3D protective textile wherein the layers are easily separable

Abstract

The current invention relates to protective textile, comprising a first layer and a second layer, wherein the first layer comprises a first yarn that forms a majority of the yarns in the first layer, and the second layer adjoins the first layer and comprises a second yarn. The textile comprises at least one binding yarn that attaches the first layer to the second layer, wherein the at least one binding yarn is removable in a solution that separates the yarns of the first and second layers. The first and second yarns are amide-based yarns. The at least one binding yarn has an animal origin. The protective textile comprises at least 4 and at most 15 of the at least one binding yarn per cm, wherein each of the at least one binding yarn forms a connection between the first layer and the second layer after at least 2 wefts and at most 60 wefts.

Description

[0001] D PROTECTIVE TEXTILE WHEREIN THE LAYERS ARE EASILY SEPARABLE

[0002] TECHNICAL FIELD

[0003] 5 The invention relates to a protective textile comprising a first layer and a second layer. The first layer comprises a first yarn. The second layer adjoins the first layer, with the second layer comprising a second yarn. The protective textile comprises at least one binding yarn which attaches the first layer to the second layer. Preferably, the protective textile is made using a 3D weaving technique.

[0004] PRIOR ART

[0005] Protective textile is used for, among other things, clothing for outdoor sports, personal protective equipment such as flame-resistant clothing for firefighters. The5 use of flame-retardant coatings on textiles, heat-resistant yarns, or a combination thereof is already known. The use of a multilayer structure for optimal insulation, moisture transport, mechanical, heat, and chemical protection, and the required standards regarding this for protective clothing, and more specifically for protective clothing for firefighters, is also known. 0

[0006] EP 2689055 describes a multilayer protective textile, comprising a first layer with flame-resistant yarns, a second layer adjoining the first layer, and at least one binding yarn connecting the layers together. The binding yarn may contain flameresistant and structural yarns, which improve the mechanical properties. The5 multilayer thermally protective textile comprises various layer configurations, weave patterns, and integrated binding patterns. A disadvantage is that multiple layers of the multilayer thermally protective textile cannot be easily separated from each other, complicating recycling. Additionally, the thermal and moisture-regulating properties are less prominently incorporated into the design of the multilayer thermally protective textile, resulting in lower usability.

[0007] The present invention aims to solve at least some of the above problems or drawbacks. 5 SUMMARY OF THE INVENTION

[0008] The current invention relates to a protective textile according to claim 1. This embodiment is advantageous because protective textile made of multiple layers offers increased protection compared to single-layered textile. The construction of protective textile comprising multiple layers, resulting in increased thickness and density, provides extra protection and enhances the versatility of a protective textile. Furthermore, the use of amide-based yarns has advantages due to their good moisture-wicking properties, good abrasion resistance, and heat resistance during the use of the protective textile up to at least 40°C. An additional advantage is that the at least one binding yarn contributes to the structural integrity of the fabric, ensuring that the layers are bonded together sufficiently firmly to enhance overall performance, but not overly firmly bonded together so that dissolution of the at least one binding yarn can proceed efficiently. This ensures that the textile remains lightweight, even with the addition of extra protective layers. The fact that the textile remains lightweight is important for the comfort and freedom of movement of a user, while still providing sufficient protection. The removability of the at least one binding yarn is advantageous because it allows the first layer and the second layer to be separated for recycling applications. This is an important advantage in a time when sustainability and reuse of materials are becoming increasingly important. By using binding yarns of animal origin, there is a possibility, through a difference in chemical and / or physical properties, to separate the connections between the first layer and the second layer via the at least one binding yarn through a chemical and / or physical separation process.

[0009] Preferred embodiments of the protective textile are presented in claims 2 to 16.

[0010] A specific preferred embodiment is presented in claim 2.

[0011] This embodiment is advantageous because the use of aramid yarns provides good heat and flame-resistant properties, making it suitable for applications where exposure to high temperatures is a factor, such as in personal protective equipment and, more preferably, flame-resistant protective clothing. The solubility of the at least one binding yarn is advantageous because it allows the first layer and the second layer to be separated, creating the possibility to recycle the first layer and the second layer separately. This binding yarn is soluble in a solution that does not dissolve the yarns of the first and second layers. This means that the at least one binding yarn can be removed without damaging the rest of the textile, making it possible to recycle the textile after use. DETAILED DESCRIPTION

[0012] Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meanings as commonly understood by a person skilled in the art to which the invention pertains. For a better understanding of the description of the invention, the following terms are explained explicitly.

[0013] In this document, "a" and "the" refer to both the singular and the plural, unless the context presupposes otherwise. For example, "a segment" means one or more segments.

[0014] The terms "comprise," "comprising," "consist of," "consisting of," "provided with," "include," "including," "contain," "containing," are synonyms and are inclusive or open terms that indicate the presence of what follows, and which do not exclude or prevent the presence of other components, characteristics, elements, members, steps, as known from or disclosed in the prior art.

[0015] Quoting numeric intervals by the endpoints comprises all integers, fractions, and / or real numbers between the endpoints, including those endpoints.

[0016] The term "3D weaving technique" in the context of this invention refers to an advanced weaving technique in which threads or yarns are interwoven in multiple planes or directions, resulting in a three-dimensional textile structure made of different layers with improved properties such as strength, stiffness, or flexibility. It also allows for the combination of different properties in different layers, such as insulating properties.

