Improved flame retardant nonwoven fabrics and composites and garments made therefrom

Abstract

Embodiments of the present invention replace at least some flame retardant fibers (e.g., aramid fibers) in wadding traditionally used for thermal insulation liners with thermally stable polyamide fibers (e.g., nylon fibers). The TPP performance of garments incorporating thermal liner embodiments encompassed herein is comparable to garments formed with conventional thermal liners, even without being improved.

Description

[0001] Cross-reference to related applications This application claims the benefit of U.S. Provisional Application Serial No. 63 / 460,177, filed April 18, 2023, entitled “Improved Flame Resistant ThermalLiners and Garments Made with Same,” the entire contents of which are incorporated herein by reference. Technical Field

[0002] Embodiments of the present invention relate to improved nonwoven fabrics and protective compounds, as well as garments incorporating such nonwoven fabrics. Background Technology

[0003] Protective clothing is designed to protect the wearer from hazardous environmental conditions that the wearer may encounter. Such clothing includes those designed for use by firefighters and other rescue workers, industrial and electrical workers, and military personnel. Firefighters, emergency responders, search and rescue personnel, and military personnel may be exposed to extreme heat and / or flames during their work. Protective clothing is designed and constructed as a means of combating injury. This protective clothing, often referred to as firefighting gear (including coveralls, trousers, and jackets), can be constructed from special flame-retardant materials designed to protect workers from both heat and flames.

[0004] Standards have been established to regulate the performance of such clothing (or its constituent layers or components) to ensure adequate protection of the wearer in hazardous situations. National Fire Protection Association (NFPA) 1971 Structural fire protection and close-range fire protection suit standard ( Standard on Protective Ensembles for Structural Fire Fighting and Proximity Fire Fighting The 2018 edition of the firefighter uniform (which is incorporated herein by reference) specifies the required performance characteristics of firefighter uniforms.

[0005] Structural firefighter clothing, such as firefighter's combat suits, typically consists of a matching jacket and trousers and is primarily designed to protect the wearer from severe burns. Firefighter's combat suits or clothing conforming to NFPA 1971 typically consist of three layers (e.g., Figure 1 and Figure 2 (As shown in the diagram): outer shell 12, intermediate moisture barrier 14, and insulation lining 20. The outer shell 12 is typically a woven fabric made of flame-retardant fibers and is considered the first line of defense for firefighters. It must not only resist flames but also be strong and durable to prevent tearing, abrasion, or snagging during normal firefighting operations.

[0006] A moisture barrier 14 (which is also flame-retardant) is present to prevent water, harmful chemicals, bacteria, and bodily fluids from penetrating the firefighting suit and affecting the wearer. The moisture barrier 14 may be constructed of a nonwoven or woven flame-retardant fabric 16 laminated with a waterproof material layer 18 (such as, for example, expanded polytetrafluoroethylene (“ePTFE”), polyurethane, or a combination thereof).

[0007] The insulating lining 20 is flame-retardant and provides the primary thermal protection offered by the entire garment. A conventional insulating lining consists of batting of flame-retardant insulating material 22 quilted to a lightweight woven facecloth 24, also made of flame-retardant fibers. The facecloth 24 is typically quilted to the batting 22 in a cross-hatched or chicken wire pattern. The insulating lining 20 is the innermost layer of the firefighter's garment, with the facecloth 24 typically facing the wearer.

[0008] The wadding 22 of the insulation lining can be a single layer of nonwoven fabric, but more commonly it is formed from multiple nonwoven layers. For example, the nonwoven fabrics used in many insulation linings are 1.5 oz per square yard (“osy”) and / or 2.3 osy spunlace fabrics. These spunlace fabrics are typically formed with a high percentage (often 100%) of expensive, inherently flame-retardant fibers such as para-aramid and / or meta-aramid fibers.

