Fire-resistant materials for wearables, personal protective equipment, fire protection for lithium-ion batteries and general fire protection

Abstract

Fire-resistant materials for wearables, personal protective equipment, and lithium-ion battery fire protection, as well as general fire protection, are disclosed. Particular embodiments include a fire-resistant material comprising a first material that is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers; a second material that is a combination of oxidized PAN fibers, flame-retardant rayon (FR rayon), and P-aramid fibers; and a third material that is a combination of silica aerogel and fiberglass configured to bond with either the first material or the second material, wherein the second material is configured to bond with either the first material or the third material.

Description

[Technical Field]

[0001] Priority application This PCT patent application claims priority to U.S. non-provisional patent application Ser. No. 18 / 372,107, filed Sep. 24, 2023, which in turn claims priority to U.S. provisional patent application Ser. No. 63 / 410,118, filed Sep. 26, 2022. The entire disclosures of the referenced patent applications are considered part of the disclosure of the present application and are incorporated herein by reference in their entirety.

[0002] This patent application relates to fire resistant and flame retardant materials, wearables, and devices according to exemplary embodiments, and more particularly to fire resistant materials for wearables, personal protective equipment, fire protection of lithium ion batteries, and general fire protection.

[0003] Copyright A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all other copyrights. The following notice applies to the disclosure herein and to any drawings that form a part hereof: Copyright 2021-2023 Elven Technologies, Inc., All Rights Reserved. [Background technology]

[0004] Workers at high risk of direct flame and high temperature contact (e.g., firefighters, stunt specialists, metal and foundry workers, race car drivers, etc.) and other workers working in environments exposed to the risk of fire outbreaks require fire-resistant clothing with excellent durability and flame resistance. In some cases, fire-resistant clothing typically contains aramid fibers (e.g., heat-resistant fibers) with high strength and flame resistance, which are used in fabrics for making fire-resistant clothing. Some conventional fire-resistant fabrics use woven fabrics containing about 40% to 70% para-aramid fibers and about 10% to 40% meta-aramid fibers as the outer layer fabric used in firefighter fire-resistant clothing. Other conventional fire-resistant clothing uses fabrics made from yarns containing 50 to 80% meta-aramid fibers (by weight) and 0 to 5% para-aramid fibers (by weight) as fabrics suitable for use in fire protection. However, conventional fire-resistant fabrics use aramid fibers at high blend ratios. A high blending rate of aramid fiber increases the price of the product, which hinders the widespread use of safe products. Furthermore, conventional fire-resistant fabrics cannot achieve the level of effectiveness required to ensure the safety of personnel using fire-resistant clothing. Summary of the Invention [Means for solving the problem]

[0005] Exemplary embodiments of the disclosed fire-resistant materials for wearables, personal protective equipment, lithium-ion battery fire protection, and general fire protection relate to the creation of fire-resistant material combinations (fire-resistant shells). The fire-resistant shells serve to enable the production of different types of wearables or personal protective equipment for workers at high risk of direct flame and high temperature contact (e.g., firefighters, stunt specialists, metal and foundry workers, race car drivers, etc.). Additionally, exemplary embodiments disclosed herein can be used in the electric vehicle (EV) industry, aerospace, construction, and other industries and applications.

[0006] In various exemplary embodiments, the fire resistant shells disclosed herein may be used in a variety of applications, including: Fireproof enclosures for lithium batteries (e.g., electric vehicles, electric ships, aircraft, energy storage sites, battery storage and recycling, etc.) and high-temperature furnaces (for smelting, melting, metal forming, fire resistance testing sites, etc.) (see Figures 27 and 28). Fireproofing solutions for walls, doors, etc. in the construction industry (see Figure 30). · Aviation and space industry (see Figure 29). Wearable and personal protective equipment for workers at high risk of contact with direct flame and high temperatures (e.g. firefighters, stunt professionals, metal and foundry workers, race car drivers, etc.). Fire and temperature protection wearables for military personnel, fire and temperature protection for military machinery and equipment, and fire and temperature protection for weapon chests and storage areas (see Figure 26). ·Fire-resistant wrapping of high-voltage lines, utility poles, generator systems, and infrastructure (see Figure 25).

[0007] Details of exemplary embodiments of the disclosed fire resistant material for wearables, personal protective equipment, fire protection for lithium ion batteries, and general fire protection are provided below.

