Arc flash clothing fabric

Abstract

The present application relates to fabric for arc flash clothing. For example, an example arc flash clothing fabric includes an outer gradient layer, a middle gradient layer, and an inner gradient layer. In some examples, the outer gradient layer is formed by first yarns interlacing with third yarns, the middle gradient layer is formed by second yarns, and the inner gradient layer is formed by second yarns interlacing with fourth yarns. In some examples, the fourth yarns are more hydrophobic than the first yarns, the second yarns, and the third yarns.

Description

ARC FLASH CLOTHING FABRICCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of Chinese Application No.202510386212.6, filed March 28, 2025, the entire contents of which are incorporated herein by reference.BACKGROUND

[0002] There are many technical challenges and difficulties associated with fabric for arc flash clothing. For example, many fabrics for arc flash clothing do not provide sufficient breathability.SUMMARY OF THE INVENTION

[0003] Various embodiments described herein relate to fabric for arc flash clothing. For example, example embodiments of the present disclosure provide example fabric for arc flash clothing that improves breathability and comfort, reduces weight and thickness, and enhances protection against environmental hazards due to arc flash events.

[0004] In accordance with various embodiments of the present disclosure, an example arc flash clothing fabric is provided. In some embodiments, the example arc flash clothing fabric comprises an outer gradient layer, a middle gradient layer, and an inner gradient layer.

[0005] In some embodiments, the outer gradient layer comprises a plurality of first yarns interlacing with a plurality of third yarns.

[0006] In some embodiments, the middle gradient layer comprises a plurality of second yarns.

[0007] In some embodiments, the inner gradient layer comprises the plurality of second yarns interlacing with a plurality of fourth yarns.

[0008] In some embodiments, the plurality of fourth yarns is more hydrophobic than the plurality of first yarns, the plurality of second yarns, and the plurality of third yarns.

[0009] In some embodiments, a first hydrogen bond percentage of first material associated with the plurality of first yarns is higher than a second hydrogen bond percentage of second material associated with the plurality of second yarns.

[0010] In some embodiments, a third hydrogen bond percentage of third material associated with the plurality of third yarns is higher than a second hydrogen bond percentage of secondmaterial associated with the plurality of second yarns.

[0011] In some embodiments, the plurality of third yarns comprises elastane material.

[0012] In some embodiments, the plurality of second yarns is more hydrophobic than the plurality of first yarns and the plurality of third yarns.

[0013] In some embodiments, the plurality of first yarns and the plurality of third yarns form a plain weave pattern.

[0014] In some embodiments, the plurality of second yarns and the plurality of fourth yarns form a plain weave pattern.

[0015] In some embodiments, the inner gradient layer comprises a plurality of rib portions forming a plurality of gaps between the inner gradient layer and the outer gradient layer.

[0016] In some embodiments, the example arc flash clothing fabric further comprises a film layer attached to an outer surface of the outer gradient layer.

[0017] In some embodiments, the example arc flash clothing fabric further comprises an abrasion protection layer attached to an outer surface of the film layer.

[0018] The foregoing illustrative summary, as well as other exemplary objectives and / or advantages of the disclosure, and the manner in which the same are accomplished, are further explained in the following detailed description and its accompanying drawings.BRIEF DESCRIPTION OF DRAWINGS

[0019] The description of the illustrative embodiments may be read in conjunction with the accompanying figures. It will be appreciated that, for simplicity and clarity of illustration, elements illustrated in the figures have not necessarily been drawn to scale, unless described otherwise. For example, the dimensions of some of the elements may be exaggerated relative to other elements, unless described otherwise. Embodiments incorporating teachings of the present disclosure are shown and described with respect to the figures presented herein.

[0020] FIG. 1A is an example perspective view of an example flash clothing fabric in accordance with some embodiments of the present disclosure.

[0021] FIG. IB is an example side view of the example flash clothing fabric shown in FIG.1A in accordance with some embodiments of the present disclosure.

[0022] FIG. 2 is an example top view showing example yarns associated with an example arc flash clothing fabric in accordance with some embodiments of the present disclosure.

[0023] FIG. 3 is an example block diagram illustrating example hydrogen bonds associated with example gradient layers of an example arc flash clothing fabric in accordance with some embodiments of the present disclosure.

[0024] FIG. 4A is an example exploded view of an example arc flash clothing fabric in accordance with some embodiments of the present disclosure.

[0025] FIG. 4B is an example zoomed view of the example arc flash clothing fabric shown in FIG. 4A in accordance with some embodiments of the present disclosure.

[0026] FIG. 5 is an example exploded view of an example arc flash clothing fabric in accordance with some embodiments of the present disclosure.DETAILED DESCRIPTION OF THE INVENTION

[0027] Some embodiments of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. Indeed, these disclosures may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0028] As used herein, terms such as “front,” “rear,” “top,” etc. are used for explanatory purposes in the examples provided below to describe the relative position of certain components or portions of components. Furthermore, as would be evident to one of ordinary skill in the art in light of the present disclosure, the terms “substantially” and “approximately” indicate that the referenced element or associated description is accurate to within applicable engineering tolerances.