[0009] NFPA 1971 requires garments and / or their individual layers or components to pass a number of different performance tests, including when performed according to ASTM D6413 ( Standard Test Methods for Flame Retardancy of Textiles ( Standard Test Method for Flame Resistance of Textiles The test method described in (2015 edition, incorporated herein by reference) measures a char length of 4 inches or less and an afterflame of two seconds (or less). To test the char length and afterflame, the fabric sample is suspended vertically above the flame for twelve seconds. The fabric must self-extinguish within two seconds (i.e., it must have an afterflame of 2 seconds or less). After the fabric self-extinguishes, a specified weight is attached to the fabric and the fabric is lifted so that the weight is suspended from the fabric. The fabric will typically tear along the charred portion of the fabric. When testing is performed in both the warp and weft directions of the fabric, the tear length (i.e., the char length) must be 4 inches or less. Compliance is typically tested before the fabric sample is washed (and therefore while the fabric still contains residual and generally flammable chemicals from the finishing process) and after a certain number of washes (5 washes for NFPA 1971).

[0010] NFPA 1971 also includes provisions based on ASTM F2894-21 ( Using a hot air circulating oven to evaluate materials and protective clothing Standard test methods for the heat resistance of equipment ( Standard Test Method for Evaluation of Materials, Protective Clothing, and Equipment for HeatResistance Using a Hot Air Circulating Oven (2021 edition, incorporated herein by reference) Requirements relating to the degree of shrinkage of fabrics when heated during testing. To perform a heat shrinkage test on a fabric, marks are made on the fabric at intervals in both the warp and weft directions. The distances between the mark groups are recorded. The fabric is then suspended in a 500°F oven for 5 minutes. The distances between the mark groups are then measured again. The percentage of shrinkage in both the warp and weft directions is then calculated as the percentage of shrinkage and must be less than the percentage stated in the applicable standard. For example, NFPA 1971 requires that the heat shrinkage of outer shell fabrics not exceed 10% in both the warp and weft directions.

[0011] Clothing fabrics provide thermal protection to the wearer according to ISO 17492, as amended by NFPA 1971: Heat protection Fireproof clothing - heat transfer determination when exposed to flames and radiant heat ( Clothing for protection against heat and flame – Determination of heat transmission on exposure to both flame and radiant heat (2019, incorporated herein by reference) The thermal protection property (TPP) of a fabric is measured. The TPP test predicts the rate at which radiative and convective heat is transferred through the three layers of a garment fabric (outer shell, moisture barrier, and insulating lining) to the level that would cause a second-degree burn to human skin. More specifically, the test measures the amount of time it takes for sufficient heat to pass through the complex at a given energy level to cause a second-degree burn. The minimum TPP rating for outerwear and trousers conforming to NFPA 1971 is 35 calories / cm². 2 (This is equivalent to approximately 17.5 seconds of protection before a second-degree burn occurs). The higher this number, the more protective the clothing system is considered to be. The TPP test method is fully described in Chapter 8.10 of NFPA 1971. Summary of the Invention

[0012] The terms “invention,” “the invention,” “the present invention,” and “this invention” as used in this patent are intended to refer broadly to all subject matter of this patent and the appended claims. Statements containing these terms should not be construed as limiting the subject matter described herein or limiting the meaning or scope of the appended claims. Embodiments of the invention covered by this patent are defined by the appended claims, not by this summary. This summary is a high-level overview of various aspects of the invention and introduces several concepts that will be further described in the detailed description sections below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by referring to the entire specification, all drawings, and each claim of this patent.

[0013] Embodiments of the present invention replace at least some of the flame-retardant fibers (e.g., aramid) in the wadding traditionally used in thermal insulation linings with heat-stable polyamide fibers (e.g., nylon fibers). The TPP performance of garments incorporating the thermal insulation lining embodiments covered herein is comparable, if not improved, to garments formed with conventional thermal insulation linings. Attached Figure Description

[0014] The illustrative embodiments of the present invention will now be described in detail with reference to the accompanying drawings: Figure 1 This diagram illustrates a partial cross-sectional view of existing protective clothing.

[0015] Figure 2 It indicated Figure 1 An exploded perspective view of a portion of a conventional protective garment. Detailed Implementation

[0016] The subject matter of embodiments of the invention is specifically described herein to satisfy legal requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be implemented in other ways, may include different elements or steps, and may be used in combination with other existing or future technologies. Except where the order of the various steps or the arrangement of the elements is explicitly described, this description should not be construed as implying any particular order or arrangement of the various steps or elements.

