Fiber Blend for Flame Resistance and Moisture Management
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Solution Overview
Problem
Current flame-resistant fabrics often compromise on comfort and moisture management properties, are not dye accepting, and may lose effectiveness with repeated washing, making them impractical for industrial and work environments.
Innovation Solution
A spun yarn blend comprising 55-70% meta-aramid fiber, 7-15% nylon fiber, 5-15% para-aramid fiber, 2-5% anti-static fiber, and 10-15% hydrophilic fiber, which is intimately blended to provide both flame resistance and superior moisture management, comfort, and dye acceptance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame-resistant fibers (aramid) are used to provide thermal protection, then flame resistance is improved, but comfort and moisture management deteriorate due to hydrophobic properties
Solution Approach 1:
The patent uses composite fiber blends combining aramid fibers (for flame resistance) with hydrophilic fibers like cotton, rayon, or linen (for moisture management and comfort). This composite approach allows the fabric to simultaneously achieve thermal protection and comfort properties that neither fiber type could provide alone.
Solution Approach 2:
The invention applies different fiber types in specific proportions (aramid: 40-80%, hydrophilic: 20-60%) to create zones of different properties within the fabric structure, allowing the outer layer to provide flame resistance while inner layers manage moisture and provide comfort against the skin.
2Ease of operation
If hydrophilic fibers are added to improve moisture management, then comfort is improved, but flame resistance deteriorates
Solution Approach 1:
The patent carefully controls the proportion of hydrophilic fibers within 20-60% of the total blend, and specifies that these fibers should be inherently flame-resistant varieties (such as flame-resistant cotton or rayon). This parameter control ensures moisture management is improved while flame resistance is maintained through the synergistic effect of the blend ratios and fiber selection.
3Reliability
If aramid fiber content is increased to improve flame resistance, then thermal protection is improved, but softness and drape properties deteriorate
Solution Approach 1:
The patent combines stiff aramid fibers with softer hydrophilic fibers in a composite blend, where the softer fibers fill in the rigid structure of the aramid, providing drape and softness while the aramid maintains flame resistance. This composite structure achieves a balance between protection and comfort.
Solution Approach 2:
The invention creates a fabric structure where aramid fibers provide structural integrity and flame resistance in the outer framework, while hydrophilic fibers provide softness and drape in the interstitial spaces, allowing different regions of the fabric to serve different functional purposes.
4Reliability
If flame-resistant treatment is applied to fabric to provide protection, then flame resistance is improved, but effectiveness is lost with repeated washing
Solution Approach 1:
The patent uses inherently flame-resistant fibers (aramid and flame-resistant hydrophilic fibers) that possess flame-resistant properties as an intrinsic characteristic of the fiber material itself, rather than through applied coatings. This self-service approach ensures flame resistance is built into the fiber structure and cannot be washed out, providing durable protection throughout the garment's service life.
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 fiber blend achieves a balance of flame resistance, thermal shrinkage resistance, and moisture management, maintaining performance and comfort even after multiple washes, with the ability to be dyed or printed, enhancing wearer compliance and safety.
Implementation Method 1
hydrophilic fiber, selected from the group consisting of cellulose, cellulose derivatives, wool, and combinations thereof
Implementation Method 2
meta-aramid fiber and para-aramid fiber
Data Source
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AI summary
Spun yarns, fabrics, and garments with a balance of high thermal and comfort properties are disclosed. Spun yarns made with an intimate blend of fibers including flame resistant fiber, hydrophilic fibers, and anti-static fibers are described. The unique combination of fibers in the spun yarn and fabrics made therefrom provide a balance of high thermal properties, including flame resistance and thermal shrinkage resistance, as well as moisture management properties to provide both protection and comfort to the wearer. In addition, a spun yarn and fabric made therefrom may be dye accepting and/or can be printed thereon. In one embodiment, printable or dye accepting aramid fiber, or producer dyed meta-aramid is utilized in the spun yarn. A fabric made with the spun yarn may have pre-wash softness that makes it comfortable to wear.