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

Abstract

Providing fire-resistant materials for wearables, personal protective equipment, fire protection of lithium-ion batteries, and general fire protection. [Solution] A particular embodiment includes a fire-resistant material. This fire-resistant material includes a first material which is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers; a second material which is a combination of oxidized PAN fibers, flame-retardant rayon (FR rayon), and P-aramid fibers; and a third material which is a combination of silica aerogel and fiberglass configured to bond with the first or second material, wherein the second material is configured to bond with the first or third material.

Description

Technical Field

[0001] Priority Application This PCT patent application claims priority to U.S. Non-Provisional Patent Application Serial No. 18 / 372,107, filed on September 24, 2023, which claims priority to U.S. Provisional Patent Application Serial No. 63 / 410,118, filed on September 26, 2022. The entire disclosure of the referenced patent applications is considered a part of the disclosure of this application and is hereby incorporated by reference in its entirety.

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

[0003] Copyright Part of the disclosure of this patent document contains material subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or patent disclosure as it appears in the patent file or records of the U.S. Patent and Trademark Office, but retains all other copyrights. The following notice applies to the disclosure of this specification and the drawings that form a part of this specification. Copyright 2021 - 2023 Elven Technologies, Inc., All rights reserved.

Background Art

[0004] Workers at high risk of direct contact with flames and high temperatures (e.g., firefighters, stunt performers, metal and foundry workers, race car drivers, etc.) and other workers exposed to fire hazards require fire-resistant clothing with superior durability and flame retardancy. In some cases, fire-resistant clothing typically contains high-strength, flame-retardant aramid fibers (e.g., heat-resistant fibers) used in the fabrics for making the clothing. Some conventional fire-resistant fabrics use woven fabrics containing approximately 40% to 70% para-aramid fibers and approximately 10% to 40% meta-aramid fibers as the outer layer fabric for firefighters' clothing. Other conventional fire-resistant clothing uses fabrics made from yarn containing 50% to 80% (by weight) meta-aramid fibers and 0% to 5% (by weight) para-aramid fibers as fabrics suitable for fire protection. However, conventional fire-resistant fabrics use aramid fibers at high blending rates. High aramid fiber blending rates increase product prices, hindering the widespread adoption of safe products. Furthermore, conventional fire-resistant fabrics cannot achieve the level of effectiveness necessary to ensure the safety of personnel using fire-resistant clothing. [Overview of the Initiative] [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 combinations of fire-resistant materials (fire-resistant shells). Fire-resistant shells serve to enable the manufacture of different types of wearables or personal protective equipment for workers at high risk of direct contact with flames and high temperatures (e.g., firefighters, stunt specialists, metal and foundry workers, race car drivers, etc.). Furthermore, the exemplary embodiments disclosed herein can also 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 for a variety of applications, including: • Fireproof enclosures for lithium batteries (e.g., electric vehicles, electric transport ships, aircraft, energy storage facilities, battery storage and recycling, etc.), and high-temperature furnaces (for blasting, melting, metal forming, fire resistance testing, etc.) (see Figures 27 and 28). • Fire-resistant solutions for walls, doors, etc. in the construction industry (see Figure 30). • Aerospace industry (see Figure 29). Wearable and personal protective equipment for workers at high risk of direct contact with flames and high temperatures (e.g., firefighters, stunt specialists, metal and foundry workers, race car drivers, etc.). • Fire and thermal protection wearables for military personnel, fire and thermal protection for military machinery and equipment, and fire and thermal protection for weapon boxes and storage areas (see Figure 26). • Fireproof wrapping for high-voltage lines, utility poles, generator systems, and infrastructure (see Figure 25).