[0017] Embodiments of the present invention replace at least some of the more expensive inherently flame-retardant fibers (e.g., aramid fibers) used in the nonwoven layer of conventional wadding 22 with heat-stable polyamide (e.g., nylon) fibers. Because conventional polyamide materials such as nylon are thermoplastic and lack inherent flame retardancy or thermal stability, they readily melt and burn when exposed to heat and flame. Conventional nylon fibers are referred to herein as “non-thermally stable nylon fibers” or “NTS nylon fibers.” Therefore, such materials have historically been included in flame-retardant fabrics only in small amounts to avoid sacrificing the protective properties of the fabric. However, polyamide fibers with higher thermal stability (particularly, but not limited to, less melting and / or dripping) have been developed, thereby minimizing the traditionally adverse effects of nylon fibers on the thermal properties of fabrics containing them. For the purposes of this disclosure, “heat-stable nylon fibers” or “TS nylon fibers” are used to refer to a class of nylon fibers that exhibit one or more improved thermal properties compared to conventional NTS nylon fibers, such as (but not limited to) better flame resistance, stronger self-extinguishing properties, and / or reduced melting / dripping. Therefore, larger quantities of these thermally stable (“TS”) nylon fibers can be blended with other flame-retardant fibers to produce flame-retardant fabrics that achieve desired performance properties, including but not limited to those conforming to NFPA 1971 requirements. Examples of such TS nylon fibers include, but are not limited to, those taught in U.S. Patent No. 10,640,893 (incorporated herein by reference).

[0018] Embodiments of nonwoven fabrics include combinations of TS nylon fibers with one or more other flame-retardant fibers. These other flame-retardant fibers can be inherently flame-retardant fibers (e.g., aramid fibers, modified polyacrylonitrile fibers, etc.) or fibers that have been treated with flame retardants to make them flame-retardant (e.g., FR cotton, FR rayon, FR cellulose acetate, FR triacetate, and FR lyocell). In some embodiments of the nonwoven fabrics covered herein, non-FR fibers may be present.

[0019] In some embodiments, the nonwoven fabric is formed from: (i) 1-70 wt.% (inclusive); 5-70 wt.% (inclusive); 10-70 wt.% (inclusive); 15-70 wt.% (inclusive); 20-70 wt.% (inclusive); 30-70 wt.% (inclusive); 40-70 wt.% (inclusive); 50-70 wt.% (inclusive); 60-70 wt.% (inclusive); 20-65 wt.% (inclusive); 25-60 wt.% (inclusive); 30-50 wt.% (inclusive); and / or 40-60 wt.% (inclusive) of TS nylon fibers and (ii) 30-99% by weight (inclusive); 30-95% by weight (inclusive); 30-90% by weight (inclusive); 30-85% by weight (inclusive); 30-80% by weight (inclusive); 30-70% by weight (inclusive); 30-60% by weight (inclusive); 30-50% by weight (inclusive); 30-40% by weight (inclusive); 35-80% by weight (inclusive); 40-75% by weight (inclusive); 50-80% by weight (inclusive); and / or 40-60% by weight (inclusive) of other flame-retardant fibers (aramid fibers, modified polyacrylonitrile fibers, FR cellulose fibers and / or blends thereof). The nonwoven fabric embodiment may be formed from TS nylon fibers with blends of the following: • Meta-aramid fiber; • Para-aramid fiber; • Meta-aramid and para-aramid fibers; • Aramid fibers (meta- and / or para-aramid fibers) and modified polyacrylonitrile fibers; • Para-aramid fibers and modified polyacrylonitrile fibers; • Aramid fibers (meta- and / or para-aramid fibers) and FR cellulose fibers; • Para-aramid fibers and FR cellulose fibers; • Aramid fibers (meta- and / or para-aramid fibers) and FR rayon fibers; • Para-aramid fibers and FR rayon fibers; • Aramid fibers (meta- and / or para-aramid fibers), modified polyacrylonitrile fibers, and FR cellulose fibers; and / or • Para-aramid fibers, modified polyacrylonitrile fibers, and FR rayon fibers.