[0029] As used herein, the term “comprising” means including but not limited to and should be interpreted in the manner it is typically used in the patent context. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of.

[0030] The phrases “in one embodiment,” “according to one embodiment,” “in some embodiments,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure, and may be included in more than one embodiment of the present disclosure (importantly, such phrasesdo not necessarily refer to the same embodiment).

[0031] The word “example” or “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

[0032] If the specification states a component or feature “may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that a specific component or feature is not required to be included or to have the characteristic. Such a component or feature may be optionally included in some embodiments, or it may be excluded.

[0033] As described above, example embodiments of the present disclosure relate generally to fabric for arc flash clothing. In the present disclosure, the term “arc flash clothing” refers to a type of personal protective equipment (PPE) in the form of protective garments (such as, but not limited to, jackets, pants, gloves, and / or the like) that protects workers from hazards (such as, but not limited to, electrical hazards, thermal hazards, and / or the like) associated with arc flash events.

[0034] In the present disclosure, the term “arc flash event” refers to a sudden release of intense electrical energy that may produce an electric arc or flame. For example, an example arc flash event may be caused by a short circuit or an equipment failure in an electrical system. When an arc flash event occurs, a burst of heat and light may be released into the environment, causing burns or injuries to nearby persons. As such, workers who are at risk of exposure to arc flash events may choose to wear arc flash clothing to protect themselves against hazards associated with arc flash events. Examples of such workers may include, but not limited to, electricians, utility linemen, construction workers, industrial maintenance technicians, and / or the like.

[0035] However, there are many technical challenges and difficulties associated with arc flash clothing.

[0036] For example, many arc flash clothing use fabrics that are thick and heavy in order to provide thermal insulation and protection against intense heat that is released from an arc flash event. However, such thick and heavy fabric can restrict movements of workers wearing the arc flash clothing, which may cause workers to perform tasks less efficiently (especially when such tasks require frequent movements of workers). In addition, thick and heavy fabric is also less breathable. In the present disclosure, the term “breathability” refers to the ability of a fabric to allow air and moisture to pass through it. Thick and heavy fabric in many arc flash clothing cantrap body heat and lack proper ventilation, resulting in discomfort and potential heat exhaustion of workers after prolonged wear.

[0037] Various embodiments of the present disclosure overcome these technical challenges and difficulties, and provide various technical improvements and advantages.

[0038] For example, various example embodiments of the present disclosure provide example arc flash clothing fabric that comprises an outer gradient layer, a middle gradient layer, and an inner gradient layer. In some embodiments, the middle gradient layer is between the outer gradient layer and the inner gradient layer. In some embodiments, hydrogen bond percentage gradually increases from the inner gradient layer to the outer gradient layer, creating one-way moisture transfer from the inner gradient layer to the outer gradient layer. In some embodiments, arc flash clothing using example fabric in accordance with some embodiments of the present disclosure is suitable for prolonged and frequency wear because it transports moisture away from the skin of the wearer towards the outer surface of the arc flash clothing. As such, example arc flash clothing fabric in accordance with some embodiments of the present disclosure provide technical improvements and advantages such as, but not limited to, improved breathability and comfort, reduced weight and thickness, and enhanced protection against hazards caused by arc flash events.

[0039] Referring now to FIG. 1A and FIG. IB, example views of an example flash clothing fabric in accordance with some embodiments of the present disclosure are illustrated.

[0040] In particular, FIG. 1A illustrates an example perspective view 100A of an example arc flash clothing fabric 101 in accordance with some embodiments of the present disclosure. FIG. IB illustrates an example side view 100B of the example arc flash clothing fabric 101 shown in FIG.1A in accordance with some embodiments of the present disclosure.

[0041] In accordance with some embodiments of the present disclosure, an example arc flash clothing fabric comprises a plurality of gradient layers. In the present disclosure, the term “gradient layer” refers to a layer or a region of a fabric that provides certain hydrophilicity and / or exhibits a particular level of affinity for water. For example, an example fabric may comprise multiple regions that are associated with different degrees of hydrophilicity. In such an example, the example fabric comprises multiple gradient layers, each of which corresponds to one of the multiple regions.

[0042] In the example shown in FIG. IB, the example arc flash clothing fabric 101 comprises a plurality of gradient layers such as, but not limited to, an outer gradient layer 103, a middlegradient layer 105, and an inner gradient layer 107.

[0043] In some embodiments, the inner gradient layer 107 corresponds to a layer of the example arc flash clothing fabric 101 that is the closest to the wearer’s skin when the example arc flash clothing fabric 101 is used in an example arc flash clothing, and the outer gradient layer 103 corresponds to a layer of the example arc flash clothing fabric 101 that is the farthest away from the wearer’s skin when the example arc flash clothing fabric 101 is used in an example arc flash clothing. As shown in FIG. IB, the middle gradient layer 105 is positioned between the inner gradient layer 107 and the outer gradient layer 103.