[0017] In the context of this invention, "flame-resistant yarn" or "yarn that is flameresistant" or "yarns with flame-retardant treatment" refers to any yarn that has been subjected to material selection and / or meets specific treatments or production processes that enable it to withstand or delay combustion processes or exposure to extreme heat. Preferably, the protective textile comprises flame- resista nt yarns, ensuring that the protective textile meets at least the requirements of ISO 11612:2019, a general standard for protective clothing against heat and flames in a wide range of industrial applications, and more preferably also meets the requirements of EN 469:2020, a specific standard for protective clothing for firefighters. In the context of this invention, fibers made from "filaments" are long, continuous strands of indefinite length. Filaments are typically extruded as long, continuous fine threads during the production process. Filaments do not have natural breaking points and can stretch over long distances without interruption. In contrast, "short and long staple fibers" do have natural breaking points and are often cut into specific lengths during the processing.

[0018] A "yarn" in the context of this invention is an uninterrupted strand made from fibers. The fibers can be filaments, long or short staple fibers, which form a strand by twisting or spinning together. Yarns are used to make fabrics through weaving, knitting, or other textile processes. Yarns with short staple fibers feel softer and more pliable, while yarns with long staple fibers can have greater durability and a smoother texture.

[0019] The term "warp direction" in the current invention refers to an orientation of yarns in a fabric, where the yarns are arranged in a specific direction according to a longitudinal direction of the fabric.

[0020] The term "weft direction" refers in the current invention to an orientation of yarns in a fabric, where the yarns are arranged transversely to the warp direction and in a plane formed by the fabric.

[0021] The invention relates to a protective textile.

[0022] The protective textile comprises a first layer and a second layer. The first layer comprises a first yarn. The second layer adjoins the first layer. The second layer comprises a second yarn. Preferably, the first layer adjoins the second layer in a plane in which the first layer and the second layer extend. Preferably, the first yarn comprises a majority of yarns forming the first layer. Preferably, the second yarn comprises a majority of yarns forming the second layer.

[0023] The protective textile comprises at least one binding yarn which attaches the first layer to the second layer. Preferably, the protective textile is made using a 3D weaving technique. Preferably, the second layer is the outermost layer of a garment made from the protective textile.

[0024] According to a preferred embodiment, the first yarn and the second yarn are amide- based yarns. According to an embodiment, the first layer and the second layer are separable from each other because the at least one binding yarn is removable through a separation process that is chemical and / or physical.

[0025] According to a preferred embodiment, the at least one binding yarn comprises fibers of animal origin.

[0026] According to a preferred embodiment, the protective textile comprises at least 4 and at most 15 of the at least one binding yarn per centimeter (cm). The binding yarns extend in the warp direction.

[0027] According to a preferred embodiment, each of the at least one binding yarn forms a connection between the first layer and the second layer after at least 2 wefts and at most 60 wefts. A weft is understood to mean that a weft thread has been inserted between warp threads of the protective textile according to the weft direction.

[0028] This embodiment is advantageous because protective textile made of multiple layers offers increased protection compared to single-layered textile. The construction of protective textile comprising multiple layers, resulting in increased thickness and density, provides extra protection and enhances the versatility of a protective textile. Furthermore, the use of amide-based yarns has advantages due to their good moisture-wicking properties, good abrasion resistance, and heat resistance during the use of the protective textile up to at least 40°C. An additional advantage is that the at least one binding yarn contributes to the structural integrity of the fabric, ensuring that the layers are bonded together sufficiently firmly to enhance overall performance, but not overly firmly bonded together so that dissolution of the at least one binding yarn can proceed efficiently. This ensures that the textile remains lightweight, even with the addition of extra protective layers. The fact that the textile remains lightweight is important for the comfort and freedom of movement of a user, while still providing sufficient protection. The removability of the at least one binding yarn is advantageous because it allows the first layer and the second layer to be separated for recycling applications. This is an important advantage in a time when sustainability and reuse of materials are becoming increasingly important. By using binding yarns of animal origin, there is a possibility, through a difference in chemical and / or physical properties, to separate the connections between the first layer and the second layer via the at least one binding yarn through a chemical and / or physical separation process.

[0029] According to an embodiment, the first yarn and the second yarn are aramid yarns. Preferably, the aramid yarns are meta-aramid and / or para-aramid. The use of aramid yarns is advantageous as aramid yarns have good heat and flame-resistant properties, making them suitable for applications where exposure to high temperatures is a factor, such as in personal protective equipment and, more preferably, flame-resistant protective clothing. Moreover, aramid fibers have good tensile strength and cut resistance as necessary in personal protective equipment.

[0030] According to an embodiment, the first yarn is flame-resistant. Preferably, the first yarn has a degradation temperature above 550°C. The use of flame- resista nt yarn as a first yarn is advantageous because it allows for high resistance to heat for the entire textile. Additionally, the first yarn, due to its degradation temperature above 550°C, ensures that the first yarn does not melt near heat.

[0031] According to a preferred embodiment, the separation process is chemical, wherein the at least one binding yarn is soluble in a solution in which at least 75 wt% of the yarns of the first layer and the second layer are insoluble. Weight percent is expressed relative to the total weight of the first layer or the second layer. More preferably, at least 80 wt% of the yarns of the first layer and the second layer are insoluble in the solution, and even more preferably at least 85 wt%. It is advantageous that at least 75 wt% of the yarns of the first layer and the second layer can be separated for recycling applications, allowing a larger portion of the first layer yarns and the second layer yarns to be recovered. The solubility of the at least one binding yarn is advantageous because it allows the first layer and the second layer to be separated, creating the possibility to recycle the first layer and the second layer separately. This binding yarn is soluble in a solution that does not dissolve the yarns of the first and second layers. This means that the at least one binding yarn can be removed without damaging the rest of the textile, making it possible to recycle the textile after use.

