Arc Flash Protection Materials

Abstract

The present disclosure relates to a relatively thin, lightweight multilayer textile composite that can provide a high degree of protection from thermal hazards associated with electrical arc flashes. The multilayer textile composite includes one or more laminate or laminate layers stitched together with flame-retardant textile layers.

Description

[Technical Field]

[0001] The present invention relates to protective multilayer textile composites, and more particularly to lightweight textile composites that provide protection from high-energy electrical arc flash and similar types of applied energy. [Background technology]

[0002] Professionals working in hazardous environments where brief exposure to electric arc flashes is possible, such as equipment repair, require protective clothing to mitigate injuries. Protective clothing for workers exposed to these conditions should provide protection for the wearer, allowing them to quickly and safely escape from the hazard, rather than repairing the hazard. The National Fire Protection Association (NFPA) recognizes several levels of electric arc flash discharge. For protective clothing to be rated as offering a certain level of protection to the wearer, there are minimum protection standards that the clothing must meet in order to be sold as protective clothing. For example, clothing rated as a Category 1 level of personal protective equipment (PPE) protects the wearer from 4 calories per square centimeter (cal / cm 2 ) Category 2 PPE must be able to protect against discharges of 8 cal / cm 2 , Category 3 PPE is 25 cal / cm 2 , Category 4 PPE is 40 cal / cm 2 , Category 5 PPE is at least 75 cal / cm 2 Generally, as the NFPA category rating progresses from Class 1 to Class 5, the weight and bulk of PPE increases significantly.

[0003] Traditionally, arc-resistant protective clothing has been designed to be fire-resistant and heat-resistant. Such garments are constructed using an outermost layer of an ensemble that includes a flame-resistant, non-melting fabric made from, for example, aramid, polybenzimidazole (PBI), polyparaphenylene-2,6-benzobisoxazole (PBO), modacrylic blends, polyamines, carbon, polyacrylonitrile (PAN), and blends and combinations thereof. While these fabrics can be inherently fire-resistant, they have several limitations. Specifically, achieving the desired level of protection requires relatively heavy, relatively thick, bulky textiles, or multiple layers of these textiles. Typically, these fabrics can have a basis weight exceeding 400 grams per square meter. For example, commercially available Class 5 garments can have at least three layers, a thickness of approximately 4 millimeters, and a total weight exceeding 800 grams per square meter. The fibers used to form these textiles can also be very expensive, difficult to dye and print, and may not have sufficient abrasion resistance. Furthermore, these fibers are more absorbent and less pleasant to the touch than nylon- or polyester-based fabrics. For optimal user performance in environments subject to occasional arc-flash exposure, lightweight, breathable, water-resistant garments with enhanced burn protection are desired. The cost of waterproof, arc-flash resistant protective clothing is a significant consideration in many hazardous exposure applications and has prevented the use of typical textiles, such as those used by firefighters, that are inherently flame-retardant. Summary of the Invention

[0004] The present disclosure provides a relatively thin, lightweight multilayer textile composite that can provide a high level of protection from the thermal hazards of electrical arc flash. For example, the multilayer textile composite can provide a thermal resistance of 40 cal / cm 2 ~100cal / cm 2In a first aspect, a multilayer textile composite is provided that includes A) a first portion and B) a second portion. The first portion includes a first laminate that includes a1) a first meltable layer, a2) a first layer of thermally reactive material that includes a polymer resin and expandable graphite, and a3) a first barrier layer, the first and second portions being attached to one another via one or more stitches. In a second aspect, the first laminate further includes a4) a first flame-retardant (FR) fiber, the first flame-retardant textile layer being adjacent to the first barrier layer opposite the first layer of thermally reactive material.

[0005] In a third aspect, the multilayer textile composite of the first or second aspect comprises a second portion, said second portion comprising b) a second laminate, said second laminate comprising b1) a second meltable layer, b2) a second layer of thermally reactive material comprising a polymer resin and expandable graphite, and b3) a second barrier layer.

[0006] In a fourth embodiment, in the multilayer textile composite of any of the previous embodiments, the second laminate further comprises b4) a second flame retardant textile, said second flame retardant textile adjacent to the second barrier layer opposite the second layer of thermally reactive material.

[0007] In a fifth embodiment, the multilayer textile composite of the first embodiment or the second embodiment includes a second portion, said second portion including a third flame retardant textile.

[0008] In a sixth embodiment, the second portion is adjacent to the first barrier layer of the first portion.

[0009] In a seventh embodiment, the second portion is adjacent to the first flame retardant textile of the first portion.

[0010] In an eighth embodiment, the second portion includes a second laminate, and the second fusible layer is adjacent to the first barrier layer of the first portion.

[0011] In a ninth embodiment, the second portion includes a second laminate, and the second fusible layer is adjacent to the first flame retardant textile of the first portion.

[0012] In a tenth aspect, the multilayer textile composite of any of the previous aspects includes a third portion, the third portion being a fourth flame retardant textile, and the third portion being disposed between the first portion and the second portion.

[0013] In an eleventh embodiment, the multilayer textile composite of any of the previous embodiments comprises one or more stitches, wherein the stitches are quilting stitches, a series of one or more stitch lines, a series of overlapping stitch lines, a series of stitched geometric shapes, a series of grid pattern stitches, a series of stitches that are essentially parallel to one another, a series of tuck stitches, or a combination thereof.

[0014] In a twelfth embodiment, the multilayer composite textile of any of the previous embodiments includes quilting stitches, said quilting stitches being a stitch pattern including one or more land areas, each land area being separated by a quilting stitch, and the land areas of the quilting pattern being 1 square centimeter (cm 2 )~450cm 2 The range is.

[0015] In a thirteenth embodiment, the first meltable textile, the second meltable textile, and the flame retardant textile of any of the preceding embodiments are each independently a knitted textile, a woven textile, a nonwoven textile, or a combination thereof.

[0016] In a fourteenth aspect, the first meltable textile and the second meltable textile of any of the previous aspects can independently comprise polyamide fibers, polyester fibers, polyolefin fibers, acrylic fibers, polyurethane fibers, or combinations thereof.

[0017] In a fifteenth aspect, the flame retardant textile of any of the preceding aspects can comprise aramid, p-aramid, m-aramid, polybenzimidazole, polybenzoxazole, polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modacrylic, cellulose, flame retardant cellulose, flame retardant viscose, polyvinyl acetate, mineral fiber, protein fiber, or a combination thereof.

[0018] In a sixteenth aspect, the first layer of thermally responsive material and the second layer of thermally responsive material of any of the previous aspects can be independently applied continuously or discontinuously.

[0019] In a seventeenth embodiment, the multilayer textile composite of any of the previous embodiments has a weight in the range of 250 to 800 grams per square meter (gsm).

[0020] In an eighteenth aspect, the first barrier layer and / or the second barrier layer of any of the preceding aspects can independently comprise expanded polytetrafluoroethylene (ePTFE), polytetrafluoroethylene, polyurethane, polyethylene (PE), or a combination thereof.

[0021] In a nineteenth embodiment, one or both of the first barrier layer and the second barrier layer of any of the preceding embodiments independently comprise a multilayer film comprising two or more layers of ePTFE and polyurethane.

[0022] In a twentieth aspect, the multilayer textile composite of any of the preceding aspects, wherein the stitch connects at least a portion of the thickness of the first portion to at least a portion of the thickness of the second portion.

[0023] In a twenty-first aspect, the multilayer textile composite of any of the previous aspects, wherein the stitches connect the entire thickness of the first portion to the entire thickness of the second portion.

[0024] In a twenty-second aspect, the multilayer textile composite of any of the preceding aspects, wherein the stitching is present on at least one surface of the multilayer textile composite, or the stitching is present on both surfaces of the multilayer textile composite.

[0025] In a twenty-third aspect, the present disclosure relates to an article comprising the multilayer textile composite of any of the preceding aspects.

[0026] In a twenty-fourth aspect, the article of the preceding aspects is a blanket, a garment, a jacket, a coat, a vest, pants, overalls, coveralls, leggings, a shirt, gloves, footwear, a cap, a hood, a hat, or a combination thereof.

[0027] In a twenty-fifth aspect, the present disclosure relates to the garment of the twenty-fourth aspect, wherein the article is a garment and the first portion of the multilayer textile composite is disposed on an exterior of the garment.

[0028] In a twenty-sixth embodiment, the article of any of the preceding embodiments has a thermal conductivity of at least 40 calories per square centimeter (cal / cm) when tested by ASTM F1959. 2 ) arc thermal performance values.

[0029] Multilayer textile composites The present disclosure relates to a multilayer textile composite including A) a first portion and B) a second portion, the first portion and the second portion attached to one another via one or more stitches. The first portion includes a) a first laminate, the first laminate including a1) a first meltable layer, a2) a first layer of a heat-reactive material including a polymer resin and expandable graphite, and a3) a first barrier layer. It is believed that the first portion can dissipate a first portion of the energy of an arc flash exposure, thereby minimizing the amount of energy transferred to the second portion. Optionally, the multilayer textile composite further includes a third portion, the third portion being located between the first portion and the second portion and attached to the multilayer composite textile via one or more stitches.

[0030] The first portion includes a first laminate, the first laminate including: a1) a first meltable layer; a2) a first layer of a thermally reactive material including a polymer resin and expandable graphite; and a3) a barrier layer. The first portion further includes: a4) a first flame-retardant textile, the first flame-retardant textile being adjacent to the first barrier layer. In some embodiments, the first meltable layer is a textile that is the outermost layer on one side of the multilayer textile composite. The first meltable layer can be a woven, knitted, or nonwoven textile layer. The first meltable layer can be a meltable textile. As used herein, the term "meltable" refers to a material that is meltable according to the Melt and Thermal Stability Tests described below.

[0031] In some embodiments, the second part can be a second laminate comprising b1) a second meltable layer, b2) a second layer of a thermally reactive material comprising a polymeric resin and expandable graphite, and b3) a second barrier layer. In some embodiments, the second laminate can further comprise b4) a second flame retardant textile.