[0020] Embodiments of the nonwoven fabric can be formed from any of the fiber blends (or combinations thereof) described above, provided in any weight percentage (or combination thereof) as set forth above. In some embodiments, the nonwoven fabric is free of meta-aramid fibers. In some embodiments, the nonwoven fabric comprises at least 20 wt%, at least 25 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 55 wt%, at least 60 wt%, or at least 65 wt% of TS nylon fibers. In some embodiments, the nonwoven fabric comprises at least 5 wt%, at least 10 wt%, at least 15 wt%, at least 20 wt%, at least 25 wt%, or at least 30 wt% of para-aramid fibers.

[0021] In some implementations, the nonwoven fabric is a spunlace fabric, but it can also be other types of nonwoven fabrics, including but not limited to needle-punched, air-laid, or wet-laid nonwoven fabrics.

[0022] While nonwoven fabrics can be used in any suitable application, in some embodiments, nonwoven fabrics replace one or more (or all) nonwoven layers of the wadding 22 of the insulation lining 20 (see [link to relevant documentation]). Figure 2 The wadding layers provided in the insulation liner 20 may be the same, but need not be the same. Instead, different wadding layers may be combined in different ways within the insulation liner 20. In some embodiments, the wadding 22 is formed of multiple nonwoven layers, one or more of which are the nonwoven fabrics of the present invention disclosed herein and one or more of which are conventional wadding layers.

[0023] In some implementations, the weight of the nonwoven fabric is 0.3 to 10 osy (inclusive); 0.3-9 osy (inclusive); 0.3-8 osy (inclusive); 0.3-7 osy (inclusive); 0.3-6 osy (inclusive); 0.3-5 osy (inclusive); 0.3-4 osy (inclusive); 0.3-3 osy (inclusive); 0.3-2 osy (inclusive); 0.3-1 osy (inclusive); 1-8 osy (inclusive); 2-7 osy (inclusive); 3-5 osy (inclusive); and / or 4-6 osy (inclusive).

[0024] Table 1 below provides examples of prior art insulating liners (“Comparative Insulating Liners”) and non-limiting examples of insulating liners according to embodiments of the present invention (“Insulating Liners of the Present Invention”). The various layers of the insulating liner are assembled and quilted together.

[0025] Table 1 The term "Titanium"TM "Face towel cloth" refers to a flame-retardant woven fabric formed from 100% meta-aramid filament yarn in the weft direction and short-fiber yarn in the warp direction, which is a blend of 65% rayon fiber, 25% para-aramid fiber, and 10% NTS nylon fiber. The fabric weighs approximately 3.5 osy and is available from TenCate®.

[0026] The term "Defender® M Facial Tissue" refers to a flame-retardant woven fabric formed from short-staple yarns of a blend of 65% rayon, 25% para-aramid, and 10% NTS nylon fibers supplied in both the warp and weft directions. The fabric weighs approximately 3.2 osy and is available from TenCate®.

[0027] The control insulation lining described in Table 1 and the insulation lining of the present invention are incorporated into conventional material layups of firefighter clothing conforming to NFPA 1971 to form a garment composite for firefighting suits (i.e., a fabric composite having an outer shell, a moisture barrier, and an insulation lining). More specifically, the control insulation lining and the insulation lining of the present invention are incorporated into the garment composites described in Table 2.

