments where a yarn or fabric is made of a single material, e.g., 100% nylon 6, the melting point of the material is the melting point of nylon 6. However, in embodiments of a yarn or fabric that is a mixture of both meltable and non-meltable fibers, the melting of the meltable material can be masked by the non-meltable component. For example, in the case of a fabric that is a 50 / 50 blend of nylon 6,6 and cotton, the melting nylon 6,6 can be absorbed by the cotton component, and when subjected to the melting and heat stability tests described herein, the fabric sample may appear not to melt. Thus, the presence of meltable fibers in a blend of meltable and non-meltable fibers renders the fiber, filament, yarn, or fabric a meltable material for the purposes of the present disclosure.

[0131] When the terms "inner" and "outer" are used to describe the layers of a laminated structure, they are intended to indicate the positions of the first and second portions relative to each other and relative to the third portion, and are based on the placement of the layers in the finished article. In the finished article (e.g., a garment such as a jacket), the first fusible fabric is intended to be the outermost layer of the garment, while the second portion is intended to be the innermost layer, closest to the wearer's body.

[0132] As used herein, the term "quilting" refers to the process of joining two materials by sewing two or more layers together with one or more rows of thread, where the stitching secures the two materials together at at least a portion of their surfaces while leaving other portions in contact but separable from each other. The term "quilted" refers to the structure produced by the quilting process.

[0133] As used herein, the moisture vapor transmission rate (MVTR) is a measure of how much water can pass through one square meter of a membrane in 24 hours. The greater the MVTR, the higher the breathability.

[0134] The present disclosure relates to a multi-layer fabric composite. The multi-layer fabric composite can be used in a garment that can provide a relatively lightweight garment for a wearer and provide a relatively high level of protection from injury when the garment is exposed to a high-energy arc flash discharge.

[0135] Embodiments of the multi-layer fabric composite can be seen in Figure 1 which shows a multi-layer fabric composite 100 that includes a first portion 110 and a second portion 120. The first portion 110 includes a first laminate that includes a first fusible layer 130, a first layer 140 of a heat-reactive material, and a first barrier layer 150. Also shown is a sewing 105. The sewing 105 is shown only in cross-section. The sewing 105 can be a quilting stitch or can be a basting stitch. In this figure, the second portion 120 is represented by a first flame-retardant fabric.

[0136] Figure 2 Another embodiment of a multi-layer fabric composite 200 is shown. In this embodiment, the multi-layer fabric composite 200 includes a first portion 210 and a second portion 220. The first portion includes a first laminate that includes a first fusible layer 230, a first layer 240 of a heat-reactive material, and a first barrier layer 250. The second portion includes a second laminate that includes a second fusible fabric 260, a second layer 270 of a heat-reactive material, and a second barrier layer 280. Each sewing 205 is also shown in perspective and penetrates the entire thickness of the multi-layer fabric composite 200.

[0137] Figure 3 Another embodiment of the multi-layer fabric composite 300 is shown. In this embodiment, the multi-layer fabric composite 300 includes a first portion 310 and a second portion 320. The first portion includes a first laminate that includes a first fusible layer 330, a first layer 340 of a heat-reactive material, and a first barrier layer 350. The second portion includes a second laminate that includes a second fusible fabric 360, a second layer 370 of a heat-reactive material, a second barrier layer 380, a layer of an adhesive 390, and a second flame-retardant fabric 395 opposite the adhesive 390. Stitching 305 is also shown in perspective, and the stitching 305 penetrates the entire thickness of the multi-layer fabric composite 300.

[0138] Figure 4 Another embodiment is shown. In this embodiment, the multi-layer fabric composite 400 includes a first portion 410, a second portion 420, and a third portion 425 between the first portion 410 and the second portion 420. The first portion 410 includes a first laminate that includes a first fusible fabric 430, a first layer 440 of a heat-reactive material, and a first barrier layer 450. The first barrier layer 450 is adjacent to one side of the third portion 425, and the opposite side of the third portion 425 is adjacent to the second portion 420. Stitching 405 penetrates the entire thickness of the multi-layer fabric composite 400. In this figure, the second portion 420 is shown as a second flame-retardant fabric, and the third portion 425 is shown as the fourth flame-retardant fabric.

