Welded Thermal Liner Composite for Lightweight Arc and Heat Protection
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Solution Overview
Problem
Existing composite materials for personal protective garments containing non-thermoplastic layers face challenges in achieving high protection against heat, flames, and electric arcs while maintaining low weight and being economically viable, as conventional methods like sewing or embossing require all layers to be thermoplastic.
Innovation Solution
A textile composite material comprising a thermoplastic insulation layer bonded with non-thermoplastic outer layers using plastic welding, specifically embossing or ultrasonic welding, with controlled welding conditions to integrate the thermoplastic material into the non-thermoplastic fabric structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional embossing or sewing methods are used to attach layers, then all layers must be thermoplastic to achieve durable connection, but this restricts the use of non-thermoplastic protective fibers (aramid, wool, cellulose) that are required for flame and heat resistance
Solution Approach 1:
The patent introduces a thermoplastic intermediate layer between non-thermoplastic outer layers. This intermediate layer acts as a mediator that can be welded to provide durable connection while allowing the outer layers to be made of non-thermoplastic protective materials like aramid or treated cellulose for flame resistance.
Solution Approach 2:
The patent creates a composite structure with three distinct layers: non-thermoplastic outer layers for protection, a thermoplastic intermediate layer for bonding, and non-thermoplastic inner layers for comfort. This composite approach allows each layer to fulfill its specific function while working together as a unified protective garment.
2Weight of moving object
If lightweight materials are used to reduce heat stress, then protection against heat, flames, and electric arcs may be compromised, but high protection values are required for personal protective clothing
Solution Approach 1:
The patent applies different material properties to different layers: the outer layers use heavy, flame-resistant non-thermoplastic materials for maximum protection against heat and flames, while the inner layer uses lightweight thermoplastic materials for comfort and breathability. This local differentiation allows the garment to provide high protection without excessive overall weight.
Solution Approach 2:
By combining different material types in a layered composite structure, the patent achieves both lightweight properties and high protection values. The thermoplastic intermediate layer provides structural integrity and flame resistance, while the non-thermoplastic outer layers provide additional protective barriers.
3Reliability
If non-thermoplastic fibers are used for flame resistance, then conventional welding methods cannot be applied to attach layers, but economical manufacturing is required
Solution Approach 1:
The thermoplastic intermediate layer serves as a mediator that enables conventional welding processes to be used. The outer non-thermoplastic layers are not directly welded but are attached through the thermoplastic intermediate layer, which can be economically manufactured using standard welding equipment and processes.
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 solution provides high protection with low weight and meets international standards, offering improved thermal and arc protection without increasing garment weight, while being economically feasible.
Implementation Method 1
the combined layers are pressed by a heated roller with a structured surface. The surface is so hot that it causes the layers to melt locally and to fuse together
Implementation Method 2
the combined layers are pressed by a heated roller with a structured surface
Implementation Method 3
the combined layers are pressed by a heated roller with a structured surface. The surface is so hot that it causes the layers to melt locally
Implementation Method 4
a textile composite material, such as a thermal liner composite layer, for the application in textiles, in particular in personal protective garment, for the protection against heat
Data Source
Figure 1~2
AI summary
This invention relates to a textile composite material, such as a thermal liner composite layer, for the application in textiles, in particular in personal protective garment, for the protection against heat, flames, electric arc and other threats for the health, well-being and performance of human beings. It comprises at least a frontside layer, a thermal insulation layer and a backside layer and these three layers are attached together by plastic welding. In particular the thermal liner composite layer according to the invention shall be used to protect fire-fighters, industrial workers, etc. against the threats mentioned above. Furthermore the invention relates to a method for the manufacture of this textile composite material.