Burn protective materials
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional flame-resistant protective garments are expensive, difficult to dye or print, lack abrasion resistance, absorb excessive water, and provide poor tactile comfort, making them unsuitable for workers in hazardous environments where occasional flash fire exposure is possible.
Innovation Solution
A lightweight, breathable, waterproof, and flame-resistant textile composite is developed using a meltable outer textile layer combined with a thermally stable convective barrier and a heat reactive material comprising a polymer resin-expandable graphite mixture, which reduces afterflame time and char length when exposed to flames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inherently flame resistant fibers (aramids, PBI, PBO) are used for protective garments, then flame resistance is improved, but cost increases significantly and tactile comfort deteriorates
Solution Approach 1:
The patent applies composite materials by combining a flammable outer textile layer with a heat reactive material layer containing expandable graphite and polymer resin. This composite structure achieves flame resistance through the heat reactive layer that expands and insulates when exposed to flame, rather than relying on inherently flame resistant fibers throughout the entire garment, thereby reducing cost while maintaining protective performance.
Solution Approach 2:
The patent applies local quality by concentrating the flame-resistant properties in a specific heat reactive material layer applied to the outer surface of the textile, rather than requiring all layers to be made from expensive inherently flame resistant fibers. The heat reactive layer provides localized protection where it is most needed (at the flame-exposed surface), allowing the use of cheaper materials in inner layers.
2Reliability
If traditional inherently flame resistant fibers are used for protective garments, then flame resistance is improved, but tactile comfort and breathability deteriorate
Solution Approach 1:
The composite structure allows the inner layers to be made from comfortable, breathable materials like cotton or polyester while the outer heat reactive layer provides flame protection. This separation of functions enables tactile comfort in the contact layers while maintaining flame resistance at the protective surface.
3Reliability
If traditional inherently flame resistant fibers are used for protective garments, then flame resistance is improved, but water absorption increases and comfort deteriorates
Solution Approach 1:
The heat reactive material layer acts as a hydrophobic barrier that prevents water from penetrating to the inner layers, allowing the use of materials that would normally absorb water in the inner layers while maintaining overall water resistance at the flame-exposed surface.
4Ease of operation
If lightweight, comfortable materials are used for protective garments, then comfort and breathability are improved, but flame resistance deteriorates
Solution Approach 1:
The patent applies local quality by concentrating flame-resistant properties in a specific heat reactive material layer applied to the outer surface, allowing the bulk of the garment to be made from lightweight, comfortable materials while maintaining flame protection at the critical exposure surface.
Solution Approach 2:
The heat reactive material utilizes phase transition through thermal expansion of the expandable graphite when exposed to flame. The graphite expands dramatically upon heating, creating an insulating barrier that provides flame resistance without requiring the entire garment to be made from heavy, inherently flame resistant materials.
5Ease of manufacture
If flammable, meltable materials are used for protective garments, then comfort and cost are improved, but afterflame time increases when exposed to flame
Solution Approach 1:
The heat reactive material undergoes phase transition through thermal expansion when exposed to flame, creating a physical barrier that prevents sustained combustion. The expandable graphite expands and forms an insulating char layer that smothers the flame and prevents afterflame, allowing the use of flammable base materials without suffering from prolonged burning.
Solution Approach 2:
The patent converts the harmful effect of flammable materials into a benefit by using the heat from the flame itself to trigger the expansion of the heat reactive material. The flame heat activates the expandable graphite to expand and form a protective barrier that then prevents further burning, effectively using the harmful thermal energy to create the protective response.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The textile composite achieves a significant reduction in afterflame time and char length, enhanced breathability, and improved comfort while maintaining flame resistance, making it suitable for hazardous environments without the drawbacks of traditional materials.
Implementation Method 1
the expandable graphite has an expansion of at least 900 μm upon heating to 280° C.
Implementation Method 2
an endotherm greater than 100 J/g
Implementation Method 3
providing a heat reactive material comprising a polymer resin-expandable graphite mixture
Data Source
AI summary
A method is described for reducing the afterflame of a flammable, meltable material. A textile composite is described comprising an outer textile comprising a flammable, meltable material, and a heat reactive material comprising a polymer resin-expandable graphite mixture.