[0044] In some embodiments, hydrophilicity of the example arc flash clothing fabric 101 increases from the inner gradient layer 107 to the outer gradient layer 103, creating one-way moisture transfer from the inner gradient layer 107 to the outer gradient layer 103, thereby improving breathability of the example arc flash clothing fabric 101. In some embodiments, changes in hydrophilicity among the inner gradient layer 107, the middle gradient layer 105, and the outer gradient layer 103 may be accomplished by weaving different yarns with different hydrophilic properties.

[0045] For example, the outer gradient layer 103 is formed by and / or comprises a plurality of first yarns interlacing with a plurality of third yarns, the middle gradient layer 105 is formed by and / or comprises a plurality of second yarns, and the inner gradient layer 107 is formed by and / or comprises the plurality of second yarns interlacing with a plurality of fourth yarns.

[0046] Continuing in such an example, the plurality of fourth yarns is the most hydrophobic (for example, more hydrophobic than the plurality of first yarns, the plurality of second yarns, and the plurality of third yarns). In some examples, the plurality of second yarns is more hydrophobic than the plurality of first yarns and also more hydrophobic than the plurality of third yarns. As such, the outer gradient layer 103 (which comprises the plurality of first yarns and the plurality of third yams) is more hydrophilic than the middle gradient layer 105 (which comprises the plurality of second yams), and the middle gradient layer 105 is more hydrophilic than the inner gradient layer 107 (which comprises the plurality of second yarns and the plurality of fourth yams).

[0047] Additional details associated with example arc flash clothing fabric in accordance with some embodiments of the present disclosure are described herein, including, but not limited to, those described in connection with at least FIG. 2.

[0048] Referring to FIG. 2, an example top view 200 showing example yarns associated withan example arc flash clothing fabric 202 in accordance with some embodiments of the present disclosure is provided.

[0049] In the example shown in FIG. 2, the example arc flash clothing fabric 202 is formed by and / or comprises weaving a plurality of yarns in the warp direction with a plurality of yarns in the weft direction.

[0050] In the present disclosure, the term “warp direction” refers to a direction that extends longitudinally along a length of a fabric. In the example shown in FIG. 2, the warp direction of the example arc flash clothing fabric 202 is shown by the arrows 204. In the present disclosure, a yarn in the warp direction is also referred to as a “warp yarn.”

[0051] In the present disclosure, the term “weft direction” refers to a direction that extends transversely across a width of a fabric. In the example shown in FIG. 2, the weft direction of the example arc flash clothing fabric 202 is shown by the arrows 206. In the present disclosure, a yarn in the weft direction is also referred to as a “weft yarn.”

[0052] In some embodiments, the example arc flash clothing fabric 202 comprises yarns with different hydrophilic properties. For example, the example arc flash clothing fabric 202 comprises a plurality of first yams, a plurality of second yarns, a plurality of third yarns, and a plurality of fourth yarns. In some embodiments, the plurality of first yarns and the plurality of second yarns are warp yams in the warp direction, and the plurality of third yarns and the plurality of fourth yarns are weft yarns in the weft direction.

[0053] In the example shown in FIG. 2, the plurality of first yarns includes, but not limited to, a first yarn 208A, a first yarn 208B, a first yam 208C, a first yam 208D, and a first yarn 208E. The plurality of second yarns includes, but not limited to, a second yarn 210A, a second yam 210B, a second yarn 210C, and a second yarn 210D. The plurality of third yams includes, but not limited to, a third yarn 212A, a third yarn 212B, and a third yarn 212C. The plurality of fourth yarns includes, but not limited to, a fourth yarn 214A, a fourth yam 214B, and a fourth yam 214C.

[0054] Similar to the example arc flash clothing fabric 101 described above in connection with FIG. 1A and FIG. IB, the example arc flash clothing fabric 202 (shown in FIG. 2) comprises a plurality of gradient layers such as an outer gradient layer, a middle gradient layer, and an inner gradient layer. In some embodiments, each of the outer gradient layer, the middle gradient layer, and the inner gradient layer is formed by and / or comprises a plurality of yams.

[0055] For example, the outer gradient layer of the example arc flash clothing fabric 202 isformed by and / or comprises the plurality of first yarns (including, but not limited to, the first yarn 208A, the first yarn 208B, the first yam 208C, the first yarn 208D, and the first yam 208E) interlacing with the plurality of third yarns (including, but not limited to, the third yarn 212A, the third yarn 212B, and the third yarn 212C).

[0056] In the example shown in FIG. 2, the plurality of first yarns and the plurality of third yarns interlace with one another in an alternating sequence to form a plain weave pattern of the outer gradient layer. For example, each of the plurality of third yarns is woven over one first yarn and then under the subsequent first yam, forming a crisscross pattern that is even and consistent throughout the outer gradient layer.

[0057] For example, the third yam 212A is woven over the first yarn 208A, under the first yarn 208B, over the first yarn 208C, under the first yam 208D, and over the first yarn 208E. The third yarn 212B is woven under the first yarn 208 A, over the first yarn 208B, under the first yarn 208C, over the first yarn 208D, and under the first yarn 208E. The third yarn 212C is woven over the first yam 208A, under the first yarn 208B, over the first yarn 208C, under the first yarn 208D, and over the first yarn 208E.