[0008] Various embodiments are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. [Brief explanation of the drawings]

[0009] [Figure 1] 1 shows a legend indicating each of the five material layers used in the fire resistant shell of the exemplary embodiment and associated with the shading patterns shown in subsequent figures. [Figure 2] 1 illustrates the method steps of an exemplary embodiment in which layers 1, 2, 4, and 5 are cut or otherwise divided into garment patterns. [Figure 3] 1 illustrates a method step of an exemplary embodiment in which layer 3 is cut or otherwise divided into individually shaped pieces. [Figure 4]Illustrated are method steps of an exemplary embodiment in which individually molded pieces of layer 3 are connected to pre-cut layer 4 using fasteners such as aramid fiber threads or other flame-retardant fibers. [Figure 5] 1 shows a method step of an exemplary embodiment in which layer 4 along with attachment layer 3 are assembled into a garment by attaching the sides together with fasteners such as aramid fiber yarn or other flame-retardant fiber. [Figure 6] 1 illustrates an exemplary embodiment method step in which a pre-assembled garment from layer 2 is placed over a pre-assembled garment from layers 4 and 3, and the open edges are attached together with fasteners such as aramid fiber yarn or other flame-retardant fiber. [Figure 7] 1 illustrates an exemplary embodiment method step in which a pre-assembled garment from layer 2 is placed over a pre-assembled garment from layers 4 and 3, and the open edges are attached together with fasteners such as aramid fiber yarn or other flame-retardant fiber. [Figure 8] 1 illustrates the method steps of an exemplary embodiment in which pre-cut layer 1 and any moisture-wicking and quick-drying layers are placed end-to-end and sewn into separate garments with overlapping edges, except for open edges defined for the particular garment. [Figure 9] 1 illustrates the method steps of an exemplary embodiment of placing a garment pre-assembled from layers 2, 3, and 4 onto a garment pre-assembled from layer 1 and the optional moisture-wicking layer, using the open edges left unsewn on layer 1 and the optional moisture-wicking layer. [Figure 10] Shown are method steps of an exemplary embodiment, in which when producing a one-piece (inseparable) garment, pre-assembled layer 1 and optional moisture-wicking and quick-drying layer and pre-assembled layers 2, 3, and 4 are connected to each other on all edges (including open edges) using fasteners such as aramid fiber yarn or other flame-retardant fibers. [Figure 11]1 illustrates method steps of an exemplary embodiment for producing a separable garment, in which pre-assembled layers 2, 3, and 4 are detachable from pre-assembled layer 1 and optional moisture-wicking and quick-drying layer, and pre-assembled layers 2, 3, and 4 are connected to each other only at the open edges using either separable fasteners such as zippers, knobs, hook and loop strips (e.g., Velcro® strips), or magnets. [Figure 12] 1 illustrates the method steps of an exemplary embodiment in which layers 1, 2, 3, 4, and 5 are cut or otherwise divided into defined shapes. [Figure 13] 1 illustrates the method steps of an exemplary embodiment in which layers 2, 3, and 4 are aligned together in the same order and attached to the individual pieces along all edges using fasteners such as aramid fiber threads or other flame-retardant fibers. [Figure 14] 1 illustrates the method steps of an exemplary embodiment in which the individual pieces (including layers 2, 3, and 4) are placed in their respective locations so that they fit together like a jigsaw puzzle, and assembled into a garment by joining all overlapping edges using fasteners such as aramid fiber yarn or other flame-retardant fiber, and binding the sides with aramid fiber yarn or other flame-retardant fiber. [Figure 15] 1 illustrates the method steps of an exemplary embodiment in which all four materials are connected together in individual pieces. [Figure 16] 1 illustrates the method steps of an exemplary embodiment where all the pieces are assembled together into a garment. [Figure 17] 1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 18] 1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 19]1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 20] 1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 21] 1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 22] 1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 23] 1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 24] 1 illustrates exemplary embodiment method steps by which an exemplary embodiment refractory shell may be manufactured using the manufacturing methods disclosed herein. [Figure 25] 10A-10C illustrate examples of various applications in which the fire resistant shells disclosed herein may be used. [Figure 26] 10A-10C illustrate examples of various applications in which the fire resistant shells disclosed herein may be used. [Figure 27] 10A-10C illustrate examples of various applications in which the fire resistant shells disclosed herein may be used. [Figure 28] 10A-10C illustrate examples of various applications in which the fire resistant shells disclosed herein may be used. [Figure 29] 10A-10C illustrate examples of various applications in which the fire resistant shells disclosed herein may be used. [Figure 30] 10A-10C illustrate examples of various applications in which the fire resistant shells disclosed herein may be used. [Figure 31] FIG. 1 shows a process flow diagram illustrating an exemplary embodiment of the methods described herein. [Figure 32]FIG. 1 shows a process flow diagram illustrating an exemplary embodiment of the methods described herein. DETAILED DESCRIPTION OF THE INVENTION