[0007] Details of exemplary embodiments of fire-resistant materials disclosed for wearables, personal protective equipment, fire protection of lithium-ion batteries, and general fire protection are provided below. The present invention provides, for example, the following items: (Item 1) It is a fire-resistant material, The first material is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers, A second material consisting of a combination of oxidized PAN fibers, refractory rayon (FR rayon), and P aramid fibers, A fire-resistant material comprising a third material which 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. (Item 2) The fireproof material according to item 1, further comprising a fourth material which is a combination of oxidized PAN fibers and P-aramid fibers having a different composition from the first material, wherein the fourth material is configured to bond with the first material, the second material, or the third material. (Item 3) The fireproof material according to item 2, further comprising a fifth material which is a moisture-absorbing and quick-drying fiber, wherein the fifth material is configured to bond with the fourth material or the third material. (Item 4) The fire-resistant material described in item 1, wherein the third material comprises iron oxide and aluminum trihydrate. (Item 5) The fireproof material according to item 1, wherein the first material comprises at least 50% oxidized PAN fibers. (Item 6) The fireproof material according to item 1, wherein the first material contains at least 15% P-aramid fibers. (Item 7) The fireproof material described in item 1, wherein the second material contains at least 20% FR rayon. (Item 8) The fire-resistant material according to item 1, wherein the third material comprises at least 30% amorphous silica and at least 40% fibrous glass. (Item 9) The fire-resistant material described in item 3, wherein the moisture-absorbing and quick-drying fiber is cotton. (Item 10) The fireproof material according to item 1, wherein the second material is configured to be bonded to the first material using an adhesive. (Item 11) A method for making fire-resistant clothing, The division of a first material into garment portions, wherein the first material is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers, The second material is divided into garment portions, wherein the second material is a combination of oxidized PAN fibers, flame-retardant rayon (FR rayon), and P aramid fibers, and the division is as follows: 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 or second material, and the second material is configured to bond with the first or third material, and the division is such that The third material is combined with the first material or the second material, The second material is combined with the first material or the third material, The method comprising assembling the binding material into fire-resistant clothing by attaching the sides of the clothing portion with a fastener. (Item 12) The method according to item 11, further comprising dividing a fourth material into garment portions, wherein the fourth material is a combination of oxidized PAN fibers and P-aramid fibers of a different composition than the first material, and is configured to bond with the first material, the second material, or the third material. (Item 13) The method according to item 12, further comprising dividing a fifth material into garment portions, wherein the fifth material is a moisture-absorbing, quick-drying fiber and is configured to bond with the third or fourth material. (Item 14) The method according to item 12, further comprising placing the garment portion of the second material on top of the garment portion of the third and fourth materials combined, and using the fasteners to attach wrist collars, neck collars, ankle collars, and open edges including waist or hip lines. (Item 15) The method according to item 13, further comprising placing the garment portion of the first material on top of the garment portion which is a combination of the second, third, fourth, and fifth materials, and attaching an open edge, including a wrist collar, neck collar, ankle collar, and waist or hip line, using the fasteners. (Item 16) The method according to item 11, wherein the fastener is a flame-retardant fiber used for sewing the side portion of the clothing part. (Item 17) The method according to item 11, wherein the fastener is a separable fastener of a type selected from the group consisting of a zipper, a knob, a hook, a loop strip, and a magnet. (Item 18) A method of manufacturing a refractory shell, placing a first material on a matrix base, wherein the first material is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aramid fibers, said placing, placing a second material on the surface of the first material, wherein the second material is a combination of oxidized PAN fibers, flame-retardant rayon (FR rayon), and para-aramid fibers, said placing, placing a third material on the surface of the second material, wherein the third material is a combination of silica aerogel and fiberglass, said placing, placing a matrix cap on the 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 material, second material, and third material; and attaching the side portions of the combined first material, second material, and third material with a fastener. (Item 19) The method according to item 18, further comprising placing a fourth material on the surface of the third material, wherein the fourth material is a combination of oxidized PAN fibers and para-aramid fibers having a composition different from that of the first material. (Item 20) The method according to item 18, further comprising applying an adhesive between the first material, the second material, and the third material.

