Waffle Knitted Fabric Layer for Protective Clothing Breathability
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Solution Overview
Problem
Existing protective clothing for emergency services, such as firefighting, faces challenges in achieving a balance between breathability and heat resistance, with current fabric structures either compromising on breathability for heat resistance or increasing weight, which limits their effectiveness and comfort.
Innovation Solution
Incorporating a knitted fabric with a waffle structure as an additional layer between the outer fabric and the moisture barrier, which enhances heat resistance and breathability while maintaining waterproofness, and arranging the climate membrane towards the lining for improved moisture removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional multi-layer fabric structure is used to ensure heat resistance and waterproofness, then protection performance is improved, but breathability deteriorates
Solution Approach 1:
The fabric structure is divided into multiple functional layers: outer fabric, additional knitted fabric layer, moisture barrier with climate membrane, and lining. Each layer performs a specific function, with the knitted fabric layer providing breathability through its loop structure while the climate membrane handles moisture transport, resolving the contradiction between heat resistance and breathability through functional segmentation
Solution Approach 2:
The invention combines different material types with complementary properties: the outer fabric provides heat and flame resistance, the knitted fabric adds breathability and thermal insulation, and the climate membrane ensures waterproofness while allowing vapor transmission. This composite structure achieves both heat resistance and breathability simultaneously
2Temperature
If additional insulating fabric is added to improve heat resistance, then thermal protection is improved, but weight increases
Solution Approach 1:
The knitted fabric layer is strategically positioned between the outer fabric and moisture barrier, providing localized thermal insulation exactly where needed to protect against external heat sources. This targeted approach improves heat resistance without adding excessive weight throughout the entire garment structure
Solution Approach 2:
The knitted fabric's inherent porous loop structure provides thermal insulation through trapped air pockets, achieving heat resistance through the material's structural properties rather than adding dense, heavy insulating layers. This allows thermal protection with minimal weight increase
3Ease of operation
If the climate membrane is arranged towards the outer fabric, then moisture transport is improved, but heat protection deteriorates
Solution Approach 1:
The moisture management function is segmented from the thermal protection function: the climate membrane handles moisture transport by facing the outer fabric, while the knitted fabric layer positioned between the outer fabric and moisture barrier provides the thermal insulation buffer, allowing both functions to optimize their performance without conflict
Solution Approach 2:
The knitted fabric layer acts as an intermediary between the outer fabric and the climate membrane, providing thermal insulation while allowing the membrane to maintain its optimal orientation for moisture transport. This intermediate layer mediates between the conflicting requirements of heat protection and breathability
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
This configuration increases heat resistance indices by 15-40% and breathability by 10-35%, allowing emergency services to endure higher temperatures for longer without significant weight increase, thus improving overall performance and comfort.
Implementation Method 1
the air cushion created by the additional knitted fabric is retained, so that here there is a further improvement in heat protection
Implementation Method 2
transports moisture that forms on the skin to the outer surface of the garment
Implementation Method 3
this additional insulation improves the heat resistance of the protective clothing, but at the same time reduces the moisture transport to the outside
Data Source
Figure 1a~1c
Figure 2~4
AI summary
The fabric structure (100) has an outer fabric (2), a lining fabric (3), and a moisture barrier (4) arranged between the outer fabric and the lining fabric. The moisture barrier runs over an air-conditioning membrane (40), which is laminated on a carrier material. A knitted fabric layer (5) with a grid-like structure is arranged between the outer fabric and the moisture barrier. The air-conditioning membrane is turned towards the lining fabric. The moisture barrier comprises distance elements on sides of the carrier material.