[0010] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various embodiments. However, it will be apparent to those skilled in the art that various embodiments may be practiced without these specific details.

[0011] In various embodiments described herein, a fire-resistant material for wearables, personal protective equipment, fire protection for lithium-ion batteries, and general fire protection is disclosed. Referring to FIG. 1 , a legend is disclosed identifying the light-blocking patterns associated with each of the five material layers used in the exemplary embodiment of the fire-resistant material for wearables. Additionally, the legend in FIG. 1 indicates patterns associated with the sewing stitches, assembly, contours, and edges of the fire-resistant material for wearables. These patterns are depicted in subsequent figures provided herein to illustrate the compositions and manufacturing processes used in the exemplary embodiment of the fire-resistant material for wearables disclosed herein. Details of these compositions and manufacturing processes used in the exemplary embodiment of the fire-resistant material for wearables, personal protective equipment, fire protection for lithium-ion batteries, and general fire protection are provided below.

[0012] Composition of Fire-Resistant Materials of Various Exemplary Embodiments 1, the fire resistant shell of the exemplary embodiments is composed of several layers of material arranged in a particular order and connected or bonded (or configured to be connected) to each other in a particular way. The list and order of the layers of material according to the exemplary embodiments is set forth in Table 1 (see below) from outside (flame side) to inside (skin side). In various exemplary embodiments, the layers of the fire resistant shell may be arranged as follows: 1. Layer 1 (layer facing the flame or heat source): See the list of materials used as Layer 1 in Tables 1, 2A and 2B. 2. Layer 2: See the list of materials used for Layer 2 in Tables 1, 2A, and 2B. 3. Layer 3: See the list of materials used for Layer 3 in Tables 1, 2A, and 2B. 4. Layer 4 (Optional): See the list of materials used as Layer 4 in Tables 1, 2A, and 2B. 5. Layer 5 (Optional): See the list of materials used as Layer 5 in Tables 1, 2A, and 2B. 6. An adhesive such as glue (optional) is applied between layers to fill air pockets and adhere the layers together. See Tables 1, 2A, and 2B for a list of materials used as glue.

[0013] The compositions of these material layers are also listed below as Material 1 through Material 7, with Material 1 being the outer material and Material 7 being the skin-facing material. Additionally, exemplary embodiments may optionally include Material 6, which functions as a moisture-wicking barrier or layer. Each of these material layers is associated with a light-blocking pattern, as described below and shown in the legend of FIG. 1.

[0014] As disclosed herein, reference is made to specific materials. Various acronyms and abbreviations are defined, explained and detailed below. 1. O-PAN - or oxidized PAN - oxidized polyacrylonitrile - a type of synthetic flame-retardant (FR) fiber. 2. Fiber: P-aramid polyamide fiber, para-aramid polyamide fiber or para-aromatic polyamide fiber, a type of synthetic fire-resistant fiber. 3. PTFE - Polytetrafluoroethylene - A type of hydrophobic (water-resistant) material. 4. PBI - Polybenzimidazole - a kind of synthetic fire-resistant fiber, with a particularly high decomposition temperature. 5.FR Rayon - Rayon (rayon is a semi-synthetic fiber made from natural sources of regenerated cellulose such as wood and related agricultural products; also known as viscose) has been treated with fire-resistant (FR) chemicals.

[0015] The fire-resistant shells of the exemplary embodiments disclosed herein can be manufactured in at least two different configurations as described below. 1. 4-layer configuration (all 4 layers are used during manufacturing) - see Table 2A, or 2. 3-Layer Configuration (only Layers 1, 2, and 3 are used during manufacturing) - See Table 2B.