[0032] In other embodiments, the second portion can be a third flame-resistant textile. The third flame-resistant textile may be adjacent to the first barrier layer or, if present, adjacent to the first flame-resistant textile. The first portion is attached to the second portion via one or more stitches.

[0033] The weight of the multilayer textile composite can range from 250 to 800 grams per square meter (gsm). In other embodiments, the weight of the multilayer textile composite can range from 250 to 750 gsm, 250 to 700 gsm, 250 to 675 gsm, 250 to 650 gsm, 250 to 625 gsm, 250 to 600 gsm, 275 to 800 gsm, 275 to 750 gsm, 275 to 700 gsm, 275 to 675 gsm, 275 to 650 gsm, 275 to 625 gsm, or 375 to 600 gsm.

[0034] In further embodiments, the multilayer textile composite can be relatively thin, for example, ranging in thickness from 1.25 millimeters (mm) to 3.0 mm. In other embodiments, the thickness of the multilayer textile composite can range from 1.3 mm to 2.9 mm, 1.4 mm to 2.8 mm, 1.4 mm to 2.75 mm, 1.4 mm to 2.7 mm, or 1.4 mm to 2.6 mm.

[0035] The length and width of the multilayer textile composite are much greater than the thickness. For example, the width of the multilayer textile composite can be from 10 centimeters to about several meters. The length of the multilayer textile composite can be from 10 centimeters to hundreds or thousands of meters. Thus, the multilayer textile composite has a first major surface and a second major surface opposite the first surface. The first surface, i.e., the first major surface, can be a first portion, and specifically, the first meltable layer forms the first surface of the multilayer textile composite. The second surface, i.e., the second major surface of the multilayer textile composite, depends on the second portion. In some embodiments, the second surface can be a second barrier layer, a second flame-retardant textile, or a third flame-retardant textile.

[0036] Fusible layer The multilayer textile composite includes a first meltable layer and, optionally, a second meltable layer. The following description of the meltable layers refers to the first meltable layer, but is applicable to both the first and second meltable layers unless otherwise specified. The first meltable layer includes a textile layer that is a knitted fabric, a woven fabric, a nonwoven fabric, or a combination thereof. The first meltable layer can 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 textile layer can be determined using the melt and heat stability test described herein.

[0037] The first meltable layer can include a relatively small amount of flame-retardant fibers, non-meltable fibers, and / or antistatic fibers. When flame-retardant fibers, non-meltable fibers, and / or antistatic fibers are present, the first meltable textile remains a meltable textile when tested according to the Melt and Heat Stability Test described below. In some embodiments, the first meltable layer can be a melt-resistant, flame-resistant textile such as, for example, a phosphinate-modified polyester (e.g., a material sold under the trademark TREVIRA® CS by Trevira GmbH of Hattersheim, Germany, or under the trademark AVORA® FR by Rose Brand of Secaucus, New Jersey, USA).

[0038] The first meltable layer may comprise meltable fibers in an amount ranging from 50% to 100% by weight. The first meltable layer may comprise meltable fibers in an amount ranging from 75% to 100% by weight. The first meltable layer may comprise meltable fibers in an amount ranging from 90% to 100% by weight. The first meltable layer may comprise meltable fibers in an amount ranging from 95% to 99% by weight. The remaining fibers may be antistatic fibers, meltable elastic fibers, non-meltable elastic fibers, or combinations thereof. For example, when the first meltable layer comprises meltable fibers in an amount ranging from 95% to 99% by weight, the antistatic fibers and / or elastic fibers may be present in an amount ranging from 1 to 5% by weight. All weight percentages are based on the total weight of the first meltable layer.

[0039] The first meltable layer can have a weight of about 250 gsm or less. In other embodiments, the first meltable layer can have a weight of 30 gsm to 250 gsm, or 40 gsm to 200 gsm, or 40 gsm to 175 gsm, or 50 gsm to 200 gsm, or about 60 gsm to 200 gsm, or 50 gsm to 180 gsm, or about 60 gsm to 180 gsm, or 50 gsm to 175 gsm, or about 60 gsm to 175 gsm, or 75 gsm to 200 gsm, or about 75 gsm to 180 gsm.

[0040] The first fusible layer can be a flammable or non-flammable material. As used herein, a "flammable" material is one that is flammable when tested according to the Vertical Burn Test for Textiles described below to determine whether it is flammable or non-flammable.

[0041] The first meltable layer can include polyester fibers, polyamide fibers, polyolefin fibers, acrylic fibers, polyurethane fibers, or a combination thereof. Suitable polyesters include, for example, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, or a combination thereof. Suitable polyamides can include, for example, nylon 6, nylon 6,6, or a combination thereof. Suitable polyolefins can include, for example, polyethylene, polypropylene, or a combination thereof. In some embodiments, the first meltable layer includes polyamide fibers, polyester fibers, polyolefin fibers, or a combination thereof.

[0042] Arc-resistant laminates typically do not use meltable textiles because standards governing arc-resistant clothing require that the fabric or laminate be fire-resistant to pass the arc test (ASTM 1959). It is surprising that a multilayer textile composite containing a meltable outer textile layer can be used to provide protection against arc flash accidents.

[0043] Heat-Reactive Materials The first portion of the multilayer textile composite also includes a first layer of thermally reactive material comprising a polymer resin and expandable graphite. The first layer of thermally reactive material can be disposed between the first meltable layer and the first barrier layer. This first layer of thermally reactive material can function as an adhesive for adhering or bonding the first meltable layer to the first barrier layer. A second layer of thermally reactive material can be disposed between the second meltable layer and the second barrier layer of the second portion. The second layer of thermally reactive material can also function as an adhesive for adhering or bonding the second meltable layer to the second barrier layer. The following description of the thermally reactive material is applicable to both the first and second layers of thermally reactive material unless otherwise specified.

[0044] The layer of thermally reactive material acts as an adhesive, securing the first meltable layer to the first barrier layer or securing the second meltable layer to the second barrier layer. In some embodiments, the layer of thermally reactive material can be applied as a continuous layer. In other embodiments, the layer of thermally reactive material can be applied as a discontinuous layer. The thermally reactive material can be applied discontinuously to form a layer of thermally reactive material having less than 100% surface coverage. The thermally reactive material can be applied in a pattern of discontinuous shapes. The thermally reactive material can be applied in a dot pattern, grid pattern, line pattern, wave pattern, or other pattern, or combinations thereof.

[0045] The thermally responsive material may include expandable graphite. The thermally responsive material may include a polymer resin. The thermally responsive material may include a mixture of expandable graphite and a polymer resin.

[0046] The expandable graphite may expand by at least about 400 microns when heated to about 240°C in the TMA Expansion Test described herein. The expandable graphite may expand by at least about 500 microns when heated to about 240°C in the TMA Expansion Test described herein. The expandable graphite may expand by at least about 600 microns when heated to about 240°C in the TMA Expansion Test described herein. The expandable graphite may expand by at least about 700 microns when heated to about 240°C in the TMA Expansion Test described herein. The expandable graphite may expand by at least about 800 microns when heated to about 240°C in the TMA Expansion Test described herein. Additionally, the expandable graphite may expand by at least about 900 microns when heated to about 280°C in the TMA Expansion Test described herein.

[0047] The expandable graphite has a volumetric expansion of at least about 4 cubic centimeters per gram (cc / g), or at least about 5 cubic centimeters per gram (cc / g), or at least about 6 cubic centimeters per gram (cc / g), or at least about 7 cubic centimeters per gram (cc / g), or at least about 8 cubic centimeters per gram (cc / g), or at least about 9 cubic centimeters per gram (cc / g), or at least about 10 cubic centimeters per gram (cc / g), or at least about 11 cubic centimeters per gram (cc / g) at 300° C. when tested using the Furnace Expansion Test described herein. The expandable graphite may have an average expansion coefficient of about 19 cc / g at 300° C., or at least about 12 cubic centimeters per gram (cc / g), or at least about 19 cubic centimeters per gram (cc / g), or at least about 20 cubic centimeters per gram (cc / g), or at least about 21 cubic centimeters per gram (cc / g), at least about 22 cubic centimeters per gram (cc / g), at least about 23 cubic centimeters per gram (cc / g), at least about 24 cubic centimeters per gram (cc / g), or at least about 25 cubic centimeters per gram (cc / g). For example, the expandable graphite may have an average expansion coefficient of about 19 cc / g at 300° C. when tested using the Furnace Expansion Test described herein.

[0048] The expandable graphite can have an endothermic value of about 50 J / g or more, or about 75 J / g or more, or about 100 J / g or more, or about 125 J / g or more, or about 150 J / g or more, or about 175 J / g or more, or about 200 J / g or more, or about 225 J / g or more, or about 250 J / g or more. The endothermic value of the expandable graphite material can be determined using differential scanning calorimetry (DSC).

[0049] The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 4 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 6 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 8 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Test described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 9 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 10 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 12 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein.The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 14 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 16 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 18 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Test described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 19 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 20 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 100 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein.

[0050] The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 4 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 6 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 8 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 9 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 10 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 12 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein.The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 14 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 16 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 18 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 19 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested by the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 20 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Test described herein and an endotherm of at least about 150 Joules per gram (J / g) when tested by the DSC Endotherm Test Method described herein.

[0051] The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 4 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 6 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 8 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Test described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 9 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 10 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 12 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein.The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 14 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 16 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 18 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 19 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 20 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Test described herein and an endotherm of at least about 200 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein.

[0052] The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 4 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 6 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 8 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 9 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 10 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 12 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein.The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 14 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 16 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 18 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 19 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein. The thermally responsive material can include expandable graphite having an average coefficient of expansion at 300°C of at least about 20 cubic centimeters per gram (cc / g) when tested using the Oven Dilatation Test Method described herein and an endotherm of at least about 250 Joules per gram (J / g) when tested using the DSC Endotherm Test Method described herein.

[0053] The size of the expandable graphite particles can be selected to allow application of the thermally reactive material by a selected application method, for example, if the thermally reactive material is to be applied by a gravure printing technique, the size of the expandable graphite particles should be small enough to fit into the gravure cells.