[0139] Figure 5 Another embodiment of the multi-layer fabric composite 500 is shown. In this embodiment, the first portion 510 includes a first laminate that includes a first fusible fabric 530, a first layer 540 of a heat-reactive material, and a first barrier layer 550. The second portion 520 includes a second laminate that includes a second fusible fabric 560, a second layer 570 of a heat-reactive material, and a second barrier layer 580. There is a third portion 525. In this embodiment, one side of the third portion 525 is adjacent to the first barrier layer 550, and the opposite side of the third portion 525 is adjacent to the second fusible fabric 560 of the second portion 520. Stitching 505 penetrates the entire thickness of the multi-layer fabric composite 500.

[0140] Figure 6Another embodiment of the multi-layer fabric composite 600 is shown. In this embodiment, the multi-layer fabric composite 600 includes a first portion 610 and a second portion 620. The first portion includes a first laminate that includes a first fusible layer 630, a first layer 640 of heat-reactive material, and a first barrier layer 650. The second portion includes a second laminate that includes a second fusible fabric 660, a second layer 670 of heat-reactive material, and a second barrier layer 680. Also shown is a sewing 605, where the sewing 605 does not penetrate the entire thickness of the multi-layer fabric composite 600.

[0141] Figure 7 A multi-layer fabric composite is shown in a top view from the first fusible layer 730, along with a regular repeating pattern of a thick-stitch sewing 705, forming a series of rectangular horizontal pressure-bearing regions 706, and the distance between each thick-stitch sewing having a horizontal pressure-bearing height 707 and a horizontal pressure-bearing width 708. In this example, the horizontal pressure-bearing region 706 is the horizontal pressure-bearing height 707 multiplied by the horizontal pressure-bearing width 708.

[0142] Examples

[0143] Melting and Thermal Stability Tests

[0144] This test is used to determine the thermal stability of fabric materials. This test is based on the thermal stability test described in Section 8.3 of NFPA 1975 (2004 Edition). The test oven is a hot air circulation oven as specified in ISO 17493. The test is conducted according to the standard test method for coated fabrics ASTM D 751, using the anti-blocking procedure at elevated temperatures (Sections 89 to 93), with the following modifications:

[0145] A borosilicate glass plate measured as 100 mm x 100 mm x 3 mm is used.

[0146] A temperature set at 300 °C ± 5 °C is used. After removing the glass plate from the oven, the sample is cooled for at least 1 hour.

[0147] Any side of the sample that sticks to the glass plate upon unfolding, sticks to itself, or shows signs of melting or dripping is considered fusible. Any side of the sample lacking evidence of a fusible side is considered thermally stable.

[0148] TMA Expansion Test

[0149] The expansion of expandable graphite particles was measured using TMA (Thermomechanical Analysis). The expansion was tested using a TA Instruments TMA 2940 instrument. A ceramic (aluminum oxide) TGA pan with a diameter of approximately 8 mm and a height of 12 mm was used to hold the sample. A macro expansion probe (with a diameter of approximately 6 mm) was used, and the bottom of the pan was set as the zero point. A sheet of expandable graphite with a depth of approximately 0.1 - 0.3 mm was placed in the pan, and the depth was measured by the TMA probe. The furnace was closed, and the initial sample height was measured. The furnace was heated from 25 °C to 600 °C at a heating rate of 10 °C / min. The TMA probe displacement was plotted against temperature; the displacement was used as a measure of expansion.