[0032] According to an embodiment, the separation process is physical, wherein the at least one binding yarn can be cut using knives. Preferably, the at least one binding yarn can be cut using one or more seam rippers. The use of a physical separation process is advantageous because it allows the first layer and the second layer to be separated for recycling applications, without the need for recovery of a solution and / or the at least one binding yarn.

[0033] According to an embodiment, each of the at least one binding yarn forms a connection between the first layer and the second layer after at least 3 wefts, preferably after at least 4 wefts, more preferably after at least 5 wefts, even more preferably after at least 8 wefts, and most preferably after at least 10 wefts.

[0034] According to an embodiment, each of the at least one binding yarn forms a connection between the first layer and the second layer after at most 50 wefts, more preferably after at most 40 wefts, even more preferably after at most 30 wefts, and most preferably after at most 20 wefts.

[0035] This is advantageous because it provides the possibility to produce protective textile with sufficient connection between the first layer and the second layer, sufficiently lightweight for user convenience, and as minimal as possible so that the dissolution of the at least one binding yarn can proceed efficiently during the recycling process of the protective textile.

[0036] According to a preferred embodiment, the first layer comprises one or more additional yarns selected from a list of melamine, aramid, polybenzimidazole, modacrylic, polybenzobisoxazole, viscose with flame-retardant treatment, nylon with flame-retardant treatment, cellulose with flame-retardant treatment, or a combination thereof. Preferably, the first layer comprises one or more additional yarns selected from a list of meta-aramid, polybenzimidazole, poly(p-phenylene-2,6- benzobisoxazole), modacrylic, or a combination thereof. Each of these yarns has unique properties that contribute to the overall performance of the textile. Meta- aramid is known for its excellent heat resistance and mechanical strength. Polybenzimidazole is a synthetic fiber with exceptional thermal and chemical stability. Poly(p-phenylene-2,6-benzobisoxazole) is a high-performance fiber with excellent heat and flame resistance, while modacrylic is an inherently flameretardant fiber. The combination of these yarns in the first layer of the textile provides increased thermal protection.

[0037] According to an embodiment, the first layer of the protective textile comprises only one of the previously listed additional yarns. Preferably, the first layer comprises the additional yarn meta-aramid. In a further embodiment, the first layer comprises polybenzimidazole as an additional yarn in combination with a meta-aramid yarn as the first yarn. The specific selection of yarns contributes to the increased thermal protection and durability of the textile.

[0038] According to an embodiment, the first layer comprises an additional yarn, wherein the additional yarn is composed of two or more different materials. The materials are selected from a list of melamine, aramid, polybenzimidazole, modacrylic, polybenzobisoxazole, viscose with flame retardant treatment, nylon with flame retardant treatment, cellulose with flame retardant treatment. Preferably, the materials are selected from a list of meta-aramid, polybenzimidazole, poly(p- phenylene-2,6-benzobisoxazole), modacrylic. Each material is present in proportions ranging from 5 wt% to 95 wt% compared to the total weight of a yarn. Preferably, each material is present in at least 20 wt%, but not more than 75 wt%. This is advantageous because the additional yarns can be optimized for the required properties of the protective textile, depending on the specific application. Preferably, a proportion of meta-aramid, for increased heat resistance, is greater than a proportion of polybenzimidazole, for increased chemical stability, so that a protective textile is obtained which offers sufficient thermal resistance for protective clothing for firefighters. Here, the ratio of meta-aramid to polybenzimidazole is preferably at least 1.2.

[0039] According to a preferred embodiment, the second layer comprises one or more additional yarns selected from a list of melamine, aramid, polyarylate, poly(ethylene), ceramic, viscose with flame retardant treatment, nylon with flame retardant treatment, cellulose with flame retardant treatment or a combination thereof. Preferably, the second layer comprises one or more additional yarns selected from a list of para-aramid, polyarylate, UHMWPE, ceramic, or a combination thereof. This specific choice of materials for the second layer offers an adaptable thermal resistance, meaning that the textile can be optimally tailored to the needs of fire-resistant clothing for firefighters, obtaining a protective textile with sufficient tear resistance and cut resistance.

[0040] According to an embodiment, the second layer of the protective textile comprises only one of the previously listed additional yarns. Preferably, the second layer includes the additional yarn para-aramid. According to a further embodiment, the second layer includes an additional yarn polyacrylate in combination with paraaramid as the second yarn. In both cases, the specific selection of yarns contributes to the increased thermal protection and durability of the textile, resulting in a protective textile that has sufficient tear resistance and cut resistance. According to an embodiment, the second layer includes an additional yarn, wherein the additional yarn is composed of two or more different materials. The materials are selected from a list of melamine, aramid, polyarylate, poly(ethylene), ceramic, viscose with flame-retardant treatment, nylon with flame- retardant treatment, cellulose with flame-retardant treatment, or a combination thereof. Preferably, the materials are selected from a list of para-aramid, polyarylate, UHMWPE, ceramic, or a combination thereof. Each material is present in proportions ranging from 5 wt% to 95 wt% compared to the total weight of a yarn. Preferably, each material is present in at least 20 wt%, but not more than 75 wt%. This is advantageous because the additional yarns can be optimized for the required properties of the protective textile, depending on the specific application. Preferably, a proportion of para-aramid yarns, for increased heat resistance and cut resistance, is greater than a proportion of polyacrylate, for faster drying properties, so that a protective textile is obtained which offers sufficient thermal resistance for protective clothing for firefighters. Here, the ratio of para-aramid yarns to polyacrylate yarns is preferably at least 3.0. This also acts as a moth repellent, increasing the life of the protective fabric.

