Double-Faced Knitted Fire-Resistant Fabric With Interlocking Yarns
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Solution Overview
Problem
Current fire-resistant workwear is often heavy, uncomfortable, and aesthetically unpleasing, lacking breathability and freedom of movement, while also being prone to bacterial growth due to its construction and materials.
Innovation Solution
A double-faced knitted fabric with interlocking yarns, where one layer comprises inherently fire-resistant aramid fibers and the other layer comprises FR viscose fibers, allowing for different fabric handles and properties on each surface, and optionally incorporating elastane and antibacterial fibers for added comfort and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fire-resistant treatment is applied to fabric, then fire-resistance is improved, but fabric handle deteriorates
Solution Approach 1:
The fabric is divided into two distinct layers: a first layer with inherently fire-resistant fibers (aramid) and a second layer with fire-resistant treated fibers (FR viscose). This segmentation allows each layer to contribute differently to fire-resistance while maintaining acceptable fabric handle through the combination of both layers.
Solution Approach 2:
The invention uses a composite structure combining two different fiber types in a double-faced knitted fabric. The first layer uses inherently fire-resistant aramid fibers, while the second layer uses viscose fibers with fire-resistant treatment, creating a composite material that balances fire-protection performance with comfortable fabric handle.
2Reliability
If heavy, coarse-textured fabrics are used for workwear, then fire-resistance is improved, but comfort and freedom of movement deteriorate
Solution Approach 1:
Different regions of the fabric (first layer vs. second layer) have different fiber compositions and properties. The first layer provides primary fire-protection with aramid fibers, while the second layer enhances comfort and breathability with FR viscose fibers, allowing each zone to optimize for its specific function.
Solution Approach 2:
The double-faced knitted construction allows the fabric to dynamically adapt to movement and deformation. The elastic properties of the knitted structure enable freedom of movement while maintaining fire-protection integrity, unlike rigid heavy fabrics.
3Productivity
If workwear is worn during intense physical activity and not laundered frequently, then worker performance is maintained, but bacterial growth increases
Solution Approach 1:
The fabric structure itself provides antibacterial functionality through its dual-layer construction. The specific fiber composition and knitting structure create properties that inhibit bacterial growth, allowing the workwear to maintain hygiene without frequent laundering, thus supporting continuous worker performance.
Data Source
AI summary
A double-faced fabric of knitted construction has a first layer and a second layer. The first layer forms a first outward-facing surface of the fabric, which includes a first yarn that includes first inherently fire-resistant fibers and optionally first elastane fibers. The second layer forms a second outward-facing surface of the fabric, which includes a second yarn that includes second FR viscose fibers and optionally second elastane fibers, other cellulosic-derived fiber, synthetic fire-resistant fiber, antibacterial fiber or combination of such. The first layer and the second layer are attached to each other by interlocking relationship between the first yarn and the second yarn. The first outward-facing surface and the second outward-facing surface of the fabric may used for a garment's outer surface and the inner surface, respectively.