[0150] In-furnace expansion test

[0151] A nickel crucible was heated in a hot furnace at 300 °C for 2 minutes. The tested sample of expandable graphite (about 0.5 g) was added to the crucible and placed in the hot furnace at 300 °C for 3 minutes. After the heating period, the crucible was removed from the furnace and allowed to cool, and then the expanded graphite was transferred to a graduated cylinder to measure the expansion volume. The expansion volume was divided by the initial height of the sample to obtain the expansion rate in cc / g.

[0152] DSC endothermic test

[0153] The test was carried out using a TZERO T sealed pan on a Q2000 DSC from TA Instruments. TM For each sample, approximately 3 milligrams (mg) of expandable graphite was placed in the pan. Ventilation was formed by pressing the corner of a razor blade into the center to create a vent approximately 2 mm long and less than 1 mm wide. The DSC was equilibrated at 20 °C. Subsequently, the sample was heated from 20 °C to 400 °C at 10 °C / min. The endothermic value was obtained from the DSC curve.

[0154] Flexibility or handle measurement test

[0155] The handle measurement results of the laminated structure samples were obtained using a Thwing-Albert Handle-o-meter (from Thwing Albert Instrument Company, Philadelphia, Pennsylvania, model #211-5). A lower value indicates a lower load required to bend the sample and indicates that the sample has greater flexibility.

[0156] Thickness test

[0157] The thickness was measured by placing the film or fabric laminate between the two plates of a Mitutoyo 543-252BS Snap Gauge. The average of three measurements was used.

[0158] Thickness Variation Test

[0159] The initial thickness of the sample is tested in accordance with Section 9 of ASTM D751, except that the diameter of the pressure foot is 2.54 cm. The device is adjusted to apply a pressure of approximately 0.239 kg / cm 2 (3.4 psi) to the sample. After exposure to the horizontal flame test for 60 seconds (or after cracking if it occurs before 60 seconds), the thickness change of the sample is re-measured. After the test, the thickness and integrity of the expanded structure are observed.

[0160] Composite Weight

[0161] The weight of each sample is determined in accordance with Option C of ASTM D3776 / 3776M-20 (R2020).

[0162] Barrier Thermal Stability Test

[0163] Preferably, the air permeability of the thermally stable barrier layer after thermal exposure is less than 25 l / m 2 / sec. To determine the thermal stability of the thermally stable barrier layer, a 381-mm (15-in) square fabric sample is clamped in a metal frame and then suspended in a forced-air circulation oven at 260 °C (500 °F). After 5 minutes of exposure, the sample is removed from the oven. After allowing the sample to cool, the air permeability of the sample is tested in accordance with ISO 9237 (1995). A sample with an air permeability less than 25 l / m 2 / sec is considered a thermally stable barrier layer.

[0164] The air permeability test is carried out in accordance with ISO 9237 (1995).

[0165] The arc thermal performance value is tested in accordance with ASTM F1959 (equivalent to the flat plate test of EIC 61482-1-1).

[0166] The composite thickness test is carried out in accordance with ASTM D1777.

[0167] Preparation of Thermally Reactive Material #1

[0168] Thermally Reactive Material #1 is made according to the following procedure. The flame-retardant polyurethane resin is prepared as follows: First, the resin is formed as described in the co-owned U.S. Patent 4,532,316, and a phosphorus-based flame retardant material is added to the reactor in an amount of about 45 wt%. After the polyurethane resin is formed, 76 g of the polyurethane resin is mixed with 24 g of expandable graphite (the expandable graphite has an expansion greater than 900 mm at 280 °C, which is determined by the TMA expansion test) in a stirred container at 80 °C. The mixture is cooled and used as it is.

[0169] Laminate #1

[0170] Laminate #1 is a two - layer laminate that can be obtained from W.L.Gore and Associates (Elkton, MD) as SAAL079000F and is a melt - able polyester woven fabric adhered to a GORE - TEX ePTFE membrane, which uses a thermally reactive material containing a polyurethane resin with expandable graphite particles and is in a repeated non - continuous dot pattern. The laminate weighs approximately 228 gsm.