[0016] For customer comfort, an additional layer 5 can be added to the four-layer configuration for wearable products. However, layer 5 is an optional layer because it does not affect the flame and heat resistance of the fire-resistant shell. Nevertheless, layer 5 can be part of the manufacturing process and is described below in connection with the disclosed manufacturing methods.

[0017] Methods for manufacturing fire-resistant materials of various exemplary embodiments with or without adhesives 2-16, the fire-resistant shell of the exemplary embodiment can be manufactured using the manufacturing methods disclosed below. When assembled, the fire-resistant shell of the exemplary embodiment is semi-flexible and does not behave as a typical all-fabric-combination-based garment would. Therefore, conventional clothing or garment manufacturing and sewing techniques are insufficient for manufacturing the fire-resistant shell of the exemplary embodiment into a wearable fire-resistant garment. This manufacturing problem is solved by designing an orthosis consisting of multiple (e.g., over 300) individually shaped pieces. The multiple pieces are then assembled into a wearable fire-resistant garment using one or more of the various manufacturing methods described in detail below.

[0018] During the manufacture of the fire-resistant shell of the exemplary embodiment, different materials can be used as different layers. See Tables 2A and 2B for a description of the types of layer and material combinations that can be used. For the manufacture of a wearable garment, Layer 5 can be added (towards the skin side of the garment), which is not a necessary part of the fire-resistant shell of the exemplary embodiment, but functions as a moisture management and ventilation layer. See Table 1 for materials used as the moisture management and ventilation layer.

[0019] When manufacturing the fire-resistant shells of the exemplary embodiments, adhesives or other adhesives may or may not be added between layers, depending on the specifics of the target application. The materials and layer configurations described in Tables 2A and 2B may be manufactured with or without adhesives or other adhesives between different layers. The presence of adhesives or other adhesives between layers is indicated in this disclosure as the symbol (G). For example, various layer configurations using adhesives or other adhesives may include 1G2G4G3 (adhesive between all layers), 12G4G3 (adhesive between two layers), 1G243 (adhesive on a single layer), etc. Various configurations of the exemplary embodiments may be manufactured as described herein (see Tables 2A and 2B), but with different adhesive content or without adhesives or other adhesives.

[0020] Method 1 for assembling the entire wearable fire resistant garment of the exemplary embodiment includes the following method steps. 1. Layers 1, 2, 4, and 5 (optional moisture management and ventilation layers) are cut or otherwise compartmentalized into the pattern or application specific portions of the garment (see Figure 2). 2. Cut or otherwise divide layer 3 into individually shaped pieces (see Figure 3). Note that the shapes shown in the figures are illustrative examples and can be manufactured in a variety of different designs using the techniques disclosed herein. 3. (Either / or step) These pieces are arranged and connected or bonded to pre-cut layer 4 using aramid (e.g., Kevlar® or Nomex) thread (see FIG. 4) or bonded using an adhesive (e.g., glue) prepared and applied as a thin layer to these pieces on the side facing layer 4. 4. Layer 4, with attached layer 3, is assembled into a garment by attaching the sides with fasteners such as aramid fiber yarn (or other flame-retardant fiber) (see Figure 5). 5. (Optional Step) An adhesive (e.g., glue) is prepared and applied as a thin layer to the pre-assembled garment on the side of layer 2 facing layers 3 and 4 (on the inside of the garment of layer 2). 6. The pre-assembled garment from layer 2 is placed over the pre-assembled garment from layers 4 and 3, and the open edges (e.g., wrist collars, neck collars, ankle collars, waist or buttock lines, and other freehand cut edges) are sewn using aramid (e.g., Kevlar® or Nomex) fiber thread (see Figures 6 and 7). 7. The precut layer 1 and optional layer 5 moisture management and ventilation layer are placed end to end and sewn to another garment with overlapping edges, except for the open edges defined for the front zipper and bottom end area shown in the figure of a particular garment, e.g., a jacket (see FIG. 8). 8. Using the open edges left unsewn on Layer 1 and optional Layer 5 moisture management and ventilation layers, place the pre-assembled garment from Layers 2, 3, and 4 into the pre-assembled garment from Layer 1 and optional Layer 5 moisture management and ventilation layers (see Figure 9). 9. To create a one-piece (inseparable) garment, the pre-assembled layer 1 and optional layer 5 moisture management and ventilation layer, as well as pre-assembled layers 2, 3, and 4, are connected to each other on all edges (including open edges) using aramid (e.g., Kevlar® or Nomex) fiber yarns (see FIG. 10). 10. When a separable garment is manufactured, pre-assembled layers 2, 3, and 4 are detachable from the pre-assembled moisture management and ventilation layers of layer 1 and optional layer 5, and the pre-assembled moisture management and ventilation layers of layer 1 and optional layer 5 and pre-assembled layers 2, 3, and 4 are connected to each other only at the open edges using separable fasteners such as zippers, knobs, Velcro® strips, or magnets (see FIG. 11).