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

Brief Description of the Drawings

[0009] [Figure 1] A legend showing each of the five material layers used in the refractory shell of an exemplary embodiment and related to the light-shielding pattern shown in subsequent figures is shown. [Figure 2] Method steps of an exemplary embodiment are shown where layers 1, 2, 4, and 5 are cut or otherwise divided into clothing patterns. [Figure 3] Method steps of an exemplary embodiment are shown where layer 3 is cut or otherwise divided into individually formed pieces. [Figure 4] Method steps of an exemplary embodiment are shown where the individually formed pieces of layer 3 are connected to the precut layer 4 using fasteners such as aramid fiber yarns or other flame-resistant fibers. [Figure 5] Method steps of an exemplary embodiment are shown where layer 4 is assembled as clothing together with the adhesive layer 3 by attaching the sides together with fasteners such as aramid fiber yarns or other flame-resistant fibers. [Figure 6] Method steps of an exemplary embodiment are shown where the pre-assembled clothing from layer 2 is placed on top of the pre-assembled clothing from layers 4 and 3, and the open edges are attached together with fasteners such as aramid fiber yarns or other flame-resistant fibers. [Figure 7] Method steps of an exemplary embodiment are shown where the pre-assembled clothing from layer 2 is placed on top of the pre-assembled clothing from layers 4 and 3, and the open edges are attached together with fasteners such as aramid fiber yarns or other flame-resistant fibers. [Figure 8] Method steps of an exemplary embodiment are shown where the precut layer 1 and any moisture-wicking and quick-drying layer are placed end-to-end, and the edges are overlapped and sewn into separate clothing except for the open edges defined for a particular piece of clothing. [Figure 9]The method steps of an exemplary embodiment are shown, in which garments pre-assembled from layers 2, 3, and 4 are placed onto garments pre-assembled from layer 1 and optional moisture-wicking layers, using the open edges that remain unsewn to layer 1 and an optional moisture-wicking layer. [Figure 10] The method steps of an exemplary embodiment are shown, in which, when manufacturing a one-piece (non-separable) garment, a pre-assembled layer 1 and an optional moisture-wicking and quick-drying layer and pre-assembled layers 2, 3, and 4 are connected to each other at all edges (including open edges) using fasteners such as aramid fiber yarn or other flame-retardant fibers. [Figure 11] The method steps of an exemplary embodiment for manufacturing separable garments are shown. Pre-assembled layers 2, 3, and 4 are detachable from pre-assembled layer 1 and an optional moisture-wicking layer, and pre-assembled layer 1 and an optional moisture-wicking layer, as well as pre-assembled layers 2, 3, and 4, are connected to each other only at the opening edges using either separable fasteners such as zippers, knobs, hook and loop strips (e.g., Velcro® strips) or magnets. [Figure 12] The method steps of an exemplary embodiment are shown in which layers 1, 2, 3, 4, and 5 are cut or otherwise divided into a predetermined shape. [Figure 13] The method steps of an exemplary embodiment are shown, in which layers 2, 3, and 4 are aligned in the same order and attached to individual pieces along all edges using fasteners such as aramid fiber yarn or other flame-retardant fibers. [Figure 14] The method steps of an exemplary embodiment are shown, in which individual pieces (including layers 2, 3, and 4) are positioned in their respective places so as to fit together like a jigsaw puzzle, and assembled as a garment by joining all overlapping edges with fasteners such as aramid fiber yarn or other flame-retardant fibers, and joining the sides with aramid fiber yarn or other flame-retardant fibers. [Figure 15] The method steps of an exemplary embodiment are shown, in which all four materials are connected together to the individual pieces. [Figure 16] The method steps of an exemplary embodiment are shown, in which all the pieces are assembled together to form a garment. [Figure 17] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 18] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 19] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 20] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 21] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 22] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 23] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 24] The method steps of an exemplary embodiment show that the refractory shell of an exemplary embodiment may be manufactured using the manufacturing method disclosed herein. [Figure 25] Examples of various applications in which the fire-resistant shells disclosed herein can be used are shown. [Figure 26] Examples of various applications in which the fire-resistant shells disclosed herein can be used are shown. [Figure 27] Examples of various applications in which the fire-resistant shells disclosed herein can be used are shown. [Figure 28]Examples of various applications in which the fire-resistant shells disclosed herein can be used are shown. [Figure 29] Examples of various applications in which the fire-resistant shells disclosed herein can be used are shown. [Figure 30] Examples of various applications in which the fire-resistant shells disclosed herein can be used are shown. [Figure 31] A process flow diagram illustrating an exemplary embodiment of the method described herein is shown. [Figure 32] A process flow diagram illustrating an exemplary embodiment of the method described herein is shown. [Modes for carrying out the invention]

[0010] In the following description, many specific details are given for illustrative purposes to provide a complete understanding of the various embodiments. However, it will be apparent to those skilled in the art that various embodiments can be carried out without these specific details.

[0011] In various embodiments described herein, fire-resistant materials for wearables, personal protective equipment, fire protection of lithium-ion batteries, and general fire protection are disclosed. Referring to Figure 1, a legend is disclosed that identifies the light-shielding patterns associated with each of the five material layers used in exemplary embodiments of fire-resistant materials for wearables. Furthermore, the legend in Figure 1 shows patterns associated with the sewing stitches, assemblies, contours, and edges of the fire-resistant materials for wearables. These patterns are shown in subsequent figures provided herein to illustrate the compositions and manufacturing processes used in exemplary embodiments of fire-resistant materials for wearables disclosed herein. Details of these compositions and manufacturing processes used in the disclosed exemplary embodiments of fire-resistant materials for wearables, personal protective equipment, fire protection of lithium-ion batteries, and general fire protection are provided below.