[0041] In a preferred embodiment, the ceramic yarns are glass-based, carbon-based or a combination thereof. The use of such ceramic yarns is advantageous because it increases the heat resistance and tensile strength of the thermally protective textile. Glass-based ceramic yarns have the advantage of being chemically resistant, withstanding high operating temperatures, and having good dimensional stability at those high temperatures. Carbon-based ceramic yarns have the advantage of being lightweight compared to glass, can be made electrically conductive, and thus have antistatic properties. Moreover, carbon-based ceramic yarns are chemically resistant, even at higher operating temperatures.

[0042] According to an embodiment, the second layer comprises a maximum of 10 wt% ceramic additional yarns relative to the total weight of the second layer, preferably a maximum of 5 wt%, and even more preferably a maximum of 3 wt%. The use of a maximum of 10 wt% ceramic additional yarns in the second layer is advantageous so that the predominant heat-resistant properties of aramid fibers in the protective textile are maintained, while the properties of the ceramic additional yarns provide supportive properties to the protective textile. According to a preferred embodiment, the at least one binding yarn is an animal fiber. Preferably, the animal fiber is wool. Animal fibers, such as wool, are known for their moisture and thermal regulation and are soluble in alkaline solution. Furthermore, wool will contribute to the thermally protective properties of the protective textile due to the insulating properties of wool. According to an embodiment, the at least one binding yarn comprises silk or cashmere, angora, mohair, merino, yak, llama, alpaca types of wool. Depending on the desired properties such as insulating (angora, mohair, yak, and alpaca wool), hypoallergenic character (llama wool), better moisture-regulating character (merino wool), and soft feel (silk, cashmere, and alpaca wool), a specific type of animal fiber can be chosen for the at least one binding yarn. According to an embodiment, combinations of different types of animal fibers may be incorporated into the at least one binding yarn. This is advantageous so that multiple properties of different types of animal fibers can be combined. Preferably, the alkaline solution comprises sodium hydroxide.

[0043] According to an embodiment, the at least one binding yarn comprises fibers of plant origin. Preferably, it comprises at least one binding yarn of plant-derived cotton fibers. This is advantageous because cotton can be dissolved in an acidic solution. In further embodiments, the at least one binding yarn of plant origin comprises plant fibers from a list of: hemp, bamboo, jute, flax. According to an embodiment, combinations of different types of fibers of plant origin may be incorporated into the at least one binding yarn. This is advantageous so that multiple properties of different types of fibers of plant origin can be combined. Preferably, the acidic solution comprises sulfuric acid.

[0044] According to an embodiment, the at least one binding yarn comprises fibers of synthetic origin. Synthetic origin fibers include both synthetic and semi-synthetic fibers. Preferably, the at least one binding yarn of synthetic origin comprises fibers from viscose. This is advantageous because viscose can be dissolved in a an alkaline solution at low temperature. In other embodiments, the at least one binding yarn of synthetic origin includes fibers from a list of: lyocell, modal, polyester, polyamide. According to an embodiment, combinations of different types of fibers of synthetic origin may be incorporated into the at least one binding yarn. This is advantageous so that multiple properties of different types of fibers of synthetic origin can be combined. Preferably, the alkaline solution comprises sodium hydroxide. According to an embodiment, the solution is an alkaline solution which comprises sodium hydroxide in water of at least 4 g / L, preferably at least 5 g / L, and more preferably at least 6 g / L. Preferably, the solution is at least 60°C, more preferably at least 70°C, and even more preferably at least 80°C. This is advantageous because sodium hydroxide causes hydrolysis in at least one binding yarn that comprises an animal fiber or comprises a fiber of synthetic origin at a sufficiently high reaction temperature of at least 60°C.

[0045] According to an embodiment, the solution is an acidic solution which comprises sulfuric acid in at least 50%, preferably at least 60%, and more preferably at least 70%. Where the percentage is a volume percentage relative to the total volume of the solution with water. This is advantageous because sulfuric acid catalyzes hydrolysis in at least one binding yarn that is a fiber of plant origin.

[0046] According to an embodiment, the at least one binding yarn has a yarn count ranging between 50 dTex and 1000 dTex. Preferably, the yarn count is between 100 dTex and 500 dTex, more preferably between 200 dTex and 400 dTex. It is advantageous that the at least one binding yarn has a yarn count of up to 1000 dTex so that sufficient connections can be formed between the first layer and the second layer, without the at least one binding yarn being too prominent, which would make the protective textile too heavy and not flexible enough. It is advantageous that the at least one binding yarn has a yarn count of at least 50 dTex, allowing the binding yarn to be sufficiently strong to achieve a good attachment of the first layer to the second layer with a limited number of connections while maintaining a high flexibility of the protective textile. This is additionally advantageous to limit the amount of yarn to be dissolved during recycling of the protective textile, which benefits the speed of a dissolution process.

[0047] According to a preferred embodiment, the first layer and / or the second layer comprises at least filaments. The use of at least filaments in the first layer and / or the second layer is advantageous because it provides a sufficiently high strength of a yarn and results in less pilling compared to non-continuous fibers. Furthermore, filaments are easier to process, can be operated at high production speeds to produce the filaments, and filaments give good dimensional stability to the yarns.