[0054] The thermally responsive material can include a polymer resin. The polymer resin can have a melting or softening point less than about 280°C. The polymer resin can be sufficiently fluid or deformable to allow the expandable graphite to substantially expand upon thermal exposure of about 300°C or less. The polymer resin can be sufficiently fluid or deformable to allow the expandable graphite to substantially expand upon thermal exposure of about 280°C or less. The polymer resin can allow the expandable graphite to sufficiently expand at temperatures below the thermal decomposition temperature of the first fusible layer and / or the second fusible layer. The extensional viscosity of the polymer resin can be low enough to allow the expandable graphite to expand, yet high enough to maintain the structural integrity of the thermally responsive material after expansion of the polymer resin and expandable graphite mixture. These factors can be quantified by the storage modulus and tan δ of the polymer.

[0055] The polymer resin has a resistivity of at least about 10 dynes / cm 2 The polymer resin may have a storage modulus of 103 to 108 dynes / cm 2 The polymer resin may have a storage modulus of 10 to 10 dynes / cm 2 The polymer resin may have a storage modulus of 103 to 106 dynes / cm 2 The polymer resin may have a storage modulus of 10 to 10 dynes / cm 2 The polymer resin may have a storage modulus of 10 to 10 dynes / cm 2 The polymer resin may have a storage modulus of about 0.1 to about 10 at 200°C. Storage modulus is a measure of the elastic behavior of a polymer and can be measured using dynamic mechanical analysis (DMA). The polymer resin may have a tan δ of about 0.1 to about 10 at 200°C. Tan δ is the ratio of loss modulus to storage modulus and can be measured using DMA.

[0056] The polymer resin can have a modulus and elongation suitable for expanding the expandable graphite at temperatures up to about 300°C. The polymer resin can be elastomeric. The polymer resin can be crosslinkable, such as crosslinkable polyurethane. The polymer resin can be thermoplastic.

[0057] The polymer resin may include polymers including, but not limited to, polyester, polyether, polyurethane, polyamide, acrylic, vinyl polymer, polyolefin, silicone, epoxy, or combinations thereof.

[0058] The thermally reactive material and / or the polymer resin may include a flame-retardant material. The flame-retardant material may include melamine, phosphorus, metal hydroxides such as alumina trihydrate (ATH), borates, or combinations thereof. The flame-retardant material may include brominated compounds, chlorinated compounds, antimony oxide, organophosphorus 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, organic phosphinates, phosphonate esters, or combinations thereof. When present, the flame-retardant material may be used in a weight percentage of 1% to 50% based on the total weight of the polymer resin.

[0059] When exposed to heat from an electric arc, the thermally reactive material can form multiple tendrils comprising expanded graphite. The total surface area of ​​the thermally reactive material can be significantly increased compared to the same mixture before expansion. For example, the surface area of ​​the thermally reactive material can 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.

[0060] The tendrils can extend outward from the expanded thermally reactive material. When the thermally reactive material is disposed on the layer in a discontinuous form, the tendrils can extend to at least partially fill the open areas between the discontinuous areas of thermally reactive material. The tendrils can be elongated to have a length to width aspect ratio of at least 5:1.

[0061] In embodiments where the thermally reactive material, including a mixture of polymer resin and expandable graphite, is applied in a pattern of discrete features, the thermally reactive material expands to form tendrils that are loosely packed after expansion, creating voids between the tendrils and spaces between the patterns of thermally reactive material. Without being bound by theory, upon exposure to heat from the electric arc, the first and second fusible layers each melt and move generally away from the open areas between the discrete features of thermally reactive material.

[0062] The thermally reactive material can act as an adhesive material between the first meltable layer and the first barrier layer, and between the second meltable layer and the second barrier layer.

[0063] The thermally reactive material can be produced by a process that provides a homogeneous mixture of the polymer resin and the expandable graphite without causing substantial expansion of the expandable graphite. The polymer resin and the expandable graphite can be mixed to form a mixture that can be applied in a continuous or discontinuous pattern to the surface interfaces, i.e., the surface of at least one of the first meltable layer and the first barrier layer, and the surface of at least one of the second meltable layer and the second barrier layer. In this manner, the layers of the first and second thermally reactive material act as an adhesive, adhering or bonding the first meltable layer to the first barrier layer and the second meltable layer to the second barrier layer. The mixture of the polymer resin and the expandable graphite can be produced by any suitable mixing method. Suitable mixing methods include, but are not limited to, paddle mixers, blending, and other low-shear mixing techniques.

[0064] Thermally responsive materials comprising a polymer resin and expandable graphite can be prepared by mixing expandable graphite with a monomer or prepolymer prior to polymerization of the polymer resin. In other embodiments, thermally responsive materials can be prepared by mixing expandable graphite with a polymer resin dissolved in a solvent, followed by removing at least a portion of the solvent. In other embodiments, thermally responsive materials can be prepared by mixing expandable graphite with a polymer melt at a temperature below the expansion temperature of the graphite and above the melting point of the polymer. Without wishing to be bound by theory, mixtures prepared by these methods can include a homogeneous mixture of polymer resin and expandable graphite particles.

[0065] In a method for providing a homogeneous mixture of polymer resin and expandable graphite particles or agglomerates of expandable graphite, the expandable graphite is coated or encapsulated with the polymer resin prior to expanding the graphite. The homogeneous mixture of polymer resin and expandable graphite can be prepared prior to applying the thermally reactive material to the first or second fusible layer, or the first or second barrier layer.

[0066] The thermally responsive material may comprise about 50 wt% or less of expandable graphite, based on the total weight of the thermally responsive material. In other embodiments, the thermally responsive material may comprise about 40 wt% or less, about 30 wt% or less, about 20 wt% or less, about 10 wt% or less, about 5 wt% or less, or about 1 wt% or more of expandable graphite, based on the total weight of the thermally responsive material, with the remainder substantially comprising polymer resin. Generally, about 5 wt% to about 50 wt% of expandable graphite, based on the total weight of the thermally responsive material, is desirable. However, desirable fire resistance performance can be achieved with even lower amounts of expandable graphite. In some embodiments, loadings as low as 1 wt% can be useful. Other levels of expandable graphite may be suitable in other embodiments, depending on the desired properties and the configuration of the resulting laminate structure. Other additives, such as pigments, fillers, antimicrobial agents, processing aids, stabilizers, etc., may also be added to the thermally responsive material.

[0067] The first laminate includes a first meltable layer and a first barrier layer, with a first layer of heat-reactive material acting as an adhesive between the two layers. The first layer of heat-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 heat-reactive material can be applied to one side of the second meltable layer and / or one side of the second barrier layer.

[0068] The first layer of thermally reactive material and / or the second layer of thermally reactive material can be applied independently, continuously or discontinuously. For example, where improved breathability and / or hand feel are desired, both layers of thermally reactive material can be applied discontinuously to form a thermally reactive material layer with less than 100% surface coverage. The layers of thermally reactive material can be applied discontinuously to provide less than 100% surface coverage of the meltable textile and barrier layer.

[0069] The layers of thermally reactive material may be applied discontinuously in one or more patterns. The thermally reactive material may be applied to a first meltable layer or first barrier layer and a second meltable layer or second barrier layer to form individual thermally reactive material layers in the form of a plurality of individual pre-expansion structures. Upon expansion, the individual pre-expansion structures may form a plurality of individual expanded structures having structural integrity. The plurality of individual expanded structures having structural integrity may provide sufficient protection to the multilayer textile composite to achieve the improved properties described herein. Structural integrity means that the expanded thermally reactive material will withstand bending or folding without substantial collapse or delamination, and withstand compression during thickness measurements, as measured by the Thickness Change Test described herein.

[0070] The layer of thermally reactive material can be applied discontinuously in a pattern comprising a plurality of discrete pre-expanded structures comprising the thermally reactive material, including shapes such as dots, circles, diamonds, ellipses, stars, rectangles, squares, triangles, pentagons, hexagons, octagons, lines, waves, and combinations thereof.

[0071] The average distance between adjacent regions of the discontinuous pattern of thermally reactive material can be smaller than the size of the impinging flame. The average distance between adjacent regions of the discontinuous pattern can be about 10 millimeters (mm) or less, or about 9 mm or less, or about 8 mm or less, or about 7 mm or less, or about 6 mm or less, or about 5 mm or less, or about 4 mm or less, or about 3.5 mm or less, or about 3 mm or less, or about 2.5 mm or less, or about 2 mm or less, or about 1.5 mm or less, or about 1 mm or less, or about 0.5 mm or less, or about 0.4 mm or less, or about 0.3 mm or less, or about 0.2 mm or less. For example, in a dot pattern printed with thermally reactive material, the spacing between the edges of two adjacent dots of thermally reactive material is measured. The average distance between adjacent regions of the discontinuous pattern can be about 40 microns or more, about 50 microns or more, about 100 microns or more, or about 200 microns or more, depending on the application. In some patterns described herein, an average dot spacing measured at least about 200 microns and no greater than about 500 microns is useful.

[0072] Pitch, for example, in combination with surface coverage, can be used as a way to describe the laydown of a printed pattern. Generally, pitch is defined as the average center-to-center distance between adjacent features, such as dots, lines, or gridlines, in the printed pattern. This average is used, for example, to account for irregularly spaced printed patterns. The thermally reactive material can be applied discontinuously in a pattern with a pitch and surface coverage that provides superior flame retardant performance compared to a continuous application of a thermally reactive mixture with an equivalent weight laydown of the thermally reactive material. Pitch can be defined as the average center-to-center distance between adjacent features of the thermally reactive material. For example, pitch can be defined as the average center-to-center distance between adjacent dots or gridlines of the thermally reactive material. The pitch can be about 500 microns or greater, about 600 microns or greater, about 700 microns or greater, about 800 microns or greater, about 900 microns or greater, about 1000 microns or greater, about 1200 microns or greater, about 1500 microns or greater, about 1700 microns or greater, about 1800 microns or greater, about 2000 microns or greater, about 3000 microns or greater, about 4000 microns or greater, about 5000 microns or greater, about 6000 microns or greater, or any value therebetween. Preferred patterns of thermally reactive material can have a pitch of about 500 microns to about 6000 microns.