[0028] Table 2 shell Moisture barrier Insulating lining Control Clothing Complex 1 <![CDATA[Pioneer TM ]]> CROSSTECH BLACK® Comparison with thermal insulation lining 1 Comparison of clothing compound 2 <![CDATA[Pioneer TM ]]> CROSSTECH BLACK® Comparison with thermal insulation lining 2 Comparison of clothing complex 3 <![CDATA[Kombat TM Flex]]> CROSSTECH BLACK® Comparison with thermal insulation lining 1 Comparison of clothing complex 4 <![CDATA[Kombat TM Flex]]> CROSSTECH BLACK® Comparison with thermal insulation lining 1 Clothing compound 1 of the present invention <![CDATA[Pioneer TM ]]> CROSSTECH BLACK® In this invention, heat-insulating lining 1 Clothing compound 2 of the present invention <![CDATA[Pioneer TM ]]> CROSSTECH BLACK® In this invention, the heat-insulating lining 2 Clothing compound 3 of the present invention <![CDATA[Kombat TM Flex]]> CROSSTECH BLACK® In this invention, heat-insulating lining 1 Clothing compound 4 of the present invention <![CDATA[Kombat TM Flex]]> CROSSTECH BLACK® In this invention, heat-insulating lining 1 The terms used in Table 2 are defined as follows: • "CROSSTECH BLACK®" refers to a capped ePTFE layer laminated onto a woven meta-aramid fabric layer. This moisture barrier is flame-retardant, airtight, vapor-permeable, and waterproof. CROSSTECH BLACK® is available from Gore®.

[0029] • “Pioneer™” refers to a 100% aramid (i.e., flame-retardant) outer shell fabric available from TenCate®.

[0030] • “Kombat TM "Flex" refers to a woven flame-retardant fabric available from TenCate®.

[0031] The control and the present invention's insulating linings were positioned in the garment composite such that the top layer of the insulating lining (see Table 1) was positioned adjacent to the moisture barrier. The TPP performance of the control and the present invention's garment composites was tested prior to washing, and the results are presented in Table 3.

[0032] Table 3 <![CDATA[Complex TPP (calories / cm 2 )]]> Complex weight (osy) Complex TPP / weight ratio Control Clothing Complex 1 39.3 18.1 2.2 Comparison of clothing compound 2 42.1 18.6 2.3 Comparison of clothing complex 3 36.8 19.1 1.9 Comparison of clothing complex 4 36.1 19.1 1.9 Clothing compound 1 of the present invention 44.9 18.3 2.5 Clothing compound 2 of the present invention 45.7 18.8 2.4 Clothing compound 3 of the present invention 41.2 19.9 2.1 Clothing compound 4 of the present invention 38.8 19.7 2.0 As shown by the data in Table 3, the TPP grade of the clothing composite according to the embodiments of the present invention is at least 35 calories / cm². 2(Compliant with NFPA 1971) and higher, at least 38 calories / cm² 2 And higher, at least 40 calories / cm 2 And higher, at least 42 calories / cm 2 And higher, at least 44 calories / cm 2 And higher, at least 45 calories / cm 2 And higher.

[0033] It is a common view in the industry that nylon fibers adversely affect TPP performance. Embodiments of the present invention demonstrate that this view is incorrect. On the contrary, replacing fibers with higher protective properties (and higher cost) (meta-aramid fibers present in the control insulation lining) with lower protective (and lower cost) TS nylon fibers (such as in the insulation lining of the present invention) does not adversely affect the TPP performance of the garments therein (the garment composites of the present invention). As is evident from Table 3, garment composites containing the insulation linings of the present invention (those with TS nylon fibers) have a higher TPP rating than garment composites formed with conventional insulation linings (such as the control insulation lining containing meta-aramid fibers) but are otherwise identical.

[0034] For example, the garment complexes in Tables 4A-4C are identical in composition to the other garment complexes in the same table (i.e., formed from the same amount of the same material / layers), except that the meta-aramid fibers in the insulating lining of the control garment complex are replaced with TS nylon fibers in the garment complex of the present invention.

[0035] Table 4A <![CDATA[Complex TPP (calories / cm 2 )]]> Complex weight (osy) Complex TPP / weight ratio Control Clothing Complex 1 39.3 18.1 2.2 Clothing compound 1 of the present invention 44.9 18.3 2.5 Table 4B <![CDATA[Complex TPP (calories / cm 2 )]]> Complex weight (osy) Complex TPP / weight ratio Comparison of clothing compound 2 42.1 18.6 2.3 Clothing compound 2 of the present invention 45.7 18.8 2.4 Table 4C <![CDATA[Complex TPP (calories / cm 2 )]]> Complex weight (osy) Complex TPP / weight ratio Comparison of clothing complex 3 36.8 19.1 1.9 Comparison of clothing complex 4 36.1 19.1 1.9 Clothing compound 3 of the present invention 41.2 19.9 2.1 Clothing compound 4 of the present invention 38.8 19.7 2.0 In each case, the TPP rating of the garment composite of the present invention in the table is higher than that of the control garment composite in the same table, including: (i) at least 3-15% higher, at least 5%-15% higher, 5%-10% higher, 7%-15% higher, 7%-10% higher, 8%-15% higher, 8%-10% higher and / or 10%-15% higher, or (ii) at least 3% higher, at least 4% higher, at least 5% higher, at least 6% higher, at least 7% higher, at least 8% higher, at least 9% higher, at least 10% higher, at least 11% higher, at least 12% higher, at least 13% higher, at least 14% higher and / or at least 15% higher.