[0048] According to an embodiment, the at least one binding yarn comprises filaments. This is advantageous for the same reasons as the use of filaments in the first layer and / or the second layer. According to a preferred embodiment, the first layer and / or the second layer comprises staple fibers. Preferably, the staple fibers are short staple fibers. This is advantageous because short staple fibers feel softer and more pliable. An additional advantage is that the insulating and moisture-regulating properties of the yarns can be adjusted and increased by adding short staple fibers to the yarns of the first layer and / or the second layer.

[0049] According to an embodiment, the at least one binding yarn comprises short staple fibers. This is advantageous for the same reasons as for the use of short staple fibers in the first layer and / or the second layer.

[0050] According to a preferred embodiment, the first layer and the second layer have different weave patterns. Preferably, the first layer has a twill weave pattern. This is advantageous because the weft does not follow one-to-one on the same warp in the warp direction, resulting in a flexible yet sufficiently strong protective textile, compared to a plain weave where the weft follows one-to-one. Preferably, the second layer has a twill weave pattern. This is advantageous for the same reasoning as for the first layer.

[0051] According to a preferred embodiment, the second layer comprises a grid pattern. This is advantageous because a grid pattern ensures mechanical moisture removal via a lower surface on which the grid pattern is present. Moreover, the grid pattern provides minimal additional insulating effect by trapping air within the grid pattern. Furthermore, the grid provides extra reinforcement and protection to the lower surface on which the grid pattern is present. Preferably, the grid pattern is located on the outer side of the 3D woven protective textile.

[0052] According to an embodiment, the first layer comprises a grid pattern. This is advantageous because it promotes ventilation and counteracts heat accumulation in the protective textile. This is a significant advantage, especially in warm conditions or during intense physical activity. Preferably, a grid pattern is located on the outer side of the 3D woven protective textile.

[0053] According to a preferred embodiment, the grid pattern comprises cells. The cells comprise ribs having a length ranging from 0.2 cm to 1.8 cm. Preferably, the ribs have a length of 0.5 cm, 0.6 cm, 0.7 cm, 0.8 cm, 0.9 cm, 1.0 cm, 1.1 cm, 1.2 cm, 1.3 cm, 1.4 cm, 1.5 cm, or a value lying between any of the listed rib lengths. The use of a grid pattern comprising ribs with a length of 0.5 cm to 1.5 cm is advantageous because the cells are sufficiently small to provide extra protection for the layer in which the grid pattern is comprised while providing sufficient insulation and ventilation without creating large temperature difference zones.

[0054] According to an embodiment, the grid pattern is formed by a yarn comprising aramid. Preferably, a proportion of aramid comprised in the yarn for forming the grid pattern is more than 50 wt% relative to a total weight of the yarn and more preferably more than 65 wt% and even more preferably more than 80 wt%. This is advantageous because the heat resistance and strength of aramid are required properties for protective clothing for firefighters.

[0055] According to a preferred embodiment, the yarn count of the first yarn and the second yarn in the protective textile is a maximum of 3000 dTex. Preferably, the yarn count is a maximum of 2500 dTex, and more preferably a maximum of 2000 dTex. A yarn count of a maximum of 3000 dTex or lower contributes to a strong and sturdy thermally protective textile, resulting in an increased level of protection, especially during prolonged use.

[0056] According to a preferred embodiment, the yarn count of the first yarn and the second yarn in the thermally protective textile is at least 300 dTex. Preferably, the yarn count is at least 500 dTex, and more preferably at least 1000 dTex. A yarn count of at least 300 dTex or higher contributes to a sufficiently strong thermally protective textile in the lightest and most flexible form possible. It is known that wearing heavy textiles for extended periods can be uncomfortable and tiring for a wearer, especially in challenging conditions such as those faced by firefighters. Therefore, it is crucial to keep the textile as lightweight as possible without compromising its thermally protective properties.

[0057] According to a preferred embodiment, the yarns for the first layer and / or the second layer comprise dyes that are soluble in the solution that dissolves the at least one binding yarn. This is advantageous for the decolorization of the yarns from the first layer and / or the second layer, allowing the combination of yarns from the recycled first layer or from the recycled second layer to result in yarns of a different color than the original color, without resorting to dark colors. Preferably, the dyes are paints. More preferably, the paints are soluble in alkaline solutions. According to an alternative embodiment, the yarns for the first layer and / or the second layer comprise dyes that are not soluble in the solution that dissolves the at least one binding yarn. This is advantageous for preserving the colors of the yarns from the first layer and / or the second layer, allowing the separation of the yarns based on a difference in color.

[0058] According to a preferred embodiment, the first layer and the second layer each comprise at least 50 wt% aramid fibers relative to the total weight of the respective first layer or second layer. Preferably, the first layer and the second layer each comprise at least 55 wt% aramid fiber, more preferably at least 60 wt%, and even more preferably at least 65 wt%. The use of at least 50 wt% aramid fibers in each of the first layer and the second layer contributes to a sufficiently high heat resistance and strength of the protective textile. Aramid fibers are known for their exceptional heat and flame resistance, making them an ideal material for use in protective textiles. By using these fibers in both the first and second layers of the textile, improved heat resistance can be achieved.