[0171] Laminate #2

[0172] Laminate #2 is a commercially available three - layer laminate that can be obtained from W.L.Gore and Associates (Elkton, MD) as CORT000600B. The laminate comprises a melt - able outer layer bonded to an ePTFE membrane using a polyurethane resin containing expandable graphite particles, which is in a repeated non - continuous dot pattern. The innermost flame - retardant (FR) fabric contains FR viscose, aramid, and antistatic fibers and is bonded to the ePTFE layer using a flame - retardant polyurethane adhesive, where the adhesive is in a non - continuous dot pattern. The three - layer laminate has a height of approximately 322 gsm.

[0173] Laminate #3

[0174] Laminate #3 is a two - layer laminate. The laminate is produced by laminating a melt - able 71 gsm plain - weave polyester fabric (obtainable from Milliken&Co., Spartanburg, SC) with a GORE - ePTFE membrane (model #10898200, obtainable from W.L.Gore and Assoc., Elkton, MD) using a polyurethane resin containing expandable graphite particles (in a repeated non - continuous dot pattern). The weight of the two - layer laminate is approximately 168 gsm (5.93 oz / yd 2 ).

[0175] Laminate #4

[0176] Laminate #4 is a two - layer laminate. The laminate is produced by using a thermally reactive material (which contains a polyurethane resin with expandable graphite particles) in a repeated non - continuous dot pattern to laminate a melt - able polyester knitted fabric (model #A04Y014AZ, obtainable from Nan Ya Plastics (Kaohsiung, Taiwan, China)) with a GORE - ePTFE film (model #10898200, available from W.L.Gore and Associates (Elkton, Maryland)) is laminated. The weight of the 2-layer laminate is about 180.02 gsm (5.93 oz / yd 2 ).

[0177] Laminate #5

[0178] Laminate #5 is a 3-layer laminate. The laminate is available from W.L.Gore and Associates (Elkton, Maryland) under the model #FERM002001 and is a meltable nylon knitted fabric that is adhered to a GORE-TEX ePTFE film using a thermally reactive material in a repeating discontinuous dot pattern. The thermally reactive material comprises a polyurethane resin containing expandable graphite particles. An FR backing containing 48% aramid, 50% FR viscose, and 2% carbon fiber is bonded to the ePTFE film and is available from &Co.( Germany).

[0179] Preparing multi-layer composite fabric #1

[0180] Two-layer laminate #1 is sewn together using aramid thread as the first part and the second part. The aramid thread is available from Mid-West Quilting Co., Ltd. (Winnipeg, Manitoba). The ePTFE layer of the first part is brought into contact with the meltable layer of the second part. The sewing is continuous quilting sewing in a 10.2 cm x 10.2 cm diamond shape, thereby providing a horizontal bearing area of about 104 cm 2 The weight of the multi-layer fabric composite is about 460 gsm (13.56 oz / yd 2 ).

[0181] Preparing multi-layer composite fabric #2

[0182] The layer of laminate #1 is quilting sewn to laminate #2, where the ePTFE layer of laminate #1 contacts the meltable layer of laminate #2. The quilting sewing uses aramid thread, which is available from Mid-West Quilting Co., Ltd. (Winnipeg, Manitoba). The sewing is continuous quilting sewing in a 10.2 cm x 10.2 cm diamond shape, thereby providing a horizontal bearing area of about 104 cm 2 The weight of the multi-layer fabric composite is about 550 gsm (16.22 oz / yd 2 ).

[0183] Preparing multi-layer composite fabric #3

[0184] Sew the layers of the 2 - ply laminate #3 to the 3 - ply laminate #2, where the ePTFE layer of the laminate #3 contacts the fusible layer of the laminate #2. The quilting is done using aramid thread, which is available from Mid - West Quilting Co., Ltd. (Winnipeg, Manitoba). The sewing is continuous quilting in a 10.2 cm x 10.2 cm diamond pattern, thus providing a horizontal load - bearing area of approximately 104 cm 2 The weight of the multi - layer fabric composite is approximately 523 gsm (15.43 oz / yd 2 ).