[0073] In embodiments where properties such as hand, breathability, and / or textile weight are important, surface coverages of about 25% or more and about 90% or less, or less than about 80%, about 70%, about 60%, about 50%, about 40%, or about 30% can be used. When exposed to an electric arc, the first fusible layer can be exposed to sufficient energy to burn. In these embodiments, where higher flame-resistant properties are required, it may be desirable to have a surface coverage of the heat-reactive material on the surface of the first or second fusible layer of the thermally reactive material with a pitch of about 500 microns to about 6000 microns. For example, the surface coverage of the heat-reactive material can be about 30% to about 80% heat-reactive material on the surface of the first or second fusible layer or the first or second barrier layer of the thermally reactive material with a pitch of about 500 microns to about 6000 microns.

[0074] Methods for discontinuously depositing the thermally reactive material onto the first or second fusible layer, or onto the first or second barrier layer, to achieve less than 100% surface coverage can include applying the thermally reactive material by printing it onto the layer. Deposition of the thermally reactive material onto the first or second fusible layer and / or the first or second barrier layer can be achieved by any suitable method, such as gravure printing, screen printing, spray or scatter coating, knife coating, and any similar method that allows for application of the thermally reactive material such that the desired properties are achieved when exposed to heat from an electric arc.

[0075] The thermally reactive material can be applied to achieve an add-on weight of about 10 gsm to about 100 gsm of thermally reactive material per layer. The thermally reactive material can be applied to achieve an add-on weight of about 100 gsm or less, about 75 gsm or less, about 50 gsm or less, or about 25 gsm or less of thermally reactive material.

[0076] Methods for making the first and second laminates described herein can 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 such that the thermally reactive material provides a good bond between the barrier layer and the respective meltable layer. The layer of thermally reactive material can function as an adhesive. For example, the thermally reactive material can bond one side of the first meltable layer to one side of the first barrier layer, forming a layer of thermally reactive material between the first meltable layer and the first barrier layer. Similarly, a second layer of thermally reactive material can bond one side of the second meltable layer to one side of the second barrier layer, forming a second layer of thermally reactive material between the second meltable layer and the second barrier layer.

[0077] During the formation of the first laminate and / or the second laminate, the first layer of thermally reactive material and / or the second layer of thermally reactive material can be independently applied to the meltable layer and / or the barrier layer, either continuously or discontinuously. The first meltable layer and the first barrier layer are then bonded together, and the second meltable layer and the second barrier layer are then bonded together. Optionally, the first laminate and / or the second laminate can be passed through the nip of two or more rollers to apply pressure and / or heat to ensure a strong bond. If heat is used, the temperature should be low enough that the heat does not initiate expansion of the expandable graphite. By applying pressure (e.g., from rollers), at least the polymer resin of the thermally reactive material can be at least partially disposed within the surface pores, surface voids, or interfiber voids or spaces of one or both layers. At the very least, the polymer resin of the thermally reactive material can penetrate into the voids or spaces between the fibers and / or filaments of the meltable layer. In some embodiments, at least the polymer resin of the thermally reactive material can penetrate the barrier layer. In yet other embodiments, at least the polymer resin of the thermally reactive material can penetrate the voids or spaces between the fibers of the meltable layer and can also penetrate the barrier layer.

[0078] Barrier layer The multilayer textile composite also includes a first barrier layer and, if present, a second barrier layer. The following description of the barrier layers refers to the first barrier layer but is also applicable to the second barrier layer. In some embodiments, the barrier layers are in the form of a film. Each barrier layer can independently comprise a layer of polyimide, silicone, polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyolefin, polyethylene, polypropylene, or a combination thereof. In some embodiments, the first barrier layer and the second barrier layer can comprise expanded polytetrafluoroethylene (ePTFE).

[0079] The first barrier layer and / or the second barrier layer can independently be a monolayer film, a bilayer film, a trilayer film, or a multilayer film. Suitable monolayer films can include a layer of microporous expanded polytetrafluoroethylene film, a polyimide film, a silicone film, or a polytetrafluoroethylene film. In some embodiments, the barrier layer can be a multilayer film including a microporous expanded polymer film containing micropores and another polymer that fills at least a portion of the pores of the expanded polymer film and, optionally, forms a cap layer or film layer on one or both sides of the expanded polymer film.

[0080] In some embodiments, the two-layer barrier layer can include a first layer of microporous expanded polytetrafluoroethylene and a second layer of microporous expanded polytetrafluoroethylene. In other embodiments, the two-layer barrier layer can include a first layer of microporous expanded polytetrafluoroethylene and a polyurethane coating on the microporous expanded polytetrafluoroethylene layer, where the polyurethane layer is a coating on the surface of the microporous ePTFE 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 can 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 layers of microporous ePTFE. In other embodiments, the first barrier layer and / or the second barrier layer is a layer of microporous expanded polyolefin film, with a polyurethane layer 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 form a cap layer on the polyolefin film. In another embodiment, the first barrier layer and / or the second barrier layer is a layer of microporous expanded polyethylene film onto which a polyurethane layer is coated. The polyurethane may penetrate at least a portion of the pores of the microporous expanded polyethylene film and / or form a cap layer on the microporous expanded polyethylene film.

[0081] The barrier layer can be a film having a thickness of 1 millimeter (mm) or less and a hand feel of about 100 or less when measured by the Flexibility or Hand Feel Measurement Test described herein.

[0082] The barrier layer can 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 can be more thermally stable than the first fusible layer and / or the second fusible layer, and / or any of the first, second, third, or fourth flame-retardant textiles that may be present. A thermally stable barrier layer can help prevent heat transfer from one side (outside) of the multilayer textile composite to the other side (inside), e.g., from a first portion to a second portion, during exposure to an electric arc. A thermally stable barrier layer used as a barrier layer in the embodiments described herein has a maximum air permeability after heat exposure of about 50 liters / square meter / second (l / m) when tested according to the air permeability test ISO 9237 (1995). 2 / sec). Thermally stable barrier layers used as barrier layers in the embodiments described herein are also resistant to the formation of holes (5 millimeters or greater in diameter) after exposure to an electric arc. In other embodiments, the barrier layer has a maximum air permeability after heat exposure of about 25 l / m when tested according to the Air Permeability Test for Thermally Stable Barrier Layers disclosed herein. 2 / sec or about 15 l / m 2 If the barrier layer comprises a film, the film has a maximum air permeability after heat exposure of less than about 25 l / m when tested according to the Melt and Thermal Stability Test Method described herein. 2 If the barrier layer comprises a film, the film can have an air permeability of about 15 l / m 2 after exposure to an electric arc sufficient to expand the expandable graphite when tested according to the Thermally Stable Barrier Air Permeability Test disclosed herein. 2 / second or less.

[0083] The barrier layer has a maximum air permeability after heat exposure of about 50 l / m when tested according to the Air Permeability Test for Thermally Stable Barrier Layers disclosed herein. 2 / second or less, or approximately 45 l / m 2 / second or less, or about 40 l / m 2 / second or less, or approximately 35 l / m 2 / second or less, or about 30 l / m 2 / second or less, or approximately 25 l / m 2 / second or less, or about 20 l / m 2 / second or less, or about 15 l / m 2 / second or less, or approximately 10 l / m 2 / second or less, or about 5 l / m 2 / second or less.

[0084] The barrier layer may have a weight ranging from 4 grams per square meter (gsm) to 60 gsm, or from 5 gsm to 55 gsm, or from 6 gsm to 50 gsm, or from 8 gsm to 50 gsm, or from 10 gsm to 50 gsm, or from 10 gsm to 45 gsm, or from 10 gsm to 40 gsm, or from 10 gsm to 35 gsm, or from 30 gsm to 40 gsm, or from 20 gsm to 30 gsm, or from 15 gsm to 35 gsm, or from 20 It can be in the range of gsm to 35 gsm, or in the range of 25 gsm to 35 gsm, or in the range of 30 gsm to 35 gsm, or in the range of 15 gsm to 30 gsm, or in the range of 25 gsm to 30 gsm, or in the range of 15 gsm to 25 gsm, or in the range of 20 gsm to 25 gsm, or in the range of 15 gsm to 20 gsm, or in the range of 21 gsm to 23 gsm, or in the range of 29 gsm to 31 gsm, or any value therebetween, or about 22 gsm, or about 30 gsm.

[0085] Flame-retardant textiles This disclosure describes a first flame-retardant textile, a second flame-retardant textile, a third flame-retardant textile, and a fourth flame-retardant textile. Each of these flame-retardant textiles is an individual layer that may be present in a multilayer textile composite, and the following flame-retardant textile descriptions are appropriate for describing each individual flame-retardant textile that may be used in any portion. Each flame-retardant textile can be selected independently of the other flame-retardant textiles, if present. Thus, each flame-retardant textile may be the same or different.

[0086] The first portion can include a first flame-retardant textile. The first flame-retardant textile can be adjacent to the first barrier layer. Suitable flame-retardant textiles can include fibers or yarns made from inherently flame-retardant materials, materials treated with one or more flame retardants to render them flame-retardant, or combinations thereof. Suitable materials can include, for example, aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modacrylic, cellulose, flame-retardant cellulose, flame-retardant viscose, polyvinyl acetate, polyacrylonitrile, carbon fiber, mineral fiber, protein fiber, or combinations thereof. In some embodiments, a small amount, e.g., less than 10% by weight, of antistatic fibers or filaments can be added to the textile. Here, the weight percent of the antistatic fibers or filaments is based on the total weight of the flame retardant textile. Suitable antistatic fibers / filaments are known in the art and may include, for example, conductive metal, copper, nickel, stainless steel, steel, gold, silver, titanium, and carbon fibers.

[0087] The flame resistant textile can have a weight ranging from 100 grams per square meter (gsm) to about 300 gsm. In other embodiments, the flame resistant textile can have a weight ranging from 100 gsm to about 275 gsm, or from 100 gsm to about 250 gsm, or from 100 gsm to about 240 gsm, or from 100 gsm to about 230 gsm, or from 100 gsm to about 225 gsm, or from 100 gsm to about 220 gsm.