[0058] In some embodiments, forming the plain weave pattern of the outer gradient layer provides various technical benefits and advantages. For example, interlacing the plurality of first yarns and the plurality of third yams into a plain weave pattern improves tensile strength and structural consistency of the example arc flash clothing fabric 202, thereby improving protection against hazards caused by arc flash events. As another example, the plain weave pattern of the outer gradient layer improves air circulation of the outer gradient layer, thereby improving breathability of the example arc flash clothing fabric 202 and making it more comfortable to wear.

[0059] Additionally, or alternatively, the middle gradient layer of the example arc flash clothing fabric 202 is formed by and / or comprises the plurality of second yams (including, but not limited to, the second yam 210A, the second yarn 210B, the second yarn 210C, and the second yarn 210D).

[0060] In the example shown in FIG. 2, the plurality of second yarns is woven under the plurality of third yarns, such that the middle gradient layer is secured under the outer gradient layer of the example arc flash clothing fabric 202. For example, the second yam 210A is woven under the third yam 212A, the third yarn 212B, and the third yarn 212C. The second yarn 210B is woven under the third yarn 212A, the third yarn 212B, and the third yam 212C. The second yam 210C iswoven under the third yarn 212A, the third yam 212B, and the third yam 212C. The second yarn 210D is woven under the third yarn 212A, the third yarn 212B, and the third yarn 212C.

[0061] Additionally, or alternatively, the inner gradient layer of the example arc flash clothing fabric 202 is formed by and / or comprises the plurality of second yarns (including, but not limited to, the second yarn 210A, the second yam 21 OB, the second yarn 210C, and the second yam 210D) interlacing with the plurality of fourth yarns (including, but not limited to, the fourth yarn 214A, the fourth yarn 214B, and the fourth yarn 214C).

[0062] In the example shown in FIG. 2, the plurality of second yams and the plurality of fourth yarns interlace with one another in an alternating sequence to form a plain weave pattern of the inner gradient layer. For example, each of the plurality of fourth yams is woven over one second yarn and under the subsequent second yam, forming a crisscross pattern that is even and consistent throughout the outer gradient layer.

[0063] For example, the fourth yarn 214A is woven over the second yarn 210A, under the second yarn 210B, over the second yam 210C, and under the second yarn 210D. The fourth yarn 214B is woven under the second yarn 210A, over the second yam 210B, under the second yam 210C, and over the second yarn 210D. The fourth yarn 214C is woven over the second yarn 210A, under the second yam 210B, over the second yarn 210C, and under the second yarn 210D

[0064] In some embodiments, forming the plain weave pattern of the inner gradient layer provides various technical benefits and advantages. For example, interlacing the plurality of second yarns and the plurality of fourth yarns improves tensile strength and structural consistency of the example arc flash clothing fabric 202, thereby improving protection against hazards caused by arc flash events. As another example, the plain weave pattern of the inner gradient layer improves air circulation of the inner gradient layer, thereby improving breathability of the example arc flash clothing fabric 202 and making it more comfortable to wear.

[0065] As described above, the example arc flash clothing fabric 202 comprises yams with different hydrophilic properties.

[0066] In some embodiments, the plurality of second yarns (including, but not limited to, the second yarn 210A, the second yarn 210B, the second yarn 210C, and the second yarn 210D) is more hydrophobic than the plurality of first yarns (including, but not limited to, the first yam 208A, the first yarn 208B, the first yarn 208C, the first yarn 208D, and the first yarn 208E). In some embodiments, the plurality of second yams (including, but not limited to, the second yarn 210A,the second yarn 21 OB, the second yam 21 OC, and the second yarn 21 OD) is more hydrophobic than the plurality of third yams (including, but not limited to, the third yarn 212A, the third yam 212B, and the third yarn 212C).

[0067] In some embodiments, the plurality of fourth yarns (including, but not limited to, the fourth yarn 214A, the fourth yarn 214B, and the fourth yarn 214C) is hydrophobic. In other words, the plurality of fourth yarns is more hydrophobic than the plurality of first yarns, the plurality of second yams, and the plurality of third yarns.

[0068] In some embodiments, the differences in hydrophilic properties among different yarns may be due to different materials that form different yams. For example, the plurality of first yarns (including, but not limited to, the first yarn 208A, the first yam 208B, the first yarn 208C, the first yarn 208D, and the first yam 208E) comprises or consists of a first material, the plurality of second yarns (including, but not limited to, the second yarn 210A, the second yarn 21 OB, the second yam 210C, and the second yarn 210D) comprises or consists of a second material, the plurality of third yarns (including, but not limited to, the third yam 212A, the third yarn 212B, and the third yarn 212C) comprises or consists of a third material, and the plurality of fourth yarns (including, but not limited to, the fourth yarn 214A, the fourth yarn 214B, and the fourth yarn 214C) comprises or consists of a fourth material. Continuing in this example, the second material is the most hydrophobic among the first material, the second material, and the third material.

