Flame Resistant Knit Article with Segmented Nanoweb Bonding
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Solution Overview
Problem
Current protective clothing for firefighters, such as neck and head coverings, lacks effective protection against both flame resistance and particulate ingress, particularly after repeated laundering, and often compromises on flexibility and durability.
Innovation Solution
A durable multilayer fabric laminate comprising a first and second flame-resistant knitted fabric with an internal flame-resistant nonwoven fabric, allowing for localized movement and attachment points to maintain flexibility while providing consistent protection against flames and particles, with the nonwoven fabric positioned between the knitted fabrics to enhance particulate resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a nanoweb is face-to-face bonded to outer fabrics to provide stability and prevent localized movement, then the nanoweb is protected from destruction, but the laminate loses flexibility and comfort required for neck coverings and hoods
Solution Approach 1:
The bonding between nanoweb and outer fabrics is segmented into discrete attachment points rather than continuous bonding. This allows the nanoweb to be secured at specific locations while leaving other areas unattached, enabling localized movement and flexibility in the laminate structure.
Solution Approach 2:
The laminate structure transitions from a static, fully bonded configuration to a dynamic configuration where the nanoweb can move relative to the outer fabrics in unattached areas. This dynamic capability allows the material to adapt to body movements and maintain comfort while preserving stability at bonded points.
2Reliability
If lightweight nanoweb is bonded to outer fabrics to provide particle filtration, then filtration efficiency is improved, but the laminate becomes less durable after repeated laundering
Solution Approach 1:
The bonding is divided into discrete attachment points rather than continuous bonding. This segmentation reduces the total bonding area and associated friction, minimizing damage to the lightweight nanoweb during laundering while maintaining filtration efficiency at the bonded points.
Solution Approach 2:
Different regions of the laminate have different bonding characteristics - attached areas provide stability and filtration, while unattached areas provide flexibility and reduce friction-induced damage. This local differentiation optimizes both durability and filtration performance.
3Object-affected harmful factors
If multiple thick layers of materials are used to protect against particle ingress, then particle protection is improved, but the gear becomes less flexible and more cumbersome
Solution Approach 1:
The invention combines nanoweb material with outer fabrics to create a composite laminate that provides particle filtration while maintaining flexibility. The nanoweb's fine structure offers superior filtration compared to traditional thick layers, while the composite structure preserves comfort.
Solution Approach 2:
The protective function is concentrated at discrete attachment points where the nanoweb bonds to the outer fabric, rather than requiring continuous thick layers throughout. This segmentation allows particle protection where needed while maintaining flexibility in unattached areas.
Data Source
Figure 1~2
AI summary
An article of protective clothing comprising a durable multilayer fabric laminate formed from i) a first flame resistant knitted fabric made from yarns, the fabric having an average fabric modulus of 8 grams-force of greater; ii) a flame-resistant nonwoven fabric having a machine direction and a cross direction, and consisting of a plurality of continuous filaments having a diameter of less than 1000 nm, the filaments in the fabric being substantially oriented parallel with the machine direction and having stretch and recovery in the cross direction; and iii) a second flame resistant knitted fabric made from yarns, the fabric having an average fabric modulus of 8 grams-force of greater; wherein the nonwoven fabric is positioned between and coextensive with the first and second flame-resistant knitted fabrics; the nonwoven fabric being attached to the first knitted fabric by a set of first attachment points, the attachment points defining a first unattached area having a first effective diameter; the nonwoven fabric also being attached to the second knitted fabric by a set of second attachment points, the attachment points defining a second unattached area having a second effective diameter; wherein both the first unattached area and the second unattached area each have a value A, in square centimeters, according to the formula: C < A </= (14* B) + 100 the value B being the sum of the average fabric modulus of the first knitted fabric and the average fabric modulus of the second knitted fabric, in grams-force; and the value C being 5 square centimeters.