[0021] Method 2 for assembling the entire wearable fire resistant garment of the exemplary embodiment includes the following method steps. 1. Layers 1, 2, 3, 4, and 5 (optional moisture management and ventilation layers) are cut or divided into shapes (see Figure 12). 2. (Optional Step) An adhesive (e.g., glue) is prepared and applied to the piece as a thin layer on either or both sides of layer 3. 3. Align layers 2, 3, and 4 together in the same order and sew them into individual pieces along all edges using aramid (e.g., Kevlar® or Nomex) fiber thread (see Figure 13). If making a single piece, layer 1 is added to the free side of layer 2 and sewn together with the same suture thread. 4. Assemble the garment by placing the individual pieces (including layers 2, 3, and 4) in their respective locations so that they fit together like a jigsaw puzzle, sewing all overlapping edges together using aramid (e.g., Kevlar® or Nomex) fiber thread, and attaching the sides together with fasteners such as aramid fiber thread or other fire-resistant fiber (see FIG. 14). 5. The precut layer 1 and optional layer 5 moisture management and ventilation layer are placed end to end and sewn to another garment with overlapping edges, except for the open edges defined for the front zipper and bottom end area of ​​the particular garment, e.g., jacket (see FIG. 8). 6. Using the open edges left unsewn on Layer 1 and optional Layer 5 moisture management and ventilation layers, place the pre-assembled garment from Layers 2, 3, and 4 onto the pre-assembled garment from Layer 1 and optional Layer 5 moisture management and ventilation layers (see Figure 9). 7. When making a one-piece (inseparable) garment, the pre-assembled Layer 1 and optional Layer 5 moisture management and ventilation layer, as well as pre-assembled Layers 2, 3, and 4, are connected to each other on all edges (including open edges) using aramid (e.g., Kevlar® or Nomex) fiber yarns (see FIG. 10). 8. When a separable garment is manufactured, pre-assembled layers 2, 3, and 4 are detachable from pre-assembled layer 1 and optional layer 5 moisture management and ventilation layers, and pre-assembled layer 1 and optional moisture-wicking layer and pre-assembled layers 2, 3, and 4 are connected to each other only at the open edges using either a separable fastener such as a zipper, knob, Velcro® strip, or magnet.

[0022] Method 3 for assembling the entire wearable fire resistant garment of the exemplary embodiment includes the following method steps. 1. Connect all four materials into individual pieces, with or without adhesive between layers 1 and 2, layers 2 and 3, and layers 3 and 4, as shown in Figure 15. 2. Assemble all these pieces as shown in Figure 16 to make the garment. Various exemplary embodiments with or without adhesive for non-wearable applications.

[0023] How to make 3- or 4-ply fireproof materials Specific designs are depicted in Figures 17-24. Both three-dimensional (3D) and two-dimensional (2D) shapes of refractory materials can be fabricated using the described methods.