[0069] In some embodiments, the hydrophilic property (or hydrophilicity) of a material may be measured by its hydrogen bond percentage. In the present disclosure, the term “hydrogen bond percentage” refers to a proportion of available sites on a material to form intermolecular hydrogen bonds. In some embodiments, the hydrogen bond percentage represents a percentage of hydrophilic functional groups that are capable of forming hydrogen bonds (which may be represented as “-XH” and may include, but not limited to, hydroxyl (-OH), amino (-NH2), carboxyl (-COOH), and / or the like). Because water molecules (H2O) are polar and include both partial positive and negative charges, the more -XH exist in the material to attract and interface with water molecules, the more absorbent the material is. In other words, the higher the hydrogen bond percentage, the more hydrophilic the material is.

[0070] Continuing from the above example, the first material may comprise or consist of a blend of hydrophilic yarns (including, but not limited to, viscose, lyocell, cotton, Super Absorbent Fiber (SAF)) and hydrophobic fibers (including, but not limited to, polypropylene (PP),polyethylene (PE), polylactic acid (PLA), polybutylene adipate-co-terephthalate (PBAT), aramid, fire-retardant acrylic, Chitosan, and / or the like). In some embodiments, the hydrogen bond percentage of the first material is in an example range of between approximately 30% and approximately 60%. In some embodiments, this example range provides technical benefits and advantages such as, but not limited to, increasing the hydrophilic property of the outer gradient layer and creating one-way moisture transfer from the inner gradient layer to the outer gradient layer, additional details of which are described herein.

[0071] Additionally, or alternatively, the second material may comprise or consist of a blend of hydrophilic yams (including, but not limited to, viscose, lyocell, cotton, SAF) and hydrophobic fibers (including, but not limited to, PP, PE, PLA, PBAT, aramid, fire-retardant acrylic, Chitosan, and / or the like). In some embodiments, the hydrogen bond percentage of the second material is in an example range of between approximately 20% and approximately 50%. In some embodiments, this example range provides technical benefits and advantages such as, but not limited to, decreasing the hydrophilic property of the middle gradient layer and creating one-way moisture transfer from the middle gradient layer to the outer gradient layer, additional details of which are described herein

[0072] Additionally, or alternatively, the third material may comprise or consist of a blend of hydrophilic yams (including, but not limited to, viscose, lyocell, cotton, SAF) and hydrophobic fibers (including, but not limited to, PP, PE, PLA, PBAT, aramid, fire-retardant acrylic, Chitosan, and / or the like). In some embodiments, the hydrogen bond percentage of the third material is in an example range of between approximately 30% and approximately 60%. In some embodiments, this example range provides technical benefits and advantages such as, but not limited to, increasing the hydrophilic property of the outer gradient layer and creating one-way moisture transfer from the middle gradient layer to the outer gradient layer, additional details of which are described herein.

[0073] Additionally, or alternatively, the third material may comprise elastane material (such as, but not limited to, spandex). For example, the third material may comprise 2% by weight of spandex material. In some embodiments, blending elastane material in the third material provides technical benefits and advantages such as, but not limited to, causing a plurality of rib portions to form on the inner gradient layer, additional details of which are described herein.

[0074] Additionally, or alternatively, the fourth material may comprise or consist ofhydrophobic fibers (including, but not limited to, PP, PE, PLA, PBAT, aramid, fire-retardant acrylic, Chitosan, and / or the like), providing technical benefits and advantages such as, but not limited to, reducing the hydrophilic property of the inner gradient layer and creating one-way moisture transfer from the inner gradient layer to the outer gradient layer, additional details of which are described herein.

[0075] In some embodiments, the hydrogen bond percentage of the first material and the hydrogen bond percentage of the third material may be the same or close to one another.

[0076] In some embodiments, the hydrogen bond percentage of the second material is lower than the hydrogen bond percentage of the first material and lower than the hydrogen bond percentage of the third material.

[0077] Because the outer gradient layer comprises a plurality of first yams (the first material) and a plurality of third yarns (the third material), while the middle gradient layer comprises a plurality of second yarns (the second material), the outer gradient layer is more hydrophilic than the middle gradient layer, creating one-way moisture transfer from the middle gradient layer to the outer gradient layer.

[0078] In some embodiments, the hydrogen bond percentage of the second material is higher than the hydrogen bond percentage of the fourth material (which may only comprise hydrophobic fibers). Because the middle gradient layer comprises a plurality of second yarns (the second material), while the inner gradient layer comprises a plurality of second yarns (the second material) and a plurality of fourth yarns (the fourth material), the middle gradient layer is more hydrophilic than the inner gradient layer, creating one-way moisture transfer from the inner gradient layer to the middle gradient layer.

[0079] As such, in accordance with some embodiments of the present disclosure, the hydrophilicity of the example arc flash clothing fabric 202 gradually increases from the inner gradient layer towards the outer gradient layer, creating a one-way moisture transfer from the inner gradient layer to the middle gradient layer and then to the outer gradient layer. Additional details are described in connection with at least FIG. 3.

[0080] Referring now to FIG. 3, an example block diagram 300 illustrating example hydrogen bonds associated with example gradient layers of an example arc flash clothing fabric in accordance with some embodiments of the present disclosure is provided.