[0012] Composition of fire-resistant materials in various exemplary embodiments Referring again to Figure 1, the fire-resistant shell of the exemplary embodiment consists of several layers of material arranged in a specific order and connected or joined (or configured to be joined) to one another in a specific manner. A list and order of the layers of material according to the exemplary embodiment is given in Table 1 from the outside (flame side) to the inside (skin side) (see below). In various exemplary embodiments, the layers of the fire-resistant shell may be arranged as follows: 1. Layer 1 (the layer facing the flame or heat source): Refer to the list of materials used as Layer 1 in Tables 1, 2A, and 2B. 2. Layer 2: See the list of materials used as Layer 2 in Tables 1, 2A, and 2B. 3. Layer 3: See the list of materials used as Layer 3 in Tables 1, 2A, and 2B. 4. Layer 4 (Optional): Refer to the list of materials used as Layer 4 in Tables 1, 2A, and 2B. 5. Layer 5 (Optional): Refer to the list of materials used as Layer 5 in Tables 1, 2A, and 2B. 6. An adhesive such as glue (optional) is applied between the layers to fill air pockets and bond them together. See Tables 1, 2A, and 2B for a list of materials used as glues.

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

[0014] There are references to specific materials as disclosed herein. Various acronyms and abbreviations are defined, explained and elaborated upon as follows: 1. A type of O-PAN- or PAN-oxide-polyacrylonitrile-synthetic flame retardant (FR) fiber. 2. Fibers, specifically P-aramid polyamide fibers, para-aramid polyamide fibers, or para-aromatic polyamide fibers, which are types of synthetic fire-resistant fibers. 3. PTFE - Polytetrafluoroethylene - A type of hydrophobic (water-resistant) material. 4. PBI (polybenzimidazole) is a type of synthetic fire-resistant fiber with a particularly high decomposition temperature. 5. FR Rayon - Rayon (also known as viscose) is treated with fire-resistant (FR) chemicals.

[0015] The refractory shells of 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, since layer 5 does not affect the flame resistance and heat resistance of the fireproof shell, it is an optional layer. Nevertheless, since layer 5 may be part of the manufacturing process, it is described below in relation to the disclosed manufacturing method.

[0017] Methods for manufacturing fire-resistant materials with or without adhesives, according to various exemplary embodiments. Referring here to Figures 2-16, the fire-resistant shell of the exemplary embodiment can be manufactured using the manufacturing method disclosed below. When assembled, the fire-resistant shell of the exemplary embodiment is semi-flexible and does not behave in the same way as typical all-fabric combination-based garments. Therefore, conventional garment or clothing manufacturing and sewing techniques are insufficient to manufacture the fire-resistant shell of the exemplary embodiment into wearable fire-resistant clothing. This manufacturing problem is solved by designing an apparatus consisting of multiple (e.g., more than 300) individual shaped pieces. These multiple pieces are then assembled into wearable fire-resistant clothing 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 wearable clothing, layer 5 can be added (towards the skin side of the garment), which is not a required 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 layers.

[0019] When manufacturing the refractory shells of the exemplary embodiments, adhesives or other adhesives may be added between layers or not, depending on the specificity of the target application. The materials and layer configurations described in Tables 2A and 2B may be manufactured with or without the use of adhesives or other adhesives between different layers. The presence of adhesives or other adhesives between layers is indicated in this disclosure by 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), and so on. Various configurations of the exemplary embodiments can be manufactured as described herein (see Tables 2A and 2B), but with different adhesive contents or without adhesives or other adhesives.

