Warp-Backed Fire Resistant Textile for Break Open Protection

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Solution Overview

Problem

Current fire-resistant textile materials for firefighter garments, particularly those using meta-aramid and para-aramid fibers, face issues with shrinkage, charring, and embrittlement when exposed to high temperatures, leading to inadequate break open protection and physical property deterioration.

Innovation Solution

A single, woven warp-backed fabric is developed using a combination of meta-aramid, para-aramid, polyamideimide, polybenzimidazole, and polybenzoxazole fibers, with a specific ratio of face warp threads to weft threads that provides enhanced break open resistance and thermal stability, while maintaining flexibility and reducing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If meta-aramid and para-aramid fibers are used in the fabric blend, then break open protection is improved, but the fabric shrinks, consolidates and thickens when exposed to high temperature heat sources

Engineering Contradiction:

Improvebreak open protectionVSAvoidfabric dimensional stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent changes the weave structure parameters by creating a specific relationship between face warp threads and back warp threads, where back warp threads interlace or pass under successive weft threads in a controlled ratio (1:2 to 1:20). This parameter change allows the fabric to maintain dimensional stability while preserving the protective properties of meta-aramid and para-aramid fibers during heat exposure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite fabric structure combining face warp threads (providing protective function) with back warp threads (providing dimensional stability). This composite approach allows the fabric to simultaneously achieve break open protection and resistance to shrinkage/consolidation when exposed to high temperatures.

Inventive Principle:

Principle #40Composite materials

2Reliability

If para-aramid fiber is included in the blend to prevent fiber shrinkage, then break open protection is improved, but the fabric still breaks open in tightly woven fabrics

Engineering Contradiction:

Improvebreak open protectionVSAvoidweave tightness control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent segments the warp threads into two functional groups: face warp threads that provide the primary protective barrier and back warp threads that provide structural support and prevent breaking open. This segmentation allows each group to perform its specific function effectively, with back warp threads preventing fabric failure even in tightly woven configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent adds a dimensional aspect to the fabric structure by introducing back warp threads that interact with weft threads in a specific pattern. This creates a three-dimensional structural reinforcement that prevents fabric breaking open, addressing the limitation of traditional two-layer woven structures.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If double cloth fabric structure is used to provide break open protection, then protective performance is improved, but the garment weight increases and flexibility decreases

Engineering Contradiction:

Improvebreak open protectionVSAvoidgarment weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the protective function and structural support function into a single fabric structure by integrating face warp threads and back warp threads in one weave. This eliminates the need for separate protective and structural layers required in double cloth constructions, thereby reducing weight while maintaining break open protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The back warp threads serve multiple functions: they provide structural support, prevent fabric breaking open, and maintain dimensional stability. This multi-functionality eliminates the need for additional separate layers, reducing overall garment weight while preserving protective performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If meta-aramid and para-aramid fibers are used in the fabric, then break open protection is improved, but the fabric chars, cracks and embrittles when exposed to high temperature heat sources

Engineering Contradiction:

Improvebreak open protectionVSAvoidphysical property strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The back warp threads act as a pre-established support structure that cushions and prevents fabric failure during heat exposure. This structural reinforcement is built into the fabric before use, preventing char-induced cracking and embrittlement from causing fabric breakdown.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent creates a composite structure where back warp threads provide structural integrity that compensates for the degradation of face warp threads during heat exposure. This composite approach maintains physical strength even when the protective fibers undergo thermal degradation.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12152320B2Fire resistant textile material

Publication Date: 2024.11.26 A W HAINSWORTH & SONS

AI summary

A fire resistant textile material comprising a fire resistant textile material comprising a woven face fabric composed of fibres selected from: meta-aramid, para-aramid, polyamideimide and mixtures thereof; wherein the number of warp face threads, per unit width (cm) is greater than the number of weft threads, per unit length (cm).