[0088] When the first flame-retardant textile is part of the first laminate, it can be attached to the first barrier layer via a flame-retardant adhesive. The flame-retardant adhesive can be any textile adhesive known in the art. Typically, one or more flame retardants can be added to the adhesive to impart flame retardancy. Typical flame retardants include, for example, phosphorus-based flame retardants, amine-based flame retardants, other known flame retardants, or combinations thereof.

[0089] Second part The multilayer textile composite further includes a second portion. In some embodiments, the second portion is adjacent to the first portion and attached to the first portion via one or more stitches. In other embodiments, a third portion is located between the first and second portions, and at least a portion of the first, second, and third portions are attached via one or more stitches.

[0090] The second portion can include b) a second laminate, where the second laminate includes b1) a second fusible layer, b2) a second layer of thermally reactive material, b3) a second barrier layer, and, optionally, b4) a second flame-retardant textile; or the second portion can include a third flame-retardant textile. In some of the foregoing embodiments, the second portion can be adjacent to the first barrier layer of the first portion. In embodiments in which the second portion is a third flame-retardant textile, the third flame-retardant textile is adjacent to the first barrier layer. In embodiments in which the second portion is a second laminate, the second fusible layer of the second portion is adjacent to the first barrier layer of the first portion. The second flame-retardant textile can be adhered to the second barrier layer by one or more of the flame-retardant adhesives described above.

[0091] When the second portion is a third flame-retardant textile, the third flame-retardant textile can be a woven, knitted, or nonwoven textile containing fibers such as aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modacrylic, cellulose, flame-retardant cellulose, flame-retardant viscose, polyvinyl acetate, polyacrylonitrile, carbon fiber, mineral fiber, protein fiber, or a combination thereof. In some embodiments, a small amount of antistatic fibers or filaments, for example, less than 10% by weight, may be added to the third flame-retardant textile, where the weight percent of the antistatic fibers or filaments is based on the total weight of the third flame-retardant textile. Suitable antistatic fibers / filaments are known in the art and include, for example, conductive metals, copper, nickel, stainless steel, steel, gold, silver, titanium, carbon fibers, and the like.

[0092] When the second portion is a second laminate, the second meltable layer, the second layer of thermally reactive material, and the second barrier layer can each independently use any of the materials described for the first meltable layer, the first layer of thermally reactive material, and / or the first barrier layer. For example, the first meltable layer can be a woven polyester textile and the second meltable layer can be another layer of the same woven polyester textile, or the second meltable layer can be a knitted polyamide textile. In other words, any of the materials described for the first meltable layer can independently be used for the second meltable layer, any of the materials described for the first layer of thermally reactive material can independently be used for the second layer of thermally reactive material, and any of the materials described for the first barrier layer can independently be used for the second barrier layer. In some embodiments, the first meltable layer and the second meltable layer are the same. In some embodiments, the first layer of thermally reactive material and the second layer of thermally reactive material are the same. In some embodiments, the first barrier layer and the second barrier layer are the same. In some embodiments, the first meltable layer and the second meltable layer are different. In some embodiments, the first layer of thermally responsive material and the second layer of thermally responsive material are different. In some embodiments, the first barrier layer and the second barrier layer are different.

[0093] If desired, the second laminate can further include b4) a second flame-retardant textile. This can be any of the materials described for the first flame-retardant textile. For example, the second flame-retardant textile can include one or more of aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modacrylic, cellulose, flame-retardant cellulose, flame-retardant viscose, polyvinyl acetate, mineral fibers, protein fibers, or combinations thereof. One or more of the aforementioned antistatic fibers can be present in the second flame-retardant textile in an amount of 10% by weight or less, based on the total weight of the second flame-retardant textile. When present, the first and second flame-retardant textiles can be the same or different.

[0094] The second flame retardant textile may be adhered to the second barrier layer via an adhesive, preferably an adhesive containing a flame retardant additive, as described above. Suitable textile adhesives and flame retardant-containing adhesives are known in the art and may include, for example, polyurethane adhesives, polyester adhesives, acrylic adhesives, or combinations thereof.

[0095] The second laminate is attached to the first portion with the first barrier layer positioned 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, a stitch is used to attach at least one layer of the first portion to at least one layer of the second portion.

[0096] Third part The multilayer textile composite can further include a third portion. In some embodiments of the multilayer textile composite, the third portion is present. In some embodiments of the multilayer textile composite, the third portion is absent. The third portion includes a fourth flame-retardant textile, is positioned between the first portion and the second portion, and is attached to the multilayer textile composite via one or more stitches.

[0097] The third portion includes a fourth flame-retardant textile. The fourth flame-retardant textile can be a knitted fabric, a woven fabric, a nonwoven fabric, or a multilayer combination thereof. Suitable flame-retardant textiles can include, for example, aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modacrylic, cellulose, flame-retardant cellulose, flame-retardant viscose, polyvinyl acetate, mineral fibers, protein fibers, or combinations thereof. One or more of the aforementioned antistatic fibers can be present in the second flame-retardant textile in an amount of 10% by weight or less, based on the total weight of the second flame-retardant textile. When present, the first, second, third, and fourth flame-retardant textiles can be the same or different.

[0098] stitch The first portion, second portion, and optional third portion are attached to one another by one or more stitches, which may be machine stitched, hand stitched, or a combination thereof, and which may include one or more of a quilting stitch, a series of one or more stitch lines, a series of overlapping stitch lines, a series of stitched geometric shapes, a series of grid pattern stitches, a series of essentially parallel stitches, a series of tuck stitches, or a combination thereof.

[0099] The stitching forms a connection or attachment between a first portion, e.g., a first barrier layer surface, and a second portion, e.g., a second meltable layer surface. In embodiments where a third portion is present, the third portion is located between the first and second portions and is attached to the first and second portions via stitching. In some embodiments (as illustrated in FIG. 4), one side of the third portion contacts the first barrier layer of the first portion, and the opposite side of the third portion contacts the second portion. The quilting stitch penetrates the first meltable layer, the first layer of heat-reactive material, the first barrier layer, and both the third and second portions. When the second portion is a second laminate (as illustrated in FIG. 5), the first barrier layer contacts one side of the third portion, and the opposite side of the third portion contacts the second meltable layer of the second portion. In other embodiments including a third portion, the first flame-retardant layer contacts one side of the third portion, and the opposite side of the third portion contacts the second side.

[0100] The stitches form a connecting area between the two portions and are spaced apart so that the land areas of the first and second portions are not closely connected. The stitches are spaced apart so that the land area between the stitches is about one square centimeter (cm 2 ) ~ approx. 1500cm 2 In other embodiments, the land area is in the range of 1 to 1400 cm. 2 , 1~1300cm 2 , 1~1250cm 2 , 1~1200cm 2 , 1~1150cm 2 , 1~1100cm 2 , 1~1050cm 2 , 1~1000cm 2 , 1~950cm 2 , 1~900cm 2 , 1~850cm 2 , 1~800cm 2 , 1~750cm 2 , 1~700cm 2 , 1~650cm 2 , 1~600cm 2 , 1~550cm2 , 1~500cm 2 , 1~450cm 2 , 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 6~650cm 2 , or 6 to 600 cm 2 , or 6~550cm 2 , or 6 to 500 cm 2 , or 6~450cm 2 The phrase "land area" refers to the area of ​​a layer between stitch lines that form the unbonded area between the layers. In some embodiments, such as a quilt stitch, the land area is the area enclosed by the stitches. In other embodiments, such as a series of tuck stitches, the land area can be determined by analyzing the repeating pattern of the stitches and determining the area enclosed by each repeating unit (as illustrated in FIG. 7). FIG. 7 shows a regularly repeating pattern of tuck stitches, forming a series of rectangular land areas. The distance between each tuck stitch has a land height and a land width. In this example, the land area is the product of the land height and the land width.

[0101] The stitches can penetrate the entire thickness of the multilayer textile composite. For example, as shown in exemplary Figures 1, 2, and 3, the stitches can penetrate the entire thickness of the multilayer textile composite from the first meltable layer to the second portion. For example, Figure 1 shows the stitches penetrating the entire thickness from the first meltable layer to the flame-resistant textile layer. Figure 2 shows the stitches penetrating the entire thickness from the first meltable layer to the second barrier layer. Figure 3 shows the stitches penetrating the entire thickness from the first meltable layer to the second flame-resistant textile of the second laminate. In other embodiments, the stitches can penetrate less than the entire thickness of the multilayer textile composite, for example, penetrating only certain layers of the multilayer textile composite, typically connecting at least the first barrier layer to the second meltable textile or the second flame-resistant textile. As shown in Figure 6, the first barrier layer can be sewn to the second meltable textile, and the remainder of the multilayer textile composite can be bonded via one or more adhesive layers. Once the first barrier layer and second meltable textile are stitched together, standard lamination techniques can be used to form the remaining portions of the multilayer textile composite. In some embodiments, a first or second layer of a thermally reactive material can be applied to the first barrier layer or second meltable textile, followed by the first or second meltable layer, to form a portion of the multilayer textile composite. This process can then be repeated for the remaining layers to form the multilayer textile composite. While this process is described for the first and second portions, this process can be applied to any combination of the first, second, and third portions, and at least one portion of the first portion can be stitched to at least one portion of the second portion, with or without a third portion between the first and second portions.

[0102] The stitching itself can be any material commonly used in the manufacture of sewing threads. In some embodiments, the stitching can be one or more flame-retardant fibers in the form of a sewing thread. Any material described as useful in the manufacture of flame-retardant textiles can be used to manufacture the stitching material. For example, the thread can include aramid, p-aramid, m-aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modacrylic, cellulose, flame-retardant cellulose, flame-retardant viscose, polyvinyl acetate, mineral fiber, protein fiber, or a combination thereof. Additionally, the sewing thread can be a core / shell thread comprising a core made of any of the flame-retardant fibers and a shell made of meltable fibers such as polyamide, polyester, polyolefin, acrylic, polyurethane, or a combination thereof. In other embodiments, the core can be a meltable fiber, such as polyester or polyamide, and the shell can be a flame-retardant fiber.