[0036] The extent to which the composite weight can be reduced while still achieving the required TPP protection is represented by the TPP rating to composite weight ratio, which normalizes any weight differences between the composites. The TPP rating to composite weight ratio is essentially a measure of how effectively the composite protects the wearer. The higher the ratio, the more protection the wearer receives for a given composite weight. Therefore, a higher TPP rating to composite weight ratio is desirable because a higher ratio means the composite achieves the required TPP protection at a lighter weight, thus reducing stress on the wearer. According to some embodiments, the TPP to composite weight ratio of clothing composites is at least 2.0 to 3.0, including at least 2.0; at least 2.1; at least 2.2; at least 2.3; at least 2.4; at least 2.5; at least 2.6; at least 2.7; at least 2.8; at least 2.9; and at least 3.0.

[0037] Similarly, in each case, the TPP grade and weight ratio of the garment composite of the present invention in the table are higher than those of the control garment composite in the same table, including: (i) at least 3%-15%, 3%-10%, 3%-8%, 5%-15%, 5%-10%, 5%-8%, and / or 10-15% higher, or (ii) at least 3%, at least 4%, at least 5%, at least 6%, at least 7%, at least 8%, at least 9%, at least 10%, at least 11%, at least 12%, at least 13%, at least 14%, and / or at least 15% higher. This improvement is achieved with cheaper, less protective fibers, which is contrary to conventional wisdom.

[0038] The garment composite according to embodiments of the present invention conforms to the requirements of NFPA 1971 and the equivalent European standard EN469 (2005): firefighters' protective suits ( Protective Clothing for Firemen (and subsequent versions), and the equivalent international standard ISO 11999 (2015): Firefighters' PPE - Exposure to [unspecified substances] when fighting fires in buildings Test methods and requirements for PPE used by firefighters at high levels of heat and / or flame risk ( PPE for firefighters – Test methods and requirements for PPE used by firefighters who are at risk of exposure to high levels of heat and / or flame while fighting fires occurring in structures (and subsequent versions), all of which are incorporated herein by reference. More specifically, they conform to EN367 (1992): Protective clothing; protection against heat and flame; methods for determining heat transmittance when exposed to flame. ( Protective clothing; protection against heat and fire; method for determining heat transmission on exposure toflame ) and its essentially equivalent EN ISO 9151 (2016): Combat heat and fire Flame protective clothing; measurement of heat transmittance when exposed to flames. ( Protective clothing against heat and flame; determination of heat transmission on exposure to flameThe heat transfer index (European equivalent of TPP) requirements during testing. All standards referenced herein and any subsequent versions thereof are incorporated herein by reference.

[0039] Therefore, cheaper insulating linings can be incorporated into firefighting clothing without sacrificing—and actually improving—the TPP performance of the clothing compound. In any event, clothing compounds incorporating the insulating lining implementations covered herein will meet the TPP requirements of NFPA 1971 (and all other applicable requirements). Example

[0040] The following provides a series of exemplary embodiments, including at least some explicitly listed as "exemplaries," which provide additional descriptions of various example types of the concepts described herein. These embodiments are not intended to be mutually exclusive, exhaustive, or limiting; and the invention is not limited to these exemplary embodiments, but is covered by all possible modifications and variations within the scope of the published claims and their equivalents.

[0041] Example 1. A flame-retardant and heat-insulating lining, the flame-retardant and heat-insulating lining comprising a flame-retardant face towel and at least one nonwoven layer attached to the face towel, wherein the at least one nonwoven layer comprises heat-stable nylon fibers.