[0185] Prepare the multi - layer composite fabric #4

[0186] Sew the 2 - ply laminate #3 to a layer of a 50% aramid / 50% viscose flame - retardant fabric in a plain weave, the viscose flame - retardant fabric being model #KRVC001A, available from Schüler & Co.( Germany). Bring the ePTFE layer (first part) of the laminate #3 into contact with the plain - weave fabric (second part). The quilting is done using aramid thread, which is available from Mid - West Quilting Co., Ltd. (Winnipeg, Manitoba). The sewing is continuous quilting in a 10.2 cm x 10.2 cm diamond pattern, thus providing a horizontal load - bearing area of approximately 104 cm 2 The weight of the multi - layer fabric composite is approximately 344 gsm (10.16 oz / yd 2 ).

[0187] Prepare the multi - layer composite fabric #5

[0188] Sew a layer (first part) of the 3 - ply laminate #2 to another layer (second part) of the 3 - ply laminate #2. Bring the FR fabric of the first part into contact with the fusible layer of the second part. The quilting is done using aramid thread, which is available from Mid - West Quilting Co., Ltd. (Winnipeg, Manitoba). The sewing is continuous quilting in a 10.2 cm x 10.2 cm diamond pattern, thus providing a horizontal load - bearing area of approximately 104 cm 2 The weight of the multi - layer fabric composite is approximately 640 gsm (18.9 oz / yd 2 ).

[0189] Prepare the multi - layer composite fabric #6

[0190] The layer of laminate #4 as the first part is joined to FR200 as the third part A layer of insulation [available from 3M (St. Paul, Minnesota)] and a layer of 120 gsm 50% aramid / 50% viscose plain weave fabric [model #KRVC001A, available from Schüler&Co., ( Germany)] are quilted. The ePTFE layer of the first part is brought into contact with one side of the third part, while the second part is brought into contact with the other side of the third part. The quilting uses aramid thread, which is available from Mid-West Quilting Ltd. (Winnipeg, Manitoba). The sewing is continuous quilting, in a 10.2 cm x 10.2 cm diamond pattern, thus providing an approximate horizontal bearing area of 104 cm 2 . The weight of the multi-layer fabric composite is 559 gsm.

[0191] Preparing multi-layer composite fabric #7

[0192] The layer of laminate #4 as the first part is sewn to the FR120 insulation (available from 3M (St. Paul, Minnesota)) and the layer of laminate #4 as the second part. The ePTFE layer of the first part is brought into contact with one side of the third part, while the second part is brought into contact with the fusible fabric of the third part. The quilting uses aramid thread, which is available from Mid-West Quilting Ltd. (Winnipeg, Manitoba). The sewing is continuous quilting, in a 10.2 cm x 10.2 cm diamond pattern, thus providing an approximate horizontal bearing area of 104 cm 2 . The weight of the multi-layer fabric composite is 549 gsm.

[0193] Preparing multi-layer composite fabric #8

[0194] Laminate #1 as the first part and laminate #5 as the second part are quilted together. The ePTFE membrane of the first part is brought into contact with the nylon fabric of the second part. The quilting uses aramid thread, which is available from Mid-West Quilting Ltd. (Winnipeg, Manitoba). The sewing is continuous quilting, in a 10.2 cm x 10.2 cm diamond pattern, thus providing an approximate horizontal bearing area of 104 cm 2 . The weight of the multi-layer fabric composite is 542 gsm (estimated).