[0103] Manufacturing method for textile composites Multilayer textile composites including a first portion and a second portion can be manufactured in a variety of ways. The first portion includes a first laminate including a first meltable layer, a first layer of heat-reactive material, a first barrier layer, and, in some embodiments, a first flame-retardant textile. In some embodiments, the second portion includes a second laminate including a second meltable layer, a second layer of heat-reactive material, a second barrier layer, and, optionally, a second flame-retardant textile layer. In other embodiments, the second portion can include a third flame-retardant textile. The first portion including the first laminate can be manufactured by selecting a first meltable layer, a first heat-reactive material, and a first barrier layer. The first laminate can be manufactured using standard lamination techniques, applying a first layer of heat-reactive material to one or both of the first meltable layer and / or the first barrier layer. The application of the first layer of heat-reactive material can be accomplished using printing and / or coating techniques, such as gravure printing, screen printing, flow coating, knife coating, etc. After application of the first layer of thermally reactive material, the first meltable layer and the first barrier layer can be contacted with each other, sandwiching the first layer of thermally reactive material between the first meltable layer and the first barrier layer, and bonding the two layers together. Optionally, pressure and / or heat can be applied to form a first part comprising a first laminate. If desired, a second part comprising a second laminate can be formed using a similar lamination process. In some embodiments, the first laminate and the second laminate are the same laminate. In other embodiments, the second laminate has at least one layer that is different from the first laminate.

[0104] The first portion can then be attached to the second portion by one or more stitches so that the first barrier layer contacts the second portion. In embodiments where the second portion is a second laminate, the first barrier layer is adjacent to and in contact with the second fusible layer. In some embodiments, there is no third portion between the first barrier layer and the second fusible layer. In embodiments where the second portion is a flame-retardant textile, the first barrier layer is adjacent to the flame-retardant textile. In some embodiments, the third portion is disposed between the first portion and the second portion. In some embodiments, the multilayer textile composite includes a third portion located between and in contact with the first barrier layer and the second fusible layer. In other embodiments, the multilayer composite textile includes a third portion between the first barrier layer and the second flame-retardant textile.

[0105] The stitching process can include hand-sewn stitches, machine-sewn stitches, or a combination thereof. The stitches can be continuous stitches using various patterns to form attachments between the first and second portions and land areas including the areas of the first and second portions between the stitches. In some embodiments, the stitches are quilting stitches, a series of stitched geometric shapes, a series of grid pattern stitches, a series of stitches essentially parallel to each other, a series of tuck stitches, or a combination thereof. As described herein, any quilting stitch can be used as long as the quilting stitches provide the required land area size. In other embodiments, the stitches can be tuck stitches or discontinuous stitches. The tuck stitches can include a regular series of repeating stitches that are not continuous stitches (as exemplarily shown in FIG. 7). When tuck stitches are used, the land area can be determined as the area enclosed by the repeating pattern of tuck stitches. The land area can be determined by analyzing the repeating pattern of the stitches and determining the area enclosed by each repeating unit. FIG. 7 shows a regular repeating pattern of tuck stitches, forming a series of rectangular land areas, with the distance between each tuck stitch having a land height and a land width. The land area in this example is the land height multiplied by the land width. In either the continuous stitch or non-continuous stitch embodiment, each land area is 1 square centimeter (cm 2 )~1500cm 2 In some embodiments, the land area is in the range of 6 cm 2 ~Approx. 1500cm 2 In other embodiments, the land area can range from 1 to 1400 cm 2 , 1~1300cm 2 , 1~1250cm 2 , 1~1200cm 2 , 1~1150cm 2 , 1~1100cm 2 , 1~1050cm 2, 1~1000cm 2 , 1~950cm 2 , 1~900cm 2 , 1~850cm 2 , 1~800cm 2 , 1~750cm 2 , 1~700cm 2 , 1~650cm 2 , 1~600cm 2 , 1~550cm 2 , 1~500cm 2 , 1~450cm 2 , 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 6~650cm 2 , or 6 to 600 cm 2 , or 6~550cm 2 , or 6 to 500 cm 2 , or 6~450cm 2 The range can be:

[0106] Purpose The multilayer textile composites described herein can be used to form garments, with a first portion, specifically a first fusible layer, disposed on the exterior of the garment and a second portion disposed on the interior of the garment. In some embodiments, the garment can be a jacket, shirt, gloves, pants, coveralls, overalls, footwear, cap, hat, or any combination thereof. Depending on the construction, garments including the multilayer textile composite can have a thermal conductivity of up to 40 cal / cm. 2 In another embodiment, the garment can protect the wearer from electrical arcing of 75 cal / cm 2or more than 90 cal / cm 2 or more than 100 cal / cm 2 The garment can provide protection from high-energy arc discharges while being relatively lightweight. [Brief explanation of the drawings]

[0107] [Figure 1] FIG. 1 shows an embodiment of a multi-layer textile composite in which the second portion is a flame retardant textile.

[0108] [Figure 2] FIG. 2 shows an embodiment of a multi-layer textile composite in which the second portion is a second laminate.

[0109] [Figure 3] FIG. 3 shows an embodiment of a multi-layer textile composite in which the second portion is a second laminate.

[0110] [Figure 4] FIG. 4 illustrates an embodiment of a multilayer textile composite having a second portion and a third portion, the third portion being disposed between the first and second portions.

[0111] [Figure 5] FIG. 5 shows an embodiment of a multi-layer textile composite having a first portion, a second portion, and a third portion, the second portion being a second laminate.

[0112] [Figure 6] FIG. 6 shows an embodiment of a multilayer textile composite having a first portion and a second portion, the second portion being a second laminate, with quilting stitches connecting a portion of the first portion to a portion of the second laminate.

[0113] [Figure 7] FIG. 7 shows an embodiment of a multi-layer textile composite using tuck stitching. DETAILED DESCRIPTION OF THE INVENTION

[0114] The present invention will be further described with reference to the accompanying drawings, in which like structures are numbered similarly throughout the several views. The illustrated drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Additionally, some features may be exaggerated to show details of particular components.

[0115] The drawings constitute a part of this specification and include exemplary embodiments of the present invention, illustrating various objects and features of the present invention. Further, the drawings are not necessarily to scale, and some features may be exaggerated to show details of particular components. Furthermore, dimensions, specifications, etc. shown in the drawings are intended to be illustrative and not limiting. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as representative basis for teaching those skilled in the art how to use the present invention in various ways.

[0116] In addition to the benefits and improvements disclosed, other objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings. Although detailed embodiments of the present invention are disclosed herein, it should be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Furthermore, the examples given in connection with various embodiments of the present invention are intended to be illustrative and not limiting.

[0117] Throughout this specification and claims, the following terms have the meanings expressly associated therewith unless the context clearly dictates otherwise. As used herein, the phrases "in one embodiment" and "in some embodiments" do not necessarily refer to the same embodiment, but may. Additionally, as used herein, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, but may. Thus, as shown below, various embodiments of the invention can be readily combined without departing from the scope or spirit of the invention.

[0118] The term "based on" is not exclusive and allows for additional unrecited factors to be based on, unless the context clearly dictates otherwise. Additionally, throughout this specification, the meanings of "a," "an," and "the" include the plural. The meaning of "in" includes "in" and "on."

[0119] The terms "fiber" and "filament" are used interchangeably herein. Fibers and filaments have a relatively small width and height compared to their length. The cross-sections of fibers and filaments can be virtually any shape, including round, square, or having one or more protrusions, and are well known in the art. Typically, fibers are relatively short in length, e.g., 30 centimeters or less, while filaments are greater than 30 centimeters in length and are essentially infinite, e.g., thousands of meters in length.

[0120] As used herein, the term "fusible," when used with respect to a fiber, filament, yarn, or textile, refers to a fiber that melts at 280°C or below or 300°C or below. In embodiments in which the yarn or textile is made from a single material, e.g., 100% nylon 6, the melting point of the material is that of nylon 6. However, in embodiments of yarns or textiles that contain a mixture of both meltable and non-meltable fibers, the presence of the non-meltable component may mask the melting of the meltable material. For example, in the case of a textile containing a 50 / 50 blend of nylon 6,6 and cotton, the melting nylon 6,6 may be absorbed by the cotton component, appearing to indicate that the textile sample is not meltable when subjected to the melting and thermal stability tests described herein. Thus, the presence of a meltable fiber in a mixture of meltable and non-meltable fibers makes the fiber, filament, yarn, or textile a meltable material for purposes of this disclosure.

[0121] When used to describe layers of a laminate structure, the terms "inner" and "outer" refer to the location of a first portion and a second portion relative to each other and relative to a third portion and are intended to be based on the placement of the individual layers in the finished product. For example, in a finished product such as a garment such as a jacket, the first meltable textile refers to the outermost layer of the garment and the second portion refers to the innermost layer closest to the wearer's body.

[0122] As used herein, the term "quilting" refers to the process of joining two or more layers of material by stitching them together with one or more threads in multiple rows, which stitch together to hold the two materials together across at least a portion of their surfaces while remaining separable while remaining in contact with each other. The term "quilted" refers to the structure resulting from the quilting process.

[0123] As used herein, moisture vapor transmission rate (MVTR) is a measure of the amount of water vapor that can pass through one square meter of membrane within 24 hours. The higher the MVTR, the more breathable the membrane.

[0124] The present disclosure relates to multilayer textile composites that are useful in garments that are relatively lightweight to the wearer while providing a relatively high level of injury protection when exposed to high-energy arc flash discharges.

[0125] An embodiment of a multilayer textile composite is shown in Figure 1. Figure 1 shows a multilayer textile composite 100 including a first portion 110 and a second portion 120. The first portion 110 includes a first laminate including a first meltable layer 130, a first layer of heat-reactive material 140, and a first barrier layer 150. Stitch 105 is also shown. Stitch 105 is shown only in cross section. Stitch 105 can be a quilting stitch or a tuck stitch. In this figure, the second portion 120 is represented as a first flame-retardant textile.

[0126] 2 shows another embodiment of a multilayer textile composite 200. In this embodiment, the multilayer textile composite 200 includes a first portion 210 and a second portion 220. The first portion includes a first laminate including a first meltable layer 230, a first layer of heat-reactive material 240, and a first barrier layer 250. The second portion includes a second laminate including a second meltable textile 260, a second layer of heat-reactive material 270, and a second barrier layer 280. Individual stitches 205 are also shown in perspective through the full thickness of the multilayer textile composite 200.