[0042] Example 2. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer comprises two nonwoven layers, each nonwoven layer comprising heat-stable nylon fibers.

[0043] Example 3. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer comprises a first nonwoven layer and a second nonwoven layer, wherein the first nonwoven layer comprises heat-stable nylon fibers, and the second nonwoven layer does not contain heat-stable nylon fibers.

[0044] Example 4. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer comprises at least 20% by weight of heat-stable nylon fibers.

[0045] Example 5. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer further comprises flame-retardant fibers.

[0046] Example 6. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer comprises 30-80% by weight of flame-retardant fibers.

[0047] Example 7. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the flame-retardant fiber comprises at least one of aramid fiber, modified polyacrylonitrile fiber or flame-retardant cellulose fiber.

[0048] Example 8. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the flame-retardant fiber comprises para-aramid fiber and the at least one nonwoven layer comprises at least 20% by weight of para-aramid fiber.

[0049] Example 9. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer does not contain meta-aramid fibers.

[0050] Example 10. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer comprises a spunlace fabric.

[0051] Example 11. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer comprises 40-70% by weight of thermally stable nylon fibers and 30-60% by weight of flame-retardant fibers.

[0052] Example 12. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the flame-retardant fiber comprises para-aramid fiber.

[0053] Example 13. A flame-retardant and heat-insulating lining of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer comprises 50-70% by weight of thermally stable nylon fibers and 30-50% by weight of flame-retardant fibers.

[0054] Example 14. A garment composite comprising: an outer shell layer comprising a flame-retardant fabric; a moisture-proof layer; and a heat-insulating lining layer comprising a flame-retardant face towel and at least one nonwoven layer attached to the face towel, wherein the at least one nonwoven layer comprises heat-stable nylon fibers, wherein the flame-retardant face towel is exposed on a first side of the garment composite, and the outer shell layer is exposed on a second side of the garment composite opposite to the first side.

[0055] Example 15. A garment composite of any of the foregoing or subsequent examples or combinations thereof, wherein the garment composite has a content of at least 35 calories / cm² when tested according to ISO 17492. 2 Thermal protection performance level.

[0056] Example 16. A garment composite of any of the foregoing or subsequent examples or combinations thereof, wherein the garment composite has a content of at least 40 calories / cm² when tested according to ISO 17492. 2 Thermal protection performance level.

[0057] Example 17. A garment composite of any of the foregoing or subsequent examples or combinations thereof, wherein the garment composite has a composite weight and a thermal protection rating when tested according to ISO 17492, wherein the ratio of the thermal protection rating to the composite weight is between 2.0 and 3.0, including the endpoints.

[0058] Example 18. A garment composite of any of the foregoing or subsequent examples or combinations thereof, wherein the at least one nonwoven layer further comprises flame-retardant fibers and wherein the garment composite has a composite weight and a thermal protection rating when tested according to ISO 17492, wherein the ratio of the thermal protection rating to the composite weight of the garment composite is greater than the ratio of the thermal protection rating to the composite weight of the comparative example garment composite, wherein the comparative example garment composite has at least one nonwoven layer formed of 100% flame-retardant fibers but is otherwise identical to the garment composite.

[0059] Example 19. A clothing composite of any of the foregoing or subsequent examples or combinations thereof, wherein the ratio of the thermal protection performance level of the clothing composite to the weight of the composite is at least 5% greater than the ratio of the thermal protection performance level of the comparative example clothing composite to the weight of the composite.

[0060] Example 20. A nonwoven fabric formed from a fiber blend comprising flame-retardant fibers and thermally stable nylon fibers.

[0061] Different arrangements of the above-described components, as well as components and steps not shown or described, are possible. Similarly, some features and sub-combinations are useful and can be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not limiting purposes, and alternative embodiments will become apparent to the reader of this patent. Therefore, the invention is not limited to the embodiments described above or illustrated in the drawings, and various embodiments and modifications can be made without departing from the scope of the invention.