[0059] According to a preferred embodiment, the first layer and the second layer together comprise at least 50 wt% aramid fibers relative to the total weight of the first layer and the second layer. Preferably, the first layer and the second layer together comprise at least 60 wt% aramid fiber, more preferably at least 70 wt%, and even more preferably at least 80 wt%. The use of at least 50 wt% aramid fibers in the first layer and the second layer together contributes to excellent thermal and mechanical properties. They are resistant to high temperatures and have high tensile strength, making them particularly suitable for use in protective textiles.

[0060] According to an embodiment, the first layer or the second layer has a higher percentage of aramid fibers than the second layer or the first layer, respectively. This is advantageous because a layer used on the outer side of flame-resistant clothing exhibits higher flame-resistant properties than an inner layer of the protective textile. The protective textile can thus combine different properties. Consequently, the usability on the inside and outside can be managed, comprising heat regulation, moisture regulation, flexibility, and lightness to wear, in combination with sufficient protection against heat, chemicals, cut resistance, and tear resistance. Preferably, a layer with a higher percentage of aramid fibers is an outer layer, resulting in higher thermal and mechanical reliability on the outside of flameresistant clothing made from the protective textile, while a lower percentage of aramid fibers in an inner layer could lead to a softer and more comfortable feel against the skin on the inside of flame-resistant clothing made from the protective textile. Preferably, the inner layer is the first layer and the outer layer is the second layer. The combination of the first and second layers results in a resistance to evaporative heat transfer (RET) for the protective textile of up to 30 m2-Pa / W, measured according to ISO 11092:2014. Preferably, the protective textile has an RET of 7 m2-Pa / W. More preferably, the thermally protective textile has an RET of a maximum of 5 m2-Pa / W.

[0061] According to an embodiment, the protective textile has a breaking strength of at least 450 N, measured according to ISO 13934-1:2013. Preferably, the protective textile has a breaking strength of at least 1500 N. More preferably, the breaking strength is at least 2000 N. A minimum breaking strength of 450 N is advantageous because it results in high wear resistance.

[0062] According to an embodiment, the protective textile has a tear resistance of at least 30 N, measured according to ISO 13937-2:2000. Preferably, the protective textile has a tear resistance of at least 200 N. More preferably, the tear resistance is at least 400 N. A minimum tear resistance of at least 30 N is advantageous because it ensures that the clothing is resistant to mechanical tearing forces, providing reliable protection in demanding environments and ensuring a longer lifespan of the protective textile, thereby enhancing the overall safety and reliability of the protective clothing.

[0063] According to an embodiment, the protective textile has a minimum abrasion resistance of 50,000 cycles measured according to ISO 12947-2:2016 at 12 kPa. More preferably, the minimum abrasion resistance is 100,000 cycles. A minimum abrasion resistance of 50,000 cycles is advantageous because it ensures that the clothing is resistant to mechanical friction forces, providing reliable protection in demanding environments and ensuring a longer lifespan of the protective textile, thereby enhancing the overall safety and reliability of the protective clothing.

[0064] According to an embodiment, pilling of the protective textile occurs only to a limited extent, with a maximum score of 4 to 5 measured according to ISO 12945-3:2020. This is advantageous because the thermal, chemical and mechanical protection of the protective textile is maintained. According to an embodiment, the protective textile withstands a minimum washing performance requirement of 25 washes according to EN 469:2020, preferably a minimum washing performance requirement of 50 washes. This is advantageous because it extends the lifespan of the protective textile.

[0065] According to an embodiment, the protective textile does not comprise fluorocarbon- containing chemicals, which is advantageous because it results in a more environmentally friendly protective textile.

[0066] According to an embodiment, at least one yarn of the protective textile comprises a protective coating. This is advantageous because it contributes to additional support for the protective properties of the protective textile. Preferably, the coating provides a flame- retardant effect. More preferably, the coating is applied to the second layer.

[0067] According to an embodiment, the protective textile is woven with a basic loom. A basic loom is a loom with a gripper or shuttle. This is advantageous because basic looms are simple and easy to operate, making them suitable for simple weave patterns.

[0068] According to an embodiment, the protective textile is woven with an air-jet loom. This is advantageous because air-jet looms are known for their high weaving speeds, leading to higher production efficiency. Furthermore, air-jet looms offer great versatility. The air-jet looms can handle a wide range of yarn types and bindings, offering flexibility in fabric design. There is also less wear on weaving components as air weaving is often associated with less friction.

[0069] According to an embodiment, the protective textile is woven with a water jet loom. The advantage of using a water jet loom is that no shuttle or gripper is needed, reducing the risk of yarn breakage and allowing the water jet loom to operate more smoothly. Another advantage is that water jet looms are suitable for yarns with a high twist. Moreover, water jet looms allow for more efficient use of yarns, leading to cost savings.

[0070] According to an embodiment, the thermally protective textile is woven with a Jacquard loom. The use of Jacquard looms is advantageous for producing intricate patterns and complex designs, allowing for detailed and customized textiles. Jacquard looms enable the production of fabrics with various patterns and provide precise control over individual warp yarns, allowing for the creation of unique fabrics.

[0071] According to an embodiment, the thermally protective textile comprises yarns with a high twist. A high twist means that the yarn has at least 12 twists per cm length of the yarn. This is advantageous because yarns comprised in the protective textile are less likely to pill compared to yarns with a standard twist. Moreover, the yarns have better elasticity, and the protective textile comprising predominantly yarns with a high twist will be more wrinkle-resistant. Preferably, yarns with a high twist are present in at least 30 wt% relative to the total weight of the protective textile, more preferably in at least 50 wt%, and even more preferably in at least 70 wt%.