[0024] 17-24, the fireproof shell of the exemplary embodiment can be manufactured using the manufacturing method disclosed below. FIG. 17 shows some of the elements used in the exemplary embodiment to manufacture the fireproof shell, including a matrix cap, a matrix base, and several layers of material sandwiched between the matrix cap and the matrix base. The manufacturing process in the exemplary embodiment includes the following operations: 1. Layer 1 is placed on the base of the matrix with the side intended to face the flame or heat source facing the inner surface of the base of the matrix (see Figure 18). 2. (Optional Step) An adhesive (eg, glue) is prepared and applied as a thin layer to the surface of Layer 1 that is intended to face Layer 2. 3. Place layer 2 on top of layer 1 (see Figure 19). 4. (Optional step) An adhesive (eg, glue) is prepared and applied as a thin layer to the surface of layer 2 that is intended to face layer 3. 5. Place layer 3 on top of layer 2 (see Figure 20). 6. (Optional step when constructing a four-layer composite) An adhesive (eg, glue) is prepared and applied as a thin layer to the surface of layer 3 intended to face layer 4. 7. (Optional step if building a four layer composite) Layer 4 is placed on top of layer 3 (see Figure 21). 8. Place the matrix cap on the surface of layer 3 (or layer 4 if building a four layer composite), aligning it with the base of the matrix (see Figure 22). 9. Secure the matrix cap to the base of the matrix and press together by any means capable of transmitting similar force to all sides of the matrix, including different types of clamps, presses, etc. (See Figure 23. Clamp shown in Figure 23). 10. The matrix remains fixed and pressed until the adhesive (e.g., glue) sets after a predetermined length of time. 11. After the adhesive (e.g., glue) has cured, remove the press mechanism and fasteners from the matrix. 12. Separate the matrix base and matrix cap. 13. Remove the prepared refractory composite from the base of the matrix (see Figure 24). 14. The edges of the prepared fire-resistant composite are trimmed and attached with fasteners such as aramid fiber thread or other fire-resistant fibers (see Figure 24).

[0025] 31 and 32 show process flow diagrams illustrating exemplary embodiments of the methods described herein. Referring to FIG. 31, a method 1000 for manufacturing a fire resistant garment according to an exemplary embodiment includes dividing a first material into garment portions, where the first material is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers (operational block 1010), dividing a second material into garment portions, where the second material is a combination of oxidized PAN fibers, flame retardant rayon (FR rayon), and P-aramid fibers (operational block 1020), and dividing a third material into garment portions. The method includes separating (operational block 1030), where the third material is a combination of silica aerogel and fiberglass configured to bond with the first or second material, and the second material is configured to bond with the first or third material, joining the third material with the first or second material (operational block 1040), joining the second material with the first or third material (operational block 1050), and assembling the combined materials into a fire resistant garment by attaching sides of the garment pieces with fasteners (operational block 1060).

[0026] Referring to FIG. 32 , a method 2000 for manufacturing a fire-resistant shell according to an exemplary embodiment includes disposing a first material on a matrix base, the first material being a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers (operational block 2010); disposing a second material on a surface of the first material, the second material being a combination of oxidized PAN fibers, flame-retardant rayon (FR rayon), and P-aramid fibers (operational block 2020); and disposing a third material on a surface of the second material. The method includes disposing a material, where the third material is a combination of silica aerogel and fiberglass (operational block 2030), disposing a matrix cap on a surface of the third material (operational block 2040), applying pressure to the matrix cap for a predetermined time (operational block 2050), removing the matrix base and matrix cap from the combination of the first, second, and third materials (operational block 2060), and attaching sides of the combination of the first, second, and third materials with fasteners (operational block 2070). [Table 1-1] [Table 1-2] [Table 2] [Table 3]

[0027] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments; they are not intended to serve as a complete description of all elements and features of components and systems that may utilize the structures described herein. Many other embodiments will be apparent to those skilled in the art upon reviewing the description provided herein. Other embodiments may be utilized and derived, whereby structural and logical substitutions and changes may be made without departing from the scope of the present disclosure. The illustrations herein are merely representational and may not be drawn to scale. Certain proportions thereof may be exaggerated, while other proportions may be minimized. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a limiting sense.

[0028] Descriptions herein may include terms such as "upper," "lower," "top," "lower," "first," and "second," which are used for descriptive purposes only and should not be construed as limiting. Elements, materials, shapes, dimensions, and sequences of operations may all be modified to suit a particular application. Portions of some embodiments may be included in or substituted for portions of other embodiments. The foregoing examples of dimensions and ranges are considered exemplary, but various embodiments are not limited to such dimensions or ranges.

[0029] The Abstract is provided to allow the reader to quickly ascertain the nature and gist of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

[0030] In the foregoing Detailed Description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments have more features than are expressly recited in each claim. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.

[0031] As described herein, a fire-resistant material is disclosed for wearables, personal protective equipment, fire protection for lithium-ion batteries, and general fire protection. While the disclosed inventive subject matter has been described with reference to certain exemplary embodiments, it will be understood that the words used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the disclosed inventive subject matter in all its aspects. While the disclosed inventive subject matter has been described with reference to particular means, materials, and embodiments, it is not intended that the disclosed inventive subject matter be limited to the particulars disclosed. Rather, the present subject matter extends to all functionally equivalent structures, methods, and uses, as within the scope of the appended claims.