Claims

1. A flame-retardant and heat-insulating lining, the flame-retardant and heat-insulating lining comprising a flame-retardant face towel and at least one nonwoven layer attached to the face towel, wherein the at least one nonwoven layer comprises heat-stable nylon fibers.

2. The flame-retardant and heat-insulating lining according to claim 1, wherein the at least one nonwoven layer comprises two nonwoven layers, each nonwoven layer comprising heat-stable nylon fibers.

3. The flame-retardant and heat-insulating lining according to claim 1, wherein the at least one nonwoven layer comprises a first nonwoven layer and a second nonwoven layer, wherein the first nonwoven layer comprises heat-stable nylon fibers, and the second nonwoven layer does not contain heat-stable nylon fibers.

4. The flame-retardant and heat-insulating lining according to claim 1, wherein the at least one nonwoven layer comprises at least 20% by weight of thermally stable nylon fibers.

5. The flame-retardant and heat-insulating lining according to claim 4, wherein the at least one nonwoven layer further comprises flame-retardant fibers.

6. The flame-retardant and heat-insulating lining according to claim 5, wherein the at least one nonwoven layer comprises 30-80% by weight of flame-retardant fibers.

7. The flame-retardant and heat-insulating lining according to claim 6, wherein the flame-retardant fiber comprises at least one of aramid fiber, modified polyacrylonitrile fiber, or flame-retardant cellulose fiber.

8. The flame-retardant and heat-insulating lining according to claim 5, wherein the flame-retardant fiber comprises para-aramid fiber and the at least one nonwoven layer comprises at least 20% by weight of para-aramid fiber.

9. The flame-retardant and heat-insulating lining according to claim 5, wherein the at least one nonwoven layer does not contain meta-aramid fibers.

10. The flame-retardant and heat-insulating lining according to claim 1, wherein the at least one nonwoven layer comprises a spunlace fabric.

11. The flame-retardant and heat-insulating lining according to claim 1, wherein the at least one nonwoven layer comprises 40-70% by weight of thermally stable nylon fibers and 30-60% by weight of flame-retardant fibers.

12. The flame-retardant and heat-insulating lining according to claim 11, wherein the flame-retardant fiber comprises para-aramid fiber.

13. The flame-retardant and heat-insulating lining according to claim 11, wherein the at least one nonwoven layer comprises 50-70% by weight of thermally stable nylon fibers and 30-50% by weight of flame-retardant fibers.

14. A garment composite comprising: a. An outer shell layer comprising flame-retardant fabric; b. Moisture barrier; and c. A heat-insulating lining layer comprising a flame-retardant face towel fabric and at least one nonwoven layer attached to the face towel fabric, wherein the at least one nonwoven layer comprises heat-stable nylon fibers. The flame-retardant face towel is exposed on a first side of the garment composite, while the outer shell layer is exposed on a second side of the garment composite opposite to the first side.

15. The garment composite of claim 14, wherein the garment composite has a content of at least 35 calories / cm² when tested according to ISO 17492. 2 Thermal protection performance level.

16. The clothing composite of claim 15, wherein the thermal protection rating is at least 40 calories / cm² when tested according to ISO 17492. 2 .

17. The garment composite of claim 14, wherein the garment composite has a composite weight and a thermal protection rating when tested according to ISO 17492, wherein the ratio of the thermal protection rating to the composite weight is between 2.0 and 3.0, including the endpoints.

18. The garment composite of claim 14, wherein the at least one nonwoven layer further comprises flame-retardant fibers and wherein the garment composite has a composite weight and a thermal protection rating when tested according to ISO 17492, wherein the ratio of the thermal protection rating to the composite weight of the garment composite is greater than the ratio of the thermal protection rating to the composite weight of the comparative garment composite, wherein the comparative garment composite has at least one nonwoven layer formed of 100% flame-retardant fibers but is otherwise identical to the garment composite.

19. The garment composite of claim 18, wherein the ratio of the thermal protection performance level of the garment composite to the weight of the composite is at least 5% greater than the ratio of the thermal protection performance level of the comparative garment composite to the weight of the composite.

20. A nonwoven fabric formed from a fiber blend comprising flame-retardant fibers and thermally stable nylon fibers.

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