[0081] Similar to the examples described above in connection with at least FIG. 1 A, FIG. IB,and FIG. 2, the example arc flash clothing fabric shown in FIG. 3 comprises three gradient layers: an outer gradient layer 301, a middle gradient layer 303, and an inner gradient layer 305.

[0082] In some embodiments, the inner gradient layer 305 is positioned closest to a wearer’s skin among the three gradient layers. In the example shown in FIG. 3, water molecules 307 (for example, from sweat or moisture that is released from the wearer’s skin) becomes in contact with the inner gradient layer 305. Because the middle gradient layer 303 is more hydrophilic than the inner gradient layer 305, the water molecules 307 is absorbed and spread from the inner gradient layer 305 to the middle gradient layer 303 due to hydrogen bonding, as shown by the arrow 309.

[0083] Similar to those described above, water molecules 307 comprise oxygen (O) that carries a negative charge, and the middle gradient layer 303 comprises hydrophilic functional groups (-XH) (such as, but not limited to, -OH, -NH2, and -COOH as shown in FIG. 3) from the material that forms the middle gradient layer 303 (for example, the second material). In such an example, hydrogen bonds form between oxygen (O) in water molecules 307 and hydrophilic functional groups (-XH) of the middle gradient layer 303, resulting in the middle gradient layer 303 absorbing the water molecules 307 from the inner gradient layer 305.

[0084] In some embodiments, the increased moisture absorption capability of middle gradient layer 303 (as compared to that of the inner gradient layer 305) creates pressure difference and capillary effect between the middle gradient layer 303 and the inner gradient layer 305, providing technical benefits and advantages such as, but not limited to, increasing the speed of absorbing water molecules 307 from the inner gradient layer 305 to the middle gradient layer 303 without spreading the water molecules 307 in the inner gradient layer 305. Because more hydrogen bonding occurs in the middle gradient layer 303 (as compared to that of the inner gradient layer 305), water molecules 307 do not return to the inner gradient layer 305 from the middle gradient layer 303, thereby keeping the surface of the inner gradient layer 305 (which may be in contact with a wearer’s skin) dry.

[0085] Similarly, because the outer gradient layer 301 (which may be exposed to the external environment) is more hydrophilic than the middle gradient layer 303, the water molecules 307 is absorbed and spread from the middle gradient layer 303 to the outer gradient layer 301 due to hydrogen bonding, as shown by arrow 309.

[0086] In some embodiments, the increased moisture absorption capability of outer gradient layer 301 (as compared to that of the middle gradient layer 303) creates pressure difference andcapillary effect between the outer gradient layer 301 and the middle gradient layer 303, providing technical benefits and advantages such as, but not limited to, increasing the speed of absorbing water molecules 307 from the middle gradient layer 303 to the outer gradient layer 301 without spreading the water molecules 307 in the middle gradient layer 303. Because more hydrogen bonding occurs in the outer gradient layer 301 (as compared to that of the middle gradient layer 303), water molecules 307 do not return to the middle gradient layer 303 from the outer gradient layer 301, thereby increasing moisture ventilation into the external environment.

[0087] In some embodiments, inorganic salt (such as, but not limited to, sodium chloride (NaCl), lithium chloride (LiCL), and / or the like) is sprayed on the inner gradient layer 305 (for example, the inner surface of the inner gradient layer 305 that is in contact with a wearer’s skin) after a predetermined amount of time of wearing (for example, but not limited to, four hours) to further enhance one-way moisture transfer from the inner gradient layer 305 to the outer gradient layer 301 as shown by the arrow 309.

[0088] Referring now to FIG. 4A and FIG. 4B, example views associated with an example arc flash clothing fabric in accordance with some embodiments of the present disclosure are illustrated.

[0089] In particular, FIG. 4A illustrates an example exploded view 400A of an example arc flash clothing fabric 402 in accordance with some embodiments of the present disclosure. FIG. 4B illustrates an example zoomed view 400B of the example arc flash clothing fabric 402 shown in FIG. 4A in accordance with some embodiments of the present disclosure.

[0090] Similar to the example arc flash clothing fabric described above in connection with FIG. 1 A, FIG. IB, FIG. 2, and FIG. 3, the example arc flash clothing fabric 402 shown in FIG. 4A comprises an outer gradient layer 404, a middle gradient layer 406, and an inner gradient layer 408.

[0091] In some embodiments, the outer gradient layer 404 corresponds to an outer layer of the example arc flash clothing fabric 402. In the example shown in FIG. 4A, the outer gradient layer 404 of the example arc flash clothing fabric 402 comprises an outer surface 410 that is exposed to the external environment. In some embodiments, the outer gradient layer 404 is formed by and / or comprises a plurality of first yams interlacing with a plurality of third yams, similar to the various examples described above in connection with FIG. 1A, FIG. IB, FIG. 2, and FIG. 3.

[0092] In some embodiments, the middle gradient layer 406 corresponds to a middle, baselayer of the example arc flash clothing fabric 402. In some embodiments, the middle gradient layer 406 comprises a plurality of second yarns, similar to the various examples described above in connection with FIG. 1A, FIG. IB, FIG. 2, and FIG. 3.