[0072] According to an embodiment, the protective textile comprises yarns with a high twist in an inner layer. This is advantageous due to the increased elasticity, good abrasion resistance, and resistance to pilling. Preferably, the inner layer is the first layer.

[0073] According to an embodiment, the protective textile comprises yarns with a high twist in an outer layer. This is advantageous due to the increased elasticity, good abrasion resistance, and resistance to pilling. Preferably, the outer layer is the second layer.

[0074] In what follows, the invention is described with reference to non-limiting examples that illustrate the invention and are not intended or should not be interpreted to limit the scope of the invention.

[0075] EXAMPLES

[0076] Example 1

[0077] A first example relates to a protective textile comprising para-aramid fibers, metaaramid fibers, and wool.

[0078] A composition of a protective textile is schematically represented in Table 1. A protective textile comprises a first layer and a second layer. The first layer comprises a first yarn and the second layer comprises a second yarn, wherein the first yarn and the second yarn are flame-resistant. The first yarn and the second yarn are comprised of a 92 wt% meta-aramid staple fiber Nomex®, 5 wt% para-aramid filament Kevlar®, and 3 wt% statically electrically conductive fiber. Weight percentages are expressed relative to the total weight of the yarn. The yarn comprising Nomex® meta-aramid staple fibers is represented in Table 1 as A. The yarn comprising Nomex® meta-aramid staple fibers has a linear density of 653 dTex. Additionally, the first layer and the second layer include para-aramid Kevlar® Stretch Broken yarn. The Kevlar® Stretch Broken yarn is represented in Table 1 as

[0079] B. The Kevlar® Stretch Broken yarn has a linear density of 425 dTex. The Kevlar® Stretch Broken yarn comprises long staple fibers.

[0080] The second layer adjoins the first layer, and the second layer is a negative of the first layer, according to a plane located between the first layer and the second layer. The first layer and second layer are formed by two layers of warp threads as shown in Table 1, where a double-layered weave pattern is represented using subscript (warp thread in lower position) and superscript (warp thread in upper position) for the first layer (1) and the second layer (2).

[0081] The protective textile comprises at least one binding yarn which attaches the first layer to the second layer. The at least one binding yarn is represented in Table 1 as

[0082] C. The at least one binding yarn comprises waxed Merino wool. The protective textile comprises 4.5 yarns of the at least one binding yarn per cm. The binding yarns extend in the warp direction. Each of the at least one binding yarn forms a connection between the first layer and the second layer after 6 wefts. A weft is understood to mean that a weft thread has been inserted between warp threads of the protective textile according to the weft direction. The wefts are considered as one layer, as shown at the top of Table 1, where a single weave pattern is represented. The waxed Merino wool is soluble in a solution of water with 30 g / L sodium sulfide, 6 g / L sodium hydroxide, and 10 g / L sodium dodecyl sulfate at 90°C.

[0083] The protective textile comprises the first layer and the second layer, each containing 87.5 wt% aramid fibers in yarns along the warp direction and 84.3 wt% aramid fibers in yarns along the weft direction. Weight percentages are relative to the total weight of all fibers in the warp direction or the weft direction.

[0084] Table 1: Schematic representation of the composition of a protective textile according to the first example.

[0085] Example 2

[0086] A second example relates to a protective textile comprising para-aramid fibers, meta-aramid fibers, and cellulose fibers.

[0087] A composition of a protective textile is schematically represented in Table 2. A protective textile comprises a first layer and a second layer. The first layer comprises a first yarn and the second layer comprises a second yarn, wherein the first yarn and the second yarn are flame-resistant. The first yarn and the second yarn are comprised of a meta-aramid staple fiber Nomex® in 87% by weight, a para-aramid filament Kevlar® in 5% by weight, an elastane fiber in 4% by weight, and an antistatic carbon fiber in 4% by weight. Weight percentages are expressed relative to the total weight of the yarn. The yarn comprising Nomex® meta-aramid staple fibers is represented in Table 2 as A. The yarn comprising Nomex® meta-aramid staple fibers has a linear density of 571 dTex. In addition, the first layer and the second layer comprise a para-aramid Kevlar® yarn. The Kevlar® yarn is represented in Table 2 as B. The Kevlar® yarn has a linear density of 516 dTex.

[0088] The second layer adjoins the first layer, and the second layer is a negative of the first layer, according to a plane located between the first layer and the second layer. This allows for the connection of the first layer to the second layer. The first layer and second layer are formed by two layers of warp threads as shown in Table 2, where a double-layered weave pattern is represented using subscript (warp thread in lower position) and superscript (warp thread in upper position) for the first layer (1) and the second layer (2).

[0089] The protective textile comprises at least one binding yarn which attaches the first layer to the second layer. The at least one binding yarn is represented in Table 2 as C. The at least one binding yarn comprises Lenzing® FR, a cellulose fiber from wood pulp that has undergone a flame- retardant treatment. The protective textile comprises 8 yarns of the at least one binding yarn per cm. The binding yarns extend in the warp direction. Each of the at least one binding yarn forms a connection between the first layer and the second layer after 9 wefts. A weft is understood to mean that a weft thread has been inserted between warp threads of the protective textile according to the weft direction. The wefts are considered as one layer, as shown in Table 2, where a single weave pattern is represented. The cellulose pulp is soluble in a solution of water with 70 vol% dihydrogen sulfate at 20°C.

[0090] Table 2: Schematic representation of the composition of a protective textile according to the second example.

