Two-Layer Flame-Retardant Fabric for Heat-Resistant Protective Garments
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Solution Overview
Problem
Conventional heat-resistant protective fabrics face challenges in balancing mechanical properties, thermal insulation, abrasion resistance, and appearance, with existing methods like ripstop weave and core yarn-type spun yarns resulting in uneven surfaces, reduced abrasion resistance, and increased production costs.
Innovation Solution
A two-layer fabric structure featuring a flame-retardant base cloth with a heat-resistant high-strength reinforcing cloth, connected by warp and weft yarns, forming an integral structure with a thermal insulation air space, enhancing tear strength, dimensional stability, and appearance while maintaining light weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ripstop weave is used to improve tear propagation resistance, then tear propagation resistance increases by about 30%, but lattice pattern and unevenness are formed on the outer side resulting in lower abrasion resistance and poor appearance
Solution Approach 1:
The fabric is divided into two separate layers: a base cloth layer that provides a smooth outer surface for good appearance and abrasion resistance, and a reinforcing cloth layer that provides tear propagation resistance. The layers are connected by connecting yarns to form an integral structure, allowing each layer to fulfill its specific function without compromising the other.
2Strength
If core yarn-type bicomponent spun yarn is used to improve mechanical properties, then mechanical properties improve, but production complexity increases and fine count yarn production becomes difficult
Solution Approach 1:
The invention uses a composite structure of two different fabrics (base cloth and reinforcing cloth) connected by connecting yarns, rather than relying on complex core yarn-type bicomponent spun yarns. This approach achieves improved mechanical properties through the combination of materials and structure, while avoiding the production complexity and limitations of fine count yarn production associated with core yarn methods.
3Strength
If heat-resistant high-strength fiber is introduced regularly into fabric to improve mechanical properties, then mechanical properties improve, but the fabric deteriorates by light during use and becomes whitened by repeating washing
Solution Approach 1:
The heat-resistant high-strength fiber is localized to the reinforcing cloth layer, which is positioned on the inner side or less exposed side of the fabric structure. The base cloth layer that forms the outer surface uses materials with good light resistance and color fastness. This spatial separation allows each layer to have the quality appropriate for its function and position, resolving the contradiction between strength improvement and light resistance.
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 two-layer fabric achieves improved thermal insulation, abrasion resistance, and appearance, with increased tear strength and dimensional stability, making it suitable for heat-resistant protective clothing for firefighters and hazardous environments.
Implementation Method 1
A two-layer fabric has an upper-side base cloth comprising a flame-retardant fiber and a lower-side reinforcing cloth comprising a reinforcing yarn containing a heat-resistant high-strength fiber as a main component, the reinforcing cloth being connected to the base cloth by a warp yarn and a weft yarn of the base cloth, to form an integral structure
Data Source
AI summary
A two-layer fabric according to the present invention has an integral structure containing a base cloth on the upper side and a reinforcing cloth for reinforcing the entire fabric on the under side, wherein (a) the base cloth of the two-layer fabric is flame-retardant and contains a warp yarn and a weft yarn containing 30% by weight or more of a flame-retardant fiber having a limiting oxygen index (LOI) of 26 or more and a tensile strength of 8 cN/dtex or less, (b) the reinforcing cloth of the two-layer fabric contains a warp yarn and a weft yarn containing a heat-resistant high-strength fiber having a tensile strength of 15 cN/dtex or more as a main component, and (c) the base cloth and the reinforcing cloth are connected by the warp yarn and/or the weft yarn of the base cloth, to form the integral structure. Further, a heat-resistant protective clothing contains an outer fabric layer of the two-layer fabric, stacked and sutured by sewing. The heat-resistant protective clothing has improved properties such as a thermal insulation property and abrasion resistance, in addition to excellent appearance.