[0127] 3 shows another embodiment of a multilayer textile composite 300. In this embodiment, the multilayer textile composite 300 includes a first portion 310 and a second portion 320. The first portion includes a first laminate including a first meltable layer 330, a first layer of heat-reactive material 340, and a first barrier layer 350. The second portion includes a second laminate including a second meltable textile 360, a second layer of heat-reactive material 370, a second barrier layer 380, an adhesive layer 390, and a second flame-resistant textile 395 on the opposite side of the adhesive 390. Also shown is a stitch 305 that runs through the entire thickness of the multilayer textile composite 300.

[0128] FIG. 4 illustrates another embodiment. In this embodiment, a multilayer textile 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 including a first meltable textile 430, a first layer of heat-reactive material 440, 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. A stitch 405 penetrates the entire thickness of the multilayer textile composite 400. In this illustration, the second portion 420 is represented as a second flame-resistant textile, and the third portion 425 is represented as a fourth flame-resistant textile.

[0129] 5 shows another embodiment of a multilayer textile composite 500. In this embodiment, a first portion 510 includes a first laminate including a first meltable textile 530, a first layer of heat-responsive material 540, and a first barrier layer 550. A second portion 520 includes a second laminate including a second meltable textile 560, a second layer of heat-responsive material 570, and a second barrier layer 580. A third portion 525 is present. In this embodiment, one side of the third portion 525 is adjacent to the first barrier layer 550, and an opposite side of the third portion 525 is adjacent to the second meltable textile 560 of the second portion 520. A stitch 505 penetrates the entire thickness of the multilayer textile composite 500.

[0130] 6 shows another embodiment of a multilayer textile composite 600. In this embodiment, the multilayer textile composite 600 includes a first portion 610 and a second portion 620. The first portion includes a first laminate including a first meltable layer 630, a first layer of heat-reactive material 640, and a first barrier layer 650. The second portion includes a second laminate including a second meltable textile 660, a second layer of heat-reactive material 670, and a second barrier layer 680. A stitch 605 is also shown, but the stitch 605 does not penetrate the entire thickness of the multilayer textile composite 600.

[0131] 7 shows a top view of the multilayer textile composite showing a first fusible layer 730 and a regularly repeating pattern of tuck stitches 705 forming a series of rectangular land areas 706, the distance between each tuck stitch having a land height 707 and a land width 708. The land area 706 in this example is the land height 707 multiplied by the land width 708. [Example]

[0132] example

[0133] Melting and Thermal Stability Tests

[0134] This test was used to measure the thermal stability of textile materials. The test was based on the thermal stability test described in Section 8.3 of NFPA 1975, 2004 Edition. The test oven was a hot air circulating oven as specified in ISO 17493. Testing was performed according to ASTM D751, "Standard Test Methods for Coated Fabrics," using the high temperature blocking resistance test procedure (Sections 89-93), with the following modifications:

[0135] A borosilicate glass plate measuring 100 mm x 100 mm x 3 mm was used.

[0136] A test oven was used with the temperature set at 300° C.±5° C. The test specimens were allowed to cool for a minimum of 1 hour after removing the glass plates from the oven.

[0137] Sample surfaces that stuck to the glass plates, stuck to each other when unfolded, or showed signs of melting or dripping were considered to be meltable. Sample surfaces that showed no signs of melting were considered to be heat stable.

[0138] TMA expansion test

[0139] Thermomechanical analysis (TMA) was used to measure the expansion of expandable graphite particles. Expansion was measured using a TA Instruments TMA 2940 instrument. A ceramic (alumina) TGA pan approximately 8 mm in diameter and 12 mm in height was used to hold the sample. A macroexpansion probe approximately 6 mm in diameter was used to zero the bottom of the pan. A thin piece of expandable graphite, approximately 0.1-0.3 mm deep as measured by the TMA probe, was placed in the pan. The furnace was closed, and the initial sample height was measured. The furnace was heated from approximately 25 °C to 600 °C at a heating rate of 10 °C / min. The displacement of the TMA probe was plotted against temperature and used as a measure of expansion.

[0140] Furnace expansion test

[0141] The nickel crucible was heated in a high-temperature furnace at 300°C for 2 minutes. The measured expandable graphite sample (approximately 0.5 g) was added to the crucible and kept in the high-temperature furnace at 300°C for 3 minutes. After heating, the crucible was removed from the furnace and allowed to cool. The expanded graphite was then transferred to a measuring cylinder and its expanded volume was measured. The expanded volume was divided by the initial weight of the sample to calculate the expansion coefficient (in cc / g).

[0142] DSC endothermic test

[0143] Testing was performed on a TA Instruments Q2000 DSC using TZERO T™ hermetic pans. For each sample, approximately 3 milligrams (mg) of expandable graphite was placed in the pan. A razor blade corner was pressed into the center of the pan to create a vent hole approximately 2 mm long and less than 1 mm wide. The DSC was equilibrated at 20°C. The sample was then heated from 20°C to 400°C at a rate of 10°C / min. The endotherm was obtained from the DSC curve.

[0144] Flexibility or hand feel measurement test

[0145] Hand feel measurements of laminate construction samples were performed using a Thwing-Albert handle meter (Model No. 211-5, Thwing Albert Instrument Company, Philadelphia, PA). Lower values ​​indicate less load required to bend the sample and more flexibility of the sample.

[0146] Thickness Test

[0147] Thickness was measured by sandwiching the film or textile laminate between the two plates of a Mitutoyo 543-252BS snap gauge, and the average of three measurements was used.

[0148] Thickness change test

[0149] The initial thickness of the sample was tested per ASTM D751 Section 9, except that the pressure bearing diameter was 2.54 cm. The tester applied a force of approximately 0.239 kg / cm to the specimen. 2 The test piece is adjusted to apply a pressure of 3.4 psi. After 60 seconds of exposure to the horizontal burn test (or after failure if failure occurs in less than 60 seconds), the thickness change of the sample is remeasured. After the test, the thickness and integrity of the inflated structure are observed.

[0150] Composite weight

[0151] The weight of each example was measured according to ASTM D3776 / 3776M-20 (R2020) Option C.

[0152] Barrier Thermal Stability Test

[0153] Preferably, the heat stable barrier layer has an air permeability of 25 l / m after heat exposure. 2 To determine the thermal stability of the barrier layer, 381 mm (15 in) square fabric specimens were fixed to a metal frame and then suspended in a forced air oven at 260°C (500°F). After 5 minutes of exposure, the specimens were removed from the oven. After the specimens had cooled, they were tested for air permeability according to ISO 9237 (1995). 2 Specimens with less than 1 / sec were considered to be thermally stable barrier layers.

[0154] Air permeability tests were performed according to ISO 9237 (1995).

[0155] Arc heat performance values ​​were tested according to ASTM F1959 (flat panel test equivalent to EIC 61482-1-1).

[0156] Composite thickness testing was performed according to ASTM D1777.

[0157] Preparation of thermally reactive material #1

[0158] Thermally Reactive Material #1 was manufactured according to the following procedure. A flame-retardant polyurethane resin was prepared by first molding the resin according to commonly owned U.S. Pat. No. 4,532,316, and then adding a phosphorus-based flame retardant material to the reactor in an amount of about 45% by weight. After molding the polyurethane resin, 76 grams of polyurethane resin and 24 grams of expandable graphite (expandable graphite exhibiting an expansion of more than 900 micrometers at 280°C, as determined by the TMA expansion test) were mixed in a stirred vessel at 80°C. The mixture was cooled and used as is.

[0159] Laminate #1

[0160] Laminate #1 was a two-layer laminate available as SAAL079000F from W.L. Gore and Associates, Inc., Elkton, Maryland, and was a fusible polyester woven textile bonded in a repeating, discontinuous dot pattern to a GORE-TEX® ePTFE membrane using a heat-reactive material comprising a polyurethane resin containing expandable graphite particles. The laminate weight was approximately 228 gsm.

[0161] Laminate #2

[0162] Laminate #2 is a commercially available three-layer laminate available from W.L. Gore and Associates, Inc., Elkton, Maryland, as CORT000600B. This laminate includes a melt-bonded outer layer bonded to an ePTFE membrane using a polyurethane resin containing expandable graphite particles in a repeating, discontinuous dot pattern. An innermost flame-retardant (FR) textile includes flame-retardant viscose, aramid, and antistatic fibers and is bonded to the ePTFE layer using a flame-retardant polyurethane adhesive with a discontinuous dot pattern. This three-layer laminate weighs approximately 322 gsm.

[0163] Laminate #3

[0164] Laminate #3 is a two-layer laminate. This laminate was made by laminating a 71 gsm melt weave polyester textile (available from Milliken & Co., Spartanburg, SC) to a GORE-TEX® ePTFE membrane (part number 10898200, W.L. Gore and Associates, Elkton, MD) in a repeating, discontinuous dot pattern with a polyurethane resin containing expandable graphite particles. The two-layer laminate weighed approximately 168 gsm (5.93 oz / yd). 2 )

[0165] Laminate #4

[0166] Laminate #4 is a two-layer laminate. This laminate was made by laminating a melt-sealed polyester knit textile (part number A04Y014AZ, available from Nan Ya Plastics, Kaohsiung, Taiwan) and a GORE-TEX® ePTFE membrane (part number 10898200, available from WL Gore and Associates, Elkton, Maryland) in a repeating, discontinuous dot pattern with a heat-reactive material comprising a polyurethane resin containing expandable graphite particles. The two-layer laminate weighed approximately 180 gsm (6.35 oz / yd). 2 )

[0167] Laminate #5

[0168] Laminate #5 is a three-layer laminate. This laminate, available from W.L. Gore and Associates, Inc., Elkton, Maryland, as part number FERM002001, consists of a melt-bonded nylon knit textile in a repeating, discontinuous dot pattern bonded to a GORE-TEX® ePTFE membrane using a heat-reactive material containing polyurethane resin with expandable graphite particles. The ePTFE membrane is bonded to a flame-retardant backing containing 48% aramid, 50% flame-retardant viscose, and 2% carbon fiber, available from Schuler & Co., Göppingen, Germany.