Claims

1. A fire-resistant material, a first material that is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers; a second material that is a combination of oxidized PAN fiber, fire-resistant rayon (FR rayon), and P-aramid fiber; a third material that is a combination of silica aerogel and fiberglass configured to bond with the first material or the second material, wherein the second material is configured to bond with the first material or the third material.

2. 10. The fire resistant material of claim 1, further comprising a fourth material that is a combination of oxidized PAN fiber and P-aramid fiber of a different composition than the first material, the fourth material configured to bond with the first material, the second material, or the third material.

3. 3. The fire resistant material of claim 2, further comprising a fifth material that is a moisture wicking fiber, the fifth material configured to bond with the fourth material or the third material.

4. The refractory material of claim 1 , wherein the third material comprises iron oxide and aluminum trihydrate.

5. 10. The fire resistant material of claim 1, wherein the first material comprises at least 50% oxidized PAN fibers.

6. The fire resistant material of claim 1 , wherein the first material comprises at least 15% P-aramid fiber.

7. 10. The fire resistant material of claim 1, wherein the second material comprises at least 20% FR rayon.

8. 10. The refractory material of claim 1, wherein the third material comprises at least 30% amorphous silica and at least 40% fibrous glass.

9. 4. The fire resistant material of claim 3, wherein the moisture wicking and quick drying fabric is cotton.

10. The fire resistant material of claim 1 , wherein the second material is configured to bond with the first material using an adhesive.

11. 1. A method of making fire resistant clothing, comprising: Dividing a first material into garment portions, the first material being a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers; Dividing a second material into garment portions, the second material being a combination of oxidized PAN fiber, flame-retardant rayon (FR rayon), and P-aramid fiber; dividing a third material into garment portions, wherein the third material is a combination of silica aerogel and fiberglass configured to bond with the first material or the second material, and the second material is configured to bond with the first material or the third material; combining the third material with the first material or the second material; combining the second material with the first material or the third material; and assembling the combiner material into a fire resistant garment by attaching sides of the garment portion with fasteners.

12. 12. The method of claim 11, further comprising dividing a fourth material into garment portions, the fourth material being a combination of oxidized PAN and P-aramid fibers of a different composition than the first material and configured to bond with the first material, the second material, or the third material.

13. 13. The method of claim 12, further comprising dividing a fifth material into garment portions, the fifth material being a moisture-wicking fiber and configured to bond with the third material or the fourth material.

14. 13. The method of claim 12, further comprising: placing the garment portion of the second material over the garment portion of the combined third and fourth materials; and using the fasteners to attach open edges including wrist collars, neck collars, ankle collars, and waist or buttock lines.

15. 14. The method of claim 13, further comprising: placing the garment portion of the first material over the garment portions of the combined second, third, fourth, and fifth materials; and using the fasteners to attach open edges, including wrist collars, neck collars, ankle collars, and waist or buttock lines.

16. 12. The method of claim 11, wherein the fastener is a flame-retardant fabric used to sew the sides of the garment portion.

17. 12. The method of claim 11, wherein the fastener is a separable fastener of a type selected from the group consisting of a zipper, a knob, a hook and loop strip, and a magnet.

18. 1. A method of fabricating a fire-resistant shell, comprising: disposing a first material on a matrix base, the first material being a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers; disposing a second material on a surface of the first material, the second material being a combination of oxidized PAN fiber, flame-retardant rayon (FR rayon), and P-aramid fiber; disposing a third material on a surface of the second material, the third material being a combination of silica aerogel and fiberglass; placing a matrix cap on a surface of the third material; applying pressure to the matrix cap for a predetermined time; removing the matrix base and the matrix cap from the combined first, second, and third materials; and attaching the sides of the combined first, second, and third materials with fasteners.

19. 20. The method of claim 18, further comprising disposing a fourth material on a surface of the third material, the fourth material being a combination of oxidized PAN fibers and P-aramid fibers of a different composition than the first material.

20. 20. The method of claim 18, further comprising applying an adhesive between the first material, the second material, and the third material.

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