Fire Resistant Laminates Using Segmented Meltable Textile Layers
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Solution Overview
Problem
Conventional flame-resistant protective clothing is heavy, non-breathable, and expensive due to the use of thick, inherently flame-resistant textiles and heavy flame retardant coatings, which limits its suitability for hazardous environments where lightweight, comfortable, and affordable options are needed.
Innovation Solution
A laminate construction featuring a meltable textile outer layer laminated with a waterproof film and a thermally stable inner layer, using adhesives and materials like polyurethanes and expanded PTFE to achieve breathability, water resistance, and flame resistance without the need for expensive, inherently flame-resistant fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inherently flame-resistant textiles (KEVLAR®, NOMEX®) are used for protective clothing, then flame resistance is improved, but cost and tactile comfort worsen
Solution Approach 1:
The protective clothing is divided into multiple layers: an outer meltable textile layer that provides initial flame barrier, an intermediate waterproof breathable membrane layer, and an inner comfort layer. This segmentation allows each layer to perform specific functions, with the outer layer sacrificing itself to protect the wearer, thereby reducing the need for expensive inherently flame-resistant materials throughout the entire garment.
Solution Approach 2:
A waterproof breathable membrane is introduced as an intermediary layer between the outer meltable textile and the inner clothing layers. This membrane provides the flame-resistant barrier function while allowing the outer layer to use cheaper meltable textiles, thus reducing overall cost while maintaining flame protection.
2Reliability
If heavy flame retardant coatings are applied to non-flame resistant fabrics, then flame resistance is improved, but breathability and weight worsen
Solution Approach 1:
Instead of using heavy flame retardant coatings, the invention employs a thin waterproof breathable membrane as the flame-resistant barrier. This thin film provides effective flame protection while maintaining breathability and flexibility, allowing moisture vapor to pass through while blocking flames and liquids.
Solution Approach 2:
The waterproof breathable membrane utilizes a porous structure with microscopically small pores that allow water vapor molecules to pass through while blocking liquid water and flame. This porous architecture enables the membrane to provide flame resistance without compromising breathability or adding significant weight.
3Reliability
If thick insulative layers of inherently flame-resistant aramid fabrics are used, then flame protection is improved, but weight and comfort worsen
Solution Approach 1:
The protective function is segmented across multiple thin layers rather than using a single thick layer of heavy aramid fabric. The outer meltable textile layer provides initial flame barrier, the waterproof breathable membrane provides the primary flame-resistant barrier, and the inner layers provide comfort and moisture management, collectively achieving flame protection with reduced weight.
Solution Approach 2:
The waterproof breathable membrane serves as a thin film that provides the primary flame-resistant barrier function. This thin film replaces the need for thick insulative layers of heavy aramid fabric, significantly reducing garment weight while maintaining effective flame protection.
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 laminate construction results in lightweight, breathable, waterproof, and flame-resistant garments that are easy to color and dry quickly, offering improved comfort and affordability while maintaining effective flame protection.
Implementation Method 1
a waterproof film layer oriented adjacent the inner surface of the meltable outer textile layer
Implementation Method 2
a first adhesive layer bonding the meltable outer textile layer to the waterproof film layer
Data Source
AI summary
Laminates suitable for constructing waterproof and breathable articles such as protective clothing which are both comfortable and exhibit enhanced resistance to fire are described. Particularly, flame resistant laminate constructions are described comprising a meltable textile as the outermost layer laminated to an intermediate protective layer comprising a waterproof film laminated to an innermost fabric layer comprising a thermally stable textile. Laminate constructions of the present invention exhibit breathability on the order of at least 1000 MVTR, a water entry pressure of at least 0.5 psi and have a horizontal flame break open time of at least 10 seconds.