[0091] Example 3

[0092] A third example relates to a protective textile comprising para-aramid fibers, metaaramid fibers, and wool.

[0093] A composition of a protective textile is schematically represented in Table 3. A protective textile comprises a first layer and a second layer. The first layer comprises a first yarn and the second layer comprises a second yarn, wherein the first yarn and the second yarn are heat-resistant. The first yarn and the second yarn include PBI® comprising 74 wt%, para-aramid filament Kevlar® comprising 3 wt%, and meta-aramid fiber Nomex® comprising 23 wt%. Weight percentages are expressed relative to the total weight of the yarn. The PBI comprising yarn is represented in Table 3 as A. Additionally, the first layer and the second layer include a para-aramid Kevlar® filament comprising 23 wt%, a meta-aramid Nomex® comprising 75 wt% as staple fibers, and carbon fiber comprising 2 wt% in a yarn. The Nomex® comprising yarn is represented in Table 3 as B.

[0094] The second layer adjoins the first layer, and the second layer is a negative of the first layer, according to a plane located between the first layer and the second layer. The first layer and second layer are formed by two layers of warp threads as shown in Table 3, where a double-layered weave pattern is represented using subscript (warp thread in lower position) and superscript (warp thread in upper position) for the first layer (1) and the second layer (2). Production is via an air-jet loom. The protective textile comprises at least one binding yarn which attaches the first layer to the second layer. The at least one binding yarn is represented in Table 3 as C. The at least one binding yarn comprises waxed Alpaca wool. The protective textile comprises 5 yarns of the at least one binding yarn per cm. The binding yarns extend in the warp direction. Each of the at least one binding yarn forms a connection between the first layer and the second layer after 13 wefts. A weft is understood to mean that a weft thread has been inserted between warp threads of the protective textile according to the weft direction. The wefts are considered as one layer, as shown at the top of Table 1, where a single weave pattern is represented. The waxed Alpaca wool is soluble in a solution of water with 4 g / L sodium hydroxide at 65°C.

[0095] Table 3: Schematic representation of the composition of a protective textile according to the third example.

Claims

CLAIMS1. Protective textile, comprising a first layer and a second layer, wherein the first layer comprises a first yarn, the second layer adjoins the first layer, and the second layer comprises a second yarn, wherein the protective textile comprises at least one binding yarn that attaches the first layer to the second layer, characterized in that the first layer and the second layer are separable from each other because the at least one binding yarn is removable through a separation process that is chemical and / or physical, wherein the first yarn and the second yarn are of synthetic origin, wherein the at least one binding yarn includes fibers of animal origin, wherein the protective textile comprises at least 4 and at most 15 of the at least one binding yarn per cm, and wherein each of the at least one binding yarn forms a connection between the first layer and the second layer after at least 2 wefts and at most 60 wefts.

2. The protective textile according to claim 1, characterized in that the separation process is chemical, wherein the at least one binding yarn is soluble in a solution that does not dissolve at least 75 wt% of the yarns of the first and second layers, wherein the first yarn is flame- retardant, and wherein the first yarn and the second yarn are aramid yarns.

3. The protective textile according to claim 1 or 2, characterized in that the first layer comprises one or more additional yarns selected from a list of melamine, aramid, polybenzimidazole, poly(p-phenylene-2,6- benzobisoxazole), modacrylic, polybenzobisoxazole, viscose with flameretardant treatment, nylon with flame-retardant treatment, cellulose with flame-retardant treatment, or a combination thereof.

4. The protective textile according to any of the preceding claims 1-3, characterized in that the second layer comprises one or more additional yarns selected from a list of melamine, aramid, polyarylate, polyethylene, ceramic, viscose with flame-retardant treatment, nylon with flame-retardant treatment, cellulose with flame- retardant treatment, or a combination thereof.

5. The protective textile according to claim 4, characterized in that the ceramic yarns are glass-based, carbon-based, or a combination thereof.

6. The protective textile according to any of the preceding claims 1-5, characterized in that the at least one binding yarn is wool.

7. The protective textile according to any of the preceding claims 1-6, characterized in that the first layer and / or the second layer comprise at least filaments.

8. The protective textile according to any of the preceding claims 1-7, characterized in that the first layer and / or the second layer comprise staple fibers.

9. The protective textile according to any of the preceding claims 1-8, characterized in that the first layer and the second layer have a different weave pattern, the first layer having a weave pattern of twill weaves.

10. The protective textile according to any of the preceding claims 1-9, characterized in that the second layer comprises a grid pattern.

11. The protective textile according to claim 10, characterized in that the grid pattern comprises cells with ribs having a length ranging from 0.5 cm to 1.5 cm.

12. The protective textile according to any of the preceding claims 1-11, characterized in that the yarn count of the first yarn and the second yarn is a maximum of 3000 dTex.

13. The protective textile according to any of the preceding claims 1-12, characterized in that the yarn count of the first yarn and the second yarn is a minimum of 300 dTex.

14. The protective textile according to any of the preceding claims 1-13, characterized in that yarns for the first and / or second layer comprises dyes that are soluble in the solution that dissolves the at least one binding yarn.

15. The protective textile according to any of the preceding claims 1-14, characterized in that the first and the second layer each comprise at least 50 wt% aramid fibers relative to the total weight of the respective first layer or second layer.

16. The protective textile according to any of the preceding claims 1-15, characterized in that the first and the second layer together comprise at least 50 wt% aramid fibers relative to the total weight of the first layer and the second layer.

Images