Flame-Resistant Yarn Composition for Lower Burn and Shrinkage
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Solution Overview
Problem
Existing flame-resistant garments made from meta-aramid polymer fibers do not provide sufficient protection against flash fires, as they result in high body burn predictions and significant dimensional shrinkage during exposure, failing to meet the enhanced safety requirements needed for workers in hazardous environments.
Innovation Solution
Incorporating a polymer blend of meta-aramid and polyvinylpyrrolidone (PVP) into the fibers of flame-resistant garments, specifically in a ratio of 85-97% meta-aramid to 3-15% para-aramid, enhances the protective performance by reducing body burn predictions and shrinkage, as demonstrated by thermal manikin testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If meta-aramid polymer fiber is used for flame-resistant garments, then fire resistance is provided, but body burn prediction is high and dimensional shrinkage is significant during flash fire exposure
Solution Approach 1:
The patent applies composite materials by blending meta-aramid polymer (providing fire resistance) with PVP polymer (reducing body burn and shrinkage). This composite fiber structure allows the garment to maintain fire resistance while significantly reducing body burn prediction and dimensional shrinkage during flash fire exposure, resolving the contradiction between fire resistance and harmful thermal effects.
2Reliability
If meta-aramid polymer fiber is used for flame-resistant garments, then fire resistance is provided, but dimensional shrinkage is significant during flash fire exposure
Solution Approach 1:
The patent uses composite materials by combining meta-aramid polymer with PVP polymer in a blended fiber. The PVP component acts as a dimensional stabilizer that reduces shrinkage during flash fire exposure while the meta-aramid provides fire resistance. This composite structure simultaneously addresses both fire resistance and dimensional stability requirements.
3Object-affected harmful factors
If PVP polymer is added to meta-aramid polymer blend, then body burn prediction is reduced, but fiber composition complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the PVP polymer content within a specific range (5-15 weight percent). This controlled parameter adjustment reduces body burn prediction while maintaining manageable fiber composition complexity. The defined concentration range ensures sufficient protective performance without excessive complexity in fiber formulation and processing.
Data Source
AI summary
A flame-resistant garment comprising a flame-resistant fabric, and the flame resistant fabric, each comprising a yarn comprising a) 85 to 97 weight percent of a meta-aramid fiber component, and b) 3 to 15 weight percent of a fiber made from para-aramid polymer, based on the total amount of a) and b) in the yarn; wherein the meta-aramid fiber component is:i) 50 to 100 weight percent fiber made from a polymer blend of meta-aramid polymer and polyvinylpyrrolidone (PVP) polymer, the polymer blend comprising 88 to 95 weight percent meta-aramid polymer and 5 to 12 weight percent PVP polymer, andii) 0 to 50 weight percent fiber made solely from meta-aramid polymer, based on the total amount of i) and ii) in the meta-aramid fiber component.