[0020] Method 1 for assembling an entire wearable fire-resistant garment according to an exemplary embodiment includes the following method steps: 1. Layers 1, 2, 4, and 5 (optional moisture management and ventilation layers) are cut into the garment pattern or specific-use sections, or otherwise partitioned (see Figure 2). 2. Cut layer 3 into individually molded pieces or divide it by other means (see Figure 3). Note that the shapes shown in the figures are illustrative examples and can be manufactured in various different designs using the techniques disclosed herein. 3. (Either / or step) Arrange these pieces and connect or bond them to the pre-cut layer 4 using aramid (e.g., Kevlar® or Nomex) threads (see Figure 4), or bond them using an adhesive (e.g., glue). These pieces are prepared and added as thin layers to the sides facing layer 4. 4. Layer 4, along with the attached layer 3, is assembled into a garment by attaching its sides with fasteners such as aramid fiber yarn (or other flame-retardant fibers) (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 facing layers 3 and 4 from layer 2 (on the inside of the garment from layer 2). 6. The pre-assembled garment from layer 2 is placed on top of the pre-assembled garment from layers 4 and 3, and open edges (e.g., wrist collars, neck collars, ankle collars, waistline or buttock line, and other freehand cut edges, etc.) are sewn using aramid (e.g., Kevlar® or Nomex) fiber yarn (see Figures 6 and 7). 7. The pre-cut layer 1 and the optional moisture control and ventilation layer 5 are positioned end-to-end and sewn together at overlapping edges, except for open edges defined for specific garments, such as the front zipper of a jacket and the lower edge area shown in the figure (see Figure 8). 8. Using the open edges that remain unsewn in the moisture management and ventilation layers of Layer 1 and the optional Layer 5, place the pre-assembled garments from Layers 2, 3, and 4 inside the pre-assembled garments from the moisture management and ventilation layers of Layer 1 and the optional Layer 5 (see Figure 9). 9. When manufacturing a one-piece (non-separable) garment, the pre-assembled moisture control and ventilation layers of Layer 1 and an optional Layer 5, as well as the pre-assembled Layers 2, 3, and 4, are connected to each other at all edges (including open edges) using aramid (e.g., Kevlar® or Nomex) fiber yarns (see Figure 10). 10. When manufacturing separable garments, pre-assembled layers 2, 3, and 4 are detachable from the moisture control and ventilation layers of pre-assembled layer 1 and an optional layer 5, and the moisture control and ventilation layers of pre-assembled layer 1 and an optional layer 5, as well as pre-assembled layers 2, 3, and 4, are connected to each other only at the opening edges using separable fasteners such as zippers, knobs, Velcro® strips, or magnets (see Figure 11).

[0021] Method 2 for assembling an entire wearable fire-resistant garment according to an exemplary embodiment includes the following method steps: 1. Layers 1, 2, 3, 4, and 5 (optional moisture control and ventilation layers) are cut or divided into predetermined 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 to individual pieces along all edges using aramid (e.g., Kevlar® or Nomex) fiber thread (see Figure 13). When making a single piece, layer 1 is added to the free side of layer 2 and sewn with the same suture thread. 4. The garment is assembled by positioning the individual pieces (including layers 2, 3, and 4) so ​​that they fit together like a jigsaw puzzle, sewing all overlapping edges together using aramid (e.g., Kevlar® or Nomex) fiber yarn, and fastening the sides together with aramid fiber yarn or other fire-resistant fibers (see Figure 14). 5. The pre-cut layer 1 and the optional moisture control and ventilation layer 5 are positioned end-to-end and sewn together at the overlapping edges to another garment, except for open edges defined for specific garments, such as the front zipper of a jacket and the lower edge area shown in the figure (see Figure 8). 6. Using the open edges that remain unsewn in the moisture management and ventilation layers of Layer 1 and the optional Layer 5, place the pre-assembled garments from Layers 2, 3, and 4 onto the pre-assembled garments from the moisture management and ventilation layers of Layer 1 and the optional Layer 5 (see Figure 9). 7. When manufacturing a one-piece (non-separable) garment, the pre-assembled moisture control and ventilation layers of Layer 1 and an optional Layer 5, as well as the pre-assembled Layers 2, 3, and 4, are connected to each other at all edges (including open edges) using aramid (e.g., Kevlar® or Nomex) fiber yarns (see Figure 10). 8. When manufacturing separable garments, pre-assembled layers 2, 3, and 4 are detachable from the moisture management and ventilation layers of pre-assembled layer 1 and an optional layer 5, and pre-assembled layer 1 and an optional moisture-wicking and quick-drying layer, as well as pre-assembled layers 2, 3, and 4, are connected to each other only at the opening edges using either a zipper, knob, separable fastener such as a Velcro® strip, or a magnet.

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

[0023] Manufacturing method for 3- or 4-layer fire-resistant material Figures 17-24 illustrate specific designs. Fire-resistant materials in both three-dimensional (3D) and two-dimensional (2D) shapes can be manufactured using the described methods.

