Flame resistant composite articles and methods

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Solution Overview

Problem

Traditional flame-resistant protective garments for hazardous environments are often heavy, expensive, difficult to dye or print, and lack adequate abrasion resistance and tactile comfort, while also being impractical for occasional exposure to fire and extreme heat.

Innovation Solution

A lightweight flame-resistant composite article comprising a meltable layer, a heat reactive material with a polymer resin and graphite, and a facial layer, where the heat reactive material is disposed between the meltable layer and an inner layer, forming a char with high insulation properties when exposed to flames, and a facial layer that masks surface deformations and bleed-through, allowing for a range of colors and patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If inherently flame resistant fibers (aramids, PBI, PBO) are used, then flame resistance is improved, but cost, dyeability, and tactile comfort deteriorate

Engineering Contradiction:

Improveflame resistanceVSAvoidcost and dyeability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses a composite structure combining conventional textile fibers with inherently flame resistant fibers in specific ratios (e.g., 70-90% conventional fibers, 10-30% flame resistant fibers). This composite approach provides adequate flame resistance while significantly reducing cost and improving dyeability compared to 100% inherently flame resistant fabrics.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies flame resistant properties locally rather than throughout the entire fabric. By incorporating flame resistant fibers only in specific proportions and distributions within the composite structure, the garment achieves necessary flame protection at critical areas while maintaining cost-effectiveness and manufacturability of the overall fabric.

Inventive Principle:

Principle #3Local quality

2Reliability

If inherently flame resistant fibers are used, then flame resistance is improved, but weight and tactile comfort deteriorate

Engineering Contradiction:

Improveflame resistanceVSAvoidgarment weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The composite fabric structure allows blending lighter conventional fibers (nylon, polyester) with smaller proportions of flame resistant fibers, achieving flame protection while maintaining lower overall weight compared to solid inherently flame resistant fabrics.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the compositional parameters of the fabric by controlling the ratio of conventional to flame resistant fibers, enabling optimization of weight versus flame resistance trade-offs for different application requirements.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If inherently flame resistant fibers are used, then flame resistance is improved, but appearance and printability deteriorate

Engineering Contradiction:

Improveflame resistanceVSAvoidappearance and printability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By using composite fabrics with predominantly conventional fibers (which have good dyeability and printability) combined with smaller amounts of flame resistant fibers, the patent maintains excellent appearance quality and printability while achieving adequate flame resistance.

Inventive Principle:

Principle #40Composite materials

4Reliability

If traditional flame resistant fabrics are used, then flame resistance is improved, but water absorption and tactile comfort deteriorate

Engineering Contradiction:

Improveflame resistanceVSAvoidtactile comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The composite structure combines hydrophobic conventional synthetic fibers with flame resistant fibers, creating a fabric that repels water better and feels softer against the skin compared to 100% inherently flame resistant natural or cellulose-based fabrics.

Inventive Principle:

Principle #40Composite materials

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 solution provides a lightweight, aesthetically pleasing, and cost-effective garment with enhanced burn protection and improved production flexibility, maintaining the appearance and feel of traditional garments while offering robust flame resistance and waterproofness.

Implementation Method 1

the combination of the meltable layer and the heat reactive material form a char when exposed to flame... The carbonaceous char has a very high melt point and provides insulation for those materials beneath the char

Methodology Applied

Scientific EffectChar formation: Pyrolysis

Implementation Method 2

The carbonaceous char has a very high melt point and provides insulation for those materials beneath the char

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

a meltable layer; a heat reactive material comprising a polymer resin and a graphite... the combination of the meltable layer and the heat reactive material form a char when exposed to flame

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11672292B2Flame resistant composite articles and methods

Publication Date: 2023.06.13 W L GORE & ASSOC GK

AI summary

Described are flame resistant composite articles and methods for making and using. A flame resistant composite article is described comprising a facial layer, a meltable layer, a heat reactive material, and an inner layer that provide lightweight flame resistance and can accommodate printing and a large number of appearance options.