Flame-Resistant Composite Garment with Heat-Reactive Char Layer
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Solution Overview
Problem
Traditional flame-resistant protective garments are often heavy, expensive, difficult to dye, and lack abrasion resistance, while also providing inadequate tactile comfort and water absorption, making them unsuitable for occasional fire exposure scenarios where weight and usability are critical.
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 the inner layer, forming a char with a high melt point that provides insulation upon exposure to flames, while the facial layer maintains the appearance and feel of conventional garments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inherently flame resistant fibers (aramids, PBI, PBO) are used for protective garments, then flame resistance is improved, but cost, dyeability, and tactile comfort deteriorate
Solution Approach 1:
The patent uses a composite structure with an outer flammable layer (nylon or polyester) combined with an inner heat reactive layer containing expandable graphite and polymer resin. This composite approach achieves flame resistance without relying on expensive inherently flame resistant fibers, thereby reducing cost while maintaining protective functionality.
Solution Approach 2:
The patent changes the physical and chemical parameters of the material response to heat. Instead of using materials that are inherently flame resistant, the composition undergoes parameter changes when exposed to heat - the polymer resin melts and the expandable graphite expands to form a protective char layer, achieving flame resistance through thermal transformation rather than inherent properties.
2Reliability
If inherently flame resistant fibers are used for protective garments, then flame resistance is improved, but weight and tactile comfort deteriorate
Solution Approach 1:
The patent employs a composite structure where a lightweight flammable outer layer (nylon or polyester) is combined with a thin heat reactive layer containing expandable graphite and polymer resin. This composite design achieves flame resistance with significantly reduced weight compared to garments made entirely from heavy inherently flame resistant fibers.
3Reliability
If inherently flame resistant fibers are used for protective garments, then flame resistance is improved, but water absorption and tactile comfort deteriorate
Solution Approach 1:
The patent creates a composite garment where the outer layer is made of nylon or polyester, which provides superior tactile comfort and water absorption properties compared to inherently flame resistant fibers. The flame resistance function is achieved through the inner heat reactive layer, allowing the outer layer to be optimized for comfort without compromising protection.
4Reliability
If expandable graphite coating is applied to textile, then flame resistance is improved, but surface appearance and production consistency deteriorate
Solution Approach 1:
The patent uses a composite heat reactive layer containing both expandable graphite and polymer resin. The polymer resin acts as a binder that creates a uniform matrix, distributing the expandable graphite evenly and preventing surface irregularities. This composite approach maintains production consistency and surface appearance while achieving effective flame resistance.
Solution Approach 2:
The polymer resin serves as an intermediary material that binds the expandable graphite particles together and to the textile substrate. This intermediary layer ensures uniform distribution and adhesion, preventing the graphite from creating surface defects while maintaining the flame reactive functionality.
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 results in a lightweight, waterproof, and aesthetically pleasing garment with enhanced burn protection, reduced production costs, and improved production flexibility, accommodating various colors and patterns without compromising flame resistance or breathability.
Implementation Method 1
forming a char with a high melt point that provides insulation upon exposure to flames
Implementation Method 2
the heat reactive material is disposed between the meltable layer and the inner layer, forming a char with a high melt point
Implementation Method 3
A lightweight flame-resistant composite article comprising a meltable layer, a heat reactive material with a polymer resin and graphite
Data Source
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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.