[0024] Referring here to Figures 17-24, the refractory shell of the exemplary embodiment can be manufactured using the manufacturing method disclosed below. Figure 17 shows some of the elements used in the exemplary embodiment to manufacture the refractory shell, which include 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 (e.g., 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 the surface of layer 1 (see Figure 19). 4. (Optional step) An adhesive (e.g., 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 the surface of layer 2 (see Figure 20). 6. (Optional step when constructing a 4-layer composite) An adhesive (e.g., glue) is prepared and applied as a thin layer to the surface of layer 3 that is intended to face layer 4. 7. (Optional step when constructing a 4-layer composite) Layer 4 is placed on the surface of layer 3 (see Figure 21). 8. Place the matrix cap on the surface of layer 3 (or layer 4 if constructing a 4-layer composite) and align it with the matrix base (see Figure 22). 9. Secure the matrix cap to the base of the matrix and press it together with 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 is pressed until the adhesive (e.g., glue) sets after a predetermined period of time. 11. After the adhesive (e.g., glue) has hardened, remove the press mechanism and fastening components from the matrix. 12. Separate the matrix base from the matrix cap. 13. Remove the prepared fire-resistant composite from the matrix base (see Figure 24). 14. The edges of the prepared fire-resistant composite are trimmed and attached with fasteners such as aramid fiber yarn or other fire-resistant fibers (see Figure 24).

[0025] Figures 31 and 32 show process flow diagrams illustrating exemplary embodiments of the methods described herein. Referring to Figure 31, Method 1000 for producing fire-resistant clothing according to an exemplary embodiment comprises dividing a first material into garment portions, wherein the first material is a combination of oxidized polyacrylonitrile (PAN) fibers and para-aromatic polyamide (P-aramid) fibers (operation block 1010); dividing a second material into garment portions, wherein the second material is a combination of oxidized PAN fibers, flame-retardant rayon (FR rayon), and P-aramid fibers (operation block 1020); and dividing a third material into garment portions. 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, and the process includes dividing (operation block 1030), joining the third material with the first or second material (operation block 1040), joining the second material with the first or third material (operation block 1050), and assembling the bonding material into fire-resistant clothing by fastening the sides of the garment portion with fasteners (operation block 1060).

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

[0027] The drawings of the embodiments described herein are intended to provide a general understanding of the structures of various embodiments and are not intended to serve as a complete description of all elements and features of the components and systems that may utilize the structures described herein. Many other embodiments will become apparent to those skilled in the art by reviewing the descriptions provided herein. Other embodiments can be utilized and derived, thereby allowing for structural and logical substitutions and modifications without departing from the scope of this disclosure. The drawings herein are for illustrative purposes only and may not be drawn to a fixed scale. Certain proportions may be exaggerated, while others may be minimized. Accordingly, the specification and drawings should be considered illustrative rather than limiting.

[0028] The descriptions herein may include terms such as “upper,” “lower,” “upper,” “lower,” “first,” and “second,” which are used for illustrative purposes only and should not be construed as limitations. Elements, materials, shapes, dimensions, and sets of operations may all be modified to suit a particular application. Parts of some embodiments may be included in or substituted for parts of other embodiments. While the aforementioned examples of dimensions and ranges are considered typical, various embodiments are not limited to such dimensions or ranges.

[0029] The abstract is provided to enable readers to quickly grasp the nature and intent of the technical disclosure. It is submitted with the understanding that the abstract is not to be used to interpret or limit the scope or meaning of the claims.

[0030] In the detailed description above, various features are grouped together under a single embodiment for the purpose of streamlining the disclosure. This method of disclosure should not be interpreted as reflecting an intention that the embodiments described in the claims have more features than are explicitly stated in each claim. Thus, the following claims are incorporated herein within “Modes for Carrying Out the Invention,” and each claim stands alone as a separate embodiment.

[0031] As described herein, fire-resistant materials for wearables, personal protective equipment, fire protection for lithium-ion batteries, and general fire protection are disclosed. While the subject matter of the disclosed inventions is described with reference to several exemplary embodiments, it should be understood that the language used is descriptive and illustrative, not restrictive. Modifications may be made within the scope and spirit of the subject matter of the inventions disclosed in all its embodiments, as and as modified, as currently stated. While the subject matter of the disclosed inventions has been described with reference to specific means, materials, and embodiments, the subject matter of the disclosed inventions is not intended to be limited to those specifically disclosed. Rather, the subject matter extends to all functionally equivalent structures, methods, and uses, such as those within the scope of the appended claims.

Claims

[Claim 1] The invention described herein.

Images