[0093] In some embodiments, the inner gradient layer 408 corresponds to an inner layer of the example arc flash clothing fabric 402 that may be in contact with a wearer’s skin. In some embodiments, the inner gradient layer 408 comprises the plurality of second yarns and a plurality of fourth yarns, similar to the various examples described above in connection with FIG. 1 A, FIG. IB, FIG. 2, and FIG. 3.

[0094] In some embodiments, the middle gradient layer 406 is positioned between the inner gradient layer 408 and the outer gradient layer 404. For example, both the middle gradient layer 406 and the inner gradient layer 408 comprise or share the plurality of second yarns. In such an example, the plurality of second yarns serve as connection yarns that connect the middle gradient layer 406 and the inner gradient layer 408. Additionally, or alternatively, the outer gradient layer 404 may be secured to the middle gradient layer 406 through example fabric manufacturing processes such as, but not limited to, heat setting, additional details of which are described herein.

[0095] Similar to the examples described above in connection with FIG. 1 A, FIG. IB, FIG. 2, and FIG. 3, the plurality of first yarns comprises first material, the plurality of second yarns comprises second material, the plurality of third yarns comprises third material, and the plurality of fourth yarns comprises fourth material. In some embodiments, the first material, the second material, and the third material each comprises a blend of hydrophilic yams and hydrophobic fibers, while the fourth material comprises only hydrophobic fibers without hydrophilic yarns. In some embodiments, the hydrogen bond percentages of the first material and the third material are in an example range between 30% and 60%, while the hydrogen bond percentage of the second material is in an example range between 20% and 50%. In some embodiments, the hydrogen bond percentage of the second material is lower than that of the first material and that of the third material. As such, the hydrophilicity of the example arc flash clothing fabric 402 gradually increases from the inner gradient layer 408 to the outer gradient layer 404 to allow moisture and air to permeate through the example arc flash clothing fabric 402 as shown by arrow 412, providing technical advantages and benefits such as, but not limited to, improving breathability and comfort of the example arc flash clothing fabric 402.

[0096] Referring to FIG. 4B, an example zoomed view of the example arc flash clothing fabric402 shown in FIG. 4A in accordance with some embodiments of the present disclosure is provided. In particular, FIG. 4B illustrates portions of the middle gradient layer 406 and the inner gradient layer 408 in accordance with some embodiments of the present disclosure.

[0097] In the example shown in FIG. 4B, the inner gradient layer 408 comprises a plurality of rib portions such as, but not limited to, the rib portion 408A. In some embodiments, each of the plurality of ribs portions corresponds to a raised, rounded portion that is between two portions of the middle gradient layer 406 and bulges away from the middle gradient layer 406 towards the wearer’s skin. For example, the rib portion 408A is between a first middle gradient layer portion 406A and a second middle gradient layer portion 406B of the middle gradient layer 406. In the example shown in FIG. 4B, the first middle gradient layer portion 406A and the second middle gradient layer portion 406B are parallel to one another.

[0098] In some embodiments, the plurality of rib portions of the inner gradient layer 408 may be formed through an example heat setting process. For example, as described above, the third material (which may form the plurality of third yarns of the outer gradient layer 404) may comprise elastane material (such as, but not limited to, spandex). During the example heat setting process, the example arc flash clothing fabric 402 may be exposed in an environment with its temperature raised to 190 degrees Celsius, which causes the third material (and the plurality of third yarns) to contract and shrink. Because the inner gradient layer 408 comprises a plurality of fourth yarns that are parallel to the plurality of third yams (for example, as shown in FIG. 2), the contraction of the elastane material causes the inner gradient layer 408 to arch and form a plurality of rib portions (for example, the rib portion 408A as shown in FIG. 4A and FIG. 4B), and secures the outer gradient layer 404 to the middle gradient layer 406.

[0099] In some embodiments, the plurality of rib portions of the inner gradient layer 408 (such as the rib portion 408 A) provides various technical benefits and advantages. For example, as shown in FIG. 4A and FIG. 4B, the plurality of rib portions of the inner gradient layer 408 forms a plurality of gaps between the inner gradient layer 408 and the outer gradient layer 404, further preventing moisture from returning to the inner gradient layer 408 from the outer gradient layer 404. In addition, the plurality of gaps formed by the plurality of rib portions provides a protective cushion between the wearer’ s skin and the external environment, further insulating the wearer from hazards caused by arc flash events.

[0100] Referring to FIG. 5, an example exploded view 500 of an example arc flash clothingfabric 501 in accordance with some embodiments of the present disclosure is provided.

[0101] In some embodiments, the example arc flash clothing fabric 501 comprises an outer gradient layer 503, a middle gradient layer 505, and an inner gradient layer 507, similar to the outer gradient layer 404, the middle gradient layer 406, and the inner gradient layer 408 of the example arc flash clothing fabric 402 described above in connection with FIG. 4A and FIG. 4B.

[0102] In some embodiments, the arc flash clothing fabric 501 comprises a film layer 511. In some embodiments, the film layer 511 is attached to an outer surface of the outer gradient layer 503.