[0195] Preparing multi-layer composite fabric #9

[0196] The laminate #1 as the first part and the laminate #5 as the second part are quilted together. The ePTFE film of the first part is brought into contact with the nylon fabric of the second part. The quilting is carried out using aramid thread, which is available from Mid-West Quilting Co., Ltd. (Winnipeg, Manitoba). The sewing is a continuous quilting, in a 5.1 cm x 5.1 cm diamond shape, thus providing a horizontal load-bearing area of approximately 26 cm 2 . The weight of the multi-layer fabric composite is 550 gsm (estimated).

[0197] Prepare Comparative Fabric Composite A

[0198] The layers of the 2-layer laminate #2 are attached to the layer of a 120 gsm 50% aramid / 50% viscose plain weave fabric (Model #KRVC001A, available from Schüler & Co.( Germany)). The two layers are connected to each other by sewing around the perimeter of the sample, thus simulating a hung liner in a garment. The weight of the composite is approximately 374.0 gsm.

[0199] Prepare Comparative Fabric Composite B

[0200] Two layers of 271 gsm aramid fabric are quilted together, and three plies of Basofil / aramid blend spunlace fabric are quilted with the aramid fabric. The three-layer quilting is carried out using aramid thread available from Mid-West Quilting Co., Ltd. (Winnipeg, Manitoba). The sewing is a continuous quilting, in a 10.2 cm x 10.2 cm diamond shape, thus providing a horizontal load-bearing area of approximately 104 cm 2 . The weight of the multi-layer fabric composite is 807 gsm.

[0201] Comparative Fabric Composite C

[0202] Comparative C is an OMNIQUILT TM thermal liner available from Norfab (Norristown, Pennsylvania). The weight of the material is approximately 366 gsm (estimated).

[0203] Table 1 shows the thickness, weight, and arc thermal protection values of the examples. All values are tested according to the provided procedures, unless otherwise stated.

[0204] Table 1

[0205]

[0206] Examples 1-4 show that the multi-layer fabric composites of the present disclosure can all provide relatively thin and lightweight structures, as well as protection against arc flash injuries. For example, Comparative Example A is a composite that is approximately 2 millimeters thick and provides only 47 cal / cm 2 of arc protection. In contrast, Examples 1 and 2 are less than 2 millimeters thick and can provide 92 to 105 cal / cm 2 protection, significantly higher than the performance of Comparative Example A.

Claims

1. A multi-layer fabric composite, comprising: A) a first part; and B) a second part, wherein the first part comprises a) a first laminate, the first laminate comprising: a1) a first fusible layer; a2) a first layer of a thermally reactive material comprising a polymer resin and expandable graphite; and a3) a first barrier layer; wherein the first part and the second part are attached to each other via one or more stitches.

2. The multi-layer fabric composite according to claim 1, wherein the first laminate further comprises: a4) a first flame retardant fabric, and wherein the first flame retardant fabric is adjacent to the first barrier layer and opposite to the first layer of the thermally reactive material.

3. The multi-layer fabric composite according to claim 1 or 2, wherein the second part comprises: b) a second laminate, the second laminate comprising: b1) a second fusible layer: b2) a second layer of the thermally reactive material comprising a polymer resin and expandable graphite; and b3) a second barrier layer.

4. The multi-layer fabric composite according to claim 3, wherein the second laminate further comprises: b4) a second flame retardant fabric; and wherein the second flame retardant fabric is adjacent to the second barrier layer and opposite to the second layer of the thermally reactive material.

5. The multi-layer fabric according to claim 1 or 2, wherein the second part comprises: a third flame retardant fabric.

6. The multi-layer fabric composite according to claim 1, wherein the second part is adjacent to the first barrier layer of the first part.

7. The multi-layer fabric composite according to claim 2, wherein the second part is adjacent to the first flame retardant fabric of the first part.

8. The multi-layer fabric composite according to any one of claims 1, 3, 4, or 6, wherein the second part comprises the second laminate, and the second fusible layer is adjacent to the first barrier layer of the first part.

9. The multi-layer fabric composite according to any one of claims 2, 3, 4, or 7, wherein the second part comprises the second laminate, and wherein the second fusible layer is adjacent to the first flame retardant fabric of the first part.