[0169] Preparation of multilayer composite textile #1

[0170] Two layers of laminate #1 were sewn together as a first and second section using aramid thread available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba. The ePTFE layer of the first section was in contact with the meltable layer of the second section. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2The multi-layer textile composite weighed approximately 460 gsm (13.56 oz / yd) 2 ) was.

[0171] Preparation of multilayer composite textile #2

[0172] A layer of Laminate #1 was quilted to Laminate #2, with the ePTFE layer of Laminate #1 in contact with the meltable layer of Laminate #2. Aramid thread available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba, was used for the quilting. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed approximately 550 gsm (16.22 oz / yd) 2 ) was.

[0173] Preparation of multilayer textile composite #3

[0174] A layer of two-layer laminate #3 was quilted to three-layer laminate #2, with the ePTFE layer of laminate #3 in contact with the meltable layer of laminate #2. Aramid thread available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba, was used for the quilting. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed approximately 523 gsm (15.43 oz / yd) 2 ) was.

[0175] Preparation of multilayer textile composite #4

[0176] A layer of Two-Layer Laminate #3 was quilted to a layer of a 50% aramid / 50% viscose flame-retardant plain weave textile (product number KRVC001A) available from Schuler & Co., Göppingen, Germany. The ePTFE layer of Laminate #3 (first portion) was placed in contact with the plain weave textile (second portion). Aramid yarn available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba, was used for the quilting. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed approximately 344 gsm (10.16 oz / yd) 2 ) was.

[0177] Preparation of multilayer textile composite #5

[0178] A layer of Tri-Layer Laminate #2 (first portion) was quilted to another layer of Tri-Layer Laminate #2 (second portion). The flame-retardant textile of the first portion was placed in contact with the meltable layer of the second portion. Aramid yarn available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba, was used for the quilting. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed approximately 640 gsm (18.9 oz / yd) 2 ) was.

[0179] Preparation of multilayer textile composite #6

[0180] The first layer of Laminate #4 was quilted with a third layer of FR200 THINSULATE® insulation, available from 3M Company, St. Paul, Minnesota, and a second layer of 120 gsm, 50% aramid / 50% viscose plain weave textile (product number KRVC001A), available from Schuler & Co., Göppingen, Germany. The ePTFE layer from the first layer was attached to one side of the third layer, and the second layer was attached to the other side of the third layer. Aramid yarn, available from Mid-West Quilting Co., Ltd., Winnipeg, Manitoba, was used for the quilting. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed 559 gsm.

[0181] Preparation of multilayer textile composite #7

[0182] A layer of Laminate #4 was quilted as the first section, a layer of FR120 THINSULATE® insulation (available from 3M, St. Paul, Minnesota) as the third section, and a layer of Laminate #4 as the second section. The ePTFE layer of the first section was in contact with one side of the third section, and the second section was in contact with the meltable textile of the third section. Aramid yarn available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba, was used for the quilting. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed 549 gsm.

[0183] Preparation of multilayer textile composite #8

[0184] Laminate #1 was quilted as the first section and laminate #5 was quilted as the second section. The ePTFE membrane of the first section was placed in contact with the nylon textile of the second section. Aramid thread available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba, was used for the quilting. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed 542 gsm (estimated).

[0185] Preparation of multilayer textile composite #9

[0186] Laminate #1 was quilted as the first section and laminate #5 was quilted as the second section. The ePTFE membrane of the first section was placed in contact with the nylon textile of the second section. Aramid thread available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba, was used for the quilting. The stitch was a 5.1 cm x 5.1 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 26 cm. 2 The multi-layer textile composite weighed 550 gsm (estimated).

[0187] Preparation of Comparative Textile Composite A

[0188] A layer of Two-Layer Laminate #2 was attached to a layer of 120 gsm 50% aramid / 50% viscose plain weave textile, part number KRVC001A, available from Schuler & Co., Göppingen, Germany. The two layers were joined by stitching around the perimeter of the sample, which simulated a garment hang-on liner. The composite weighed approximately 374.0 gsm.

[0189] Preparation of Comparative Textile B

[0190] Two layers of 271 gsm TWARON® aramid textile were quilted with a three-ply Basofil / aramid blend spunlace layer quilted onto a NOMEX® aramid surface. The triple layer quilting used aramid yarn available from Mid-West Quilting Co. LTD., Winnipeg, Manitoba. The stitch was a 10.2 cm x 10.2 cm diamond-shaped continuous quilting stitch with a land area of ​​approximately 104 cm. 2 The multi-layer textile composite weighed approximately 807 gsm.

[0191] Comparative textile composite C

[0192] Comparative C was OMNI QUILT™ thermal liner available from Norfab of Norristown, Pa. This material weighs approximately 366 gsm (estimated).

[0193] Table 1 shows the thickness, weight and arc heat protection values ​​of the examples. Unless otherwise stated, all values ​​are measured according to the procedures described. [Table 1]

[0194] Examples 1-4 demonstrate that the multilayer textile composites of the present disclosure can provide a relatively thin, lightweight structure and protection against arc flash injury. For example, Comparative Example A is a composite approximately 2 mm thick, with arc protection of only 47 cal / cm. 2 In contrast, Examples 1 and 2 are less than 2 mm thick and have a density of 92 to 105 cal / cm 2 , which far exceeds the performance of Comparative Example A.

Claims

1. A) a first portion, and B) a second part; A multilayer textile composite comprising: The first portion includes 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; Including, The multi-layer textile composite, wherein the first portion and the second portion are attached to one another via one or more stitches.

2. the first laminate further comprises a4) a first flame retardant textile; and The multilayer textile composite of claim 1 , wherein the first flame retardant textile is adjacent to the first barrier layer opposite the first layer of thermally reactive material.

3. The second portion includes 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; 3. The multilayer textile composite of claim 1 or 2, comprising:

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

5. 3. The multilayer textile composite of claim 1 or 2, wherein the second portion comprises a third flame retardant textile.

6. The multi-layer textile composite of claim 1 , wherein the second portion is adjacent to the first barrier layer of the first portion.

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

8. 7. The multilayer textile composite of claim 1, 3, 4, or 6, wherein the second portion comprises the second laminate and the second meltable layer is adjacent to the first barrier layer of the first portion.

9. 8. The multilayer textile composite of claim 2, 3, 4, or 7, wherein the second portion includes the second laminate and the second meltable layer is adjacent to the first flame retardant textile of the first portion.

10. the multilayer textile composite further comprises a third portion; 10. The multilayer textile composite of claim 1, wherein the third portion is located between the first portion and the second portion, and the third portion is a fourth flame-retardant textile.

11. 11. The multilayer textile composite of any one of claims 1 to 10, wherein the one or more stitches are a quilting stitch, a series of one or more stitch lines, a series of overlapping stitch lines, a series of stitched geometric shapes, a series of grid pattern stitches, a series of stitches that are essentially parallel to one another, a series of tuck stitches, or a combination thereof.

12. The one or more stitches are quilted stitches in a stitch pattern including one or more land areas, each land area being bounded by a quilted stitch, and the land area of ​​the quilted pattern is one square centimeter (cm ２ ) ~ 450cm ２ 12. The multilayer textile composite of claim 1, wherein the thickness of the multilayer textile composite is in the range of

13. 13. The multilayer textile composite of any one of claims 1 to 12, wherein the first meltable textile, the second meltable textile, and the first flame retardant textile, the second flame retardant textile, the third flame retardant textile, and the fourth flame retardant textile are each independently a knitted textile, a woven textile, a nonwoven textile, or a combination thereof.

14. 14. The multilayer textile composite of any one of claims 1 to 13, wherein the first fusible layer and / or the second fusible layer comprises polyamide fibers, polyester fibers, polyolefin fibers, acrylic fibers, polyurethane fibers, or combinations thereof.

15. 15. The multilayer textile composite of any one of claims 2 to 14, wherein the first flame retardant textile, the second flame retardant textile, the third flame retardant textile, and / or the fourth flame retardant textile each independently comprise aramid, p-aramid, m-aramid, polybenzimidazole, polybenzoxazole, polyetheretherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, polyamideimide, melamine, fluoropolymer, polytetrafluoroethylene, modacrylic, cellulose, flame retardant cellulose, flame retardant viscose, polyvinyl acetate, mineral fiber, protein fiber, or a combination thereof.

16. 16. The multilayer textile composite of any one of claims 1 to 15, wherein the first layer of thermally reactive material and the second layer of thermally reactive material are independently applied continuously or discontinuously.

17. The multilayer textile composite of any one of claims 1 to 16, wherein the multilayer textile composite has a weight in the range of 300 to 800 grams per square meter (gsm).

18. 18. The multilayer textile composite of any one of claims 1 to 17, wherein the first barrier layer and / or the second barrier layer each independently comprise expanded polytetrafluoroethylene, polytetrafluoroethylene, polyurethane, polyethylene (PE), or a combination thereof.

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

20. 21. The multilayer textile composite of any one of claims 1 to 20, wherein the stitch connects at least a portion of the thickness of the first portion with at least a portion of the thickness of the second portion.

21. The multilayer textile composite of any one of claims 1 to 21, wherein the stitch connects the entire thickness of the first portion with the entire thickness of the second portion.

22. 22. The multilayer textile composite of claim 21, wherein the stitches are present on at least one surface of the multilayer textile composite, or the stitches are present on both surfaces of the multilayer textile composite.

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

24. 24. The article of claim 23, wherein the article is a blanket, garment, jacket, coat, vest, pants, overalls, coveralls, leggings, shirt, gloves, footwear, cap, hood, hat, or combination thereof.

25. 24. The article of claim 23, wherein the article is a garment and the first portion of the multilayer textile composite is disposed on an exterior of the garment.

26. The article has a thermal resistance of at least 40 calories per square centimeter (cal / cm ) when tested according to ASTM F1959. ２ 26. The article of any one of claims 23-25, providing an arc thermal performance value of

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