[0103] In some embodiments, the film layer 511 may comprise waterproof material such as, but not limited to, polyurethane (PU), thermoplastic polyurethane (TPU), and / or the like. In some embodiments, the film layer 511 provide technical benefits and advantages such as, but not limited to, blocking external moisture in the environment from entering the outer gradient layer 503 (for example, as shown by arrow 515) while allowing internal moisture (for example, from the wearer) to be released to the environment (for example, as shown by arrow 517).

[0104] In some embodiments, the arc flash clothing fabric 501 comprises an abrasion protection layer 509. In some embodiments, the abrasion protection layer 509 is attached to an outer surface 513 of the film layer 511.

[0105] In some embodiments, the abrasion protection layer 509 may comprise anti-abrasion materials such as, but not limited to, nylon, aramid, and / or the like. In some embodiments, the abrasion protection layer 509 provides technical benefits and advantages such as, but not limited to, protecting the film layer 511 (and the example arc flash clothing fabric 501) from wear and tear.

[0106] It is to be understood that the disclosure is not to be limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation, unless described otherwise.

Claims

CLAIMS1. An arc flash clothing fabric comprising:an outer gradient layer comprises a plurality of first yarns interlacing with a plurality of third yarns;a middle gradient layer comprises a plurality of second yams; andan inner gradient layer comprises the plurality of second yarns interlacing with a plurality of fourth yarns,wherein the plurality of fourth yams is more hydrophobic than the plurality of first yarns, the plurality of second yarns, and the plurality of third yarns.

2. The arc flash clothing fabric of claim 1, wherein a first hydrogen bond percentage of first material associated with the plurality of first yarns is higher than a second hydrogen bond percentage of second material associated with the plurality of second yarns.

3. The arc flash clothing fabric of either of claims 1 or 2, wherein a third hydrogen bond percentage of third material associated with the plurality of third yarns is higher than a second hydrogen bond percentage of second material associated with the plurality of second yarns.

4. The arc flash clothing fabric of any one of claims 1 to 3, wherein the plurality of third yarns comprises elastane material.

5. The arc flash clothing fabric of any one of claims 1 to 4, wherein the plurality of second yams is more hydrophobic than the plurality of first yarns and the plurality of third yarns.

6. The arc flash clothing fabric of any one of claims 1 to 5, wherein the plurality of first yarns and the plurality of third yarns form a plain weave pattern.

7. The arc flash clothing fabric of any one of claims 1 to 6, wherein the plurality of second yarns and the plurality of fourth yarns form a plain weave pattern.

8. The arc flash clothing fabric of any one of claims 1 to 7, wherein the inner gradient layer comprises a plurality of rib portions forming a plurality of gaps between the inner gradient layer and the outer gradient layer.

9. The arc flash clothing fabric of any one of claims 1 to 8, further comprising a film layer attached to an outer surface of the outer gradient layer.

10. The arc flash clothing fabric of claim 9, further comprising an abrasion protection layer attached to an outer surface of the film layer.

11. The arc flash clothing fabric of any one of claims 1 to 10, wherein the arc flash clothing fabric is formed as wearable personal protective equipment.

12. The arc flash clothing fabric of claim 11, wherein the wearable personal protective equipment is selected from the group consisting of a jacket, pants, gloves, and combinations thereof.

13. A method of manufacturing an arc flash clothing fabric, the method comprising:providing an outer gradient layer by interlacing a plurality of first yams with a plurality of third yarns;providing a middle gradient layer comprising a plurality of second yams; and providing an inner gradient layer by interlacing the plurality of second yarns with a plurality of fourth yams,wherein the plurality of fourth yarns is more hydrophobic than the plurality of first yarns, the plurality of second yarns, and the plurality of third yarns.

14. The method of claim 13, wherein a first hydrogen bond percentage of a first material associated with the plurality of first yams is higher than a second hydrogen bond percentage of a second material associated with the plurality of second yams.

15. The method of claim 14, wherein a third hydrogen bond percentage of a third material associated with the plurality of third yams is higher than the second hydrogen bond percentage of the second material associated with the plurality of second yarns.

16. The method of either of claims 13 or 14, wherein the plurality of second yams is more hydrophobic than the plurality of first yarns and the plurality of third yarns.

17. The method of any one of claims 13 to 16, wherein providing the outer gradient layer comprises interlacing the plurality of first yarns and the plurality of third yarns in a plain weave pattern.

18. The method of any one of claims 13 to 17, wherein providing the inner gradient layer comprises interlacing the plurality of second yarns and the plurality of fourth yarns in a plain weave pattern.

19. The method of any one of claims 13 to 18, wherein the plurality of third yarns comprises elastane material, the method further comprising heat setting the arc flash clothing fabric to cause contraction of the plurality of third yarns and formation of a plurality of rib portions in the inner gradient layer and a plurality of gaps between the inner gradient layer and the outer gradient layer.

20. The method of any one of claims 13 to 19, further comprising attaching a film layer to an outer surface of the outer gradient layer.

21. The method of any one of claims 13 to 20, further comprising providing the arc flash clothing fabric is into a wearable article of personal protective equipment.

22. The method of claim 21, wherein the wearable article of personal protective equipment is selected from the group consisting of a jacket, pants, gloves, and combinations thereof.

Images