10. The multi-layer fabric composite according to any one of claims 1 to 9, wherein the multi-layer fabric composite further comprises a third part, wherein the third part is located between the first part and the second part; and wherein the third part is a fourth flame retardant fabric.

11. The multi-layer fabric composite according to any one of claims 1 to 10, wherein the one or more stitches are: quilting stitches, a series of one or more sewing threads, a series of overlapping sewing threads, a series of sewn geometric shapes, a series of sewing in a grid pattern, a series of substantially parallel sewing to each other, a series of thick stitch sewing, or a combination thereof.

12. The multi-layer composite according to any one of claims 1 to 11, wherein the one or more sewings are quilting sewings in the following sewing pattern, the sewing pattern comprising one or more horizontal pressure-bearing areas, each horizontal pressure-bearing area being bounded by the quilting sewing, and wherein the horizontal pressure-bearing areas of the quilting pattern range from 1 centimeter 2 (cm 2 ) to 450 cm 2 .

13. The multi-layer fabric composite according to any one of claims 1 to 12, wherein the first fusible fabric, the second fusible fabric, and the first, second, third, and fourth flame retardant fabrics are each independently: a knitted fabric, a woven fabric, a non-woven fabric, or a combination thereof.

14. The multi-layer fabric composite according to any one of claims 1 to 13, wherein the first fusible layer and / or the second fusible layer comprises: polyamide fiber, polyester fiber, polyolefin fiber, acrylic fiber, polyurethane fiber, or a combination thereof.

15. The multi-layer fabric composite according to any one of claims 2 to 14, wherein each of the first, second, third, and / or fourth flame retardant fabrics independently comprises: aramid, p-aramid, m-aramid, polybenzimidazole, polybenzoxazole, polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modified acrylic resin, cellulose, FR cellulose, FR viscose fiber, polyvinyl acetate, mineral fiber, protein fiber, or a combination thereof.

16. The multi-layer fabric composite according to any one of claims 1 to 15, wherein the first layer of the heat-reactive material and the second layer of the heat-reactive material are independently applied in a continuous or discontinuous manner.

17. The multi-layer fabric composite according to any one of claims 1 to 16, wherein the weight range of the multi-layer fabric composite is from 300 to 800 grams per square meter (gsm).

18. The multi-layer fabric composite according to any one of claims 1 to 17, wherein each of the first and / or second barrier layers independently comprises: expanded polytetrafluoroethylene, polytetrafluoroethylene, polyurethane, polyethylene (PE), or a combination thereof.

19. The multi-layer fabric composite according to any one of claims 1 to 18, wherein one or both of the first and second barrier layers independently comprise a multi-layer film of two or more layers of ePTFE and polyurethane.

20. The multi-layer fabric composite according to any one of claims 1 to 20, wherein the sewing connects at least a part of the thickness of the first part to at least a part of the thickness of the second part.

21. The multi-layer fabric composite according to any one of claims 1 to 21, wherein the sewing connects the entire thickness of the first part to the entire thickness of the second part.

22. The multi-layer fabric composite according to claim 21, wherein the sewing is present on at least one surface of the multi-layer fabric composite, or wherein the sewing is present on both surfaces of the multi-layer fabric composite.

23. An article comprising the multi-layer fabric composite according to any one of claims 1 to 22.

24. The article according to claim 23, wherein the article is: a blanket, clothing, a jacket, a coat, a vest, pants, work pants, a jumpsuit, gaiters, a shirt, gloves, footwear, a headgear, a hood, a hat, or a combination thereof.

25. The article according to claim 23, wherein the article is clothing, and the first part of the multi-layer fabric composite is positioned on the outer side of the clothing.

26. The article according to any one of claims 23 to 25, wherein the article provides an arc thermal performance value of at least 40 cal / cm 2 (cal / cm 2 ), which is tested according to ASTM F1959.

Images