CHEMICAL-RESISTANT FABRIC

Abstract

In some embodiments, a chemical-resistant fabric with improved resistance to chemical penetration, may include a plurality of yarns and a protective coating on a surface of the plurality of yarns. Each of the plurality of yarns may include one or more blended fabric. Each blended fabric may include one or more Aramid fibers, one or more moisture-wicking fabrics, and elastane. The protective coating includes at least one of a durable water repellent (DWR) coating or a chemical-repellent coating.

Claims

1. A chemical-resistant fabric with improved resistance to chemical penetration, comprising: a plurality of yarns, each yarn comprising one or more blended fabric, wherein each blended fabric comprises one or more Aramid fibers, one or more moisture-wicking fabrics, and elastane; and a protective coating on a surface of the plurality of yarns, wherein the protective coating includes at least one of a durable water repellent (DWR) coating or a chemical-repellent coating.

2. The chemical-resistant fabric of claim 1, wherein the one or more Aramid fibers comprises an aromatic polyamide.

3. The chemical-resistant fabric of claim 1, wherein the one or more moisture-wicking fabrics comprise at least one of polyester, nylon, or polypropylene.

4. The chemical-resistant fabric of claim 1, wherein the chemical-resistant fabric is a tight knit fabric.

5. The chemical-resistant fabric of claim 1, wherein the plurality of yarns are dyed.

6. A method of manufacturing a chemical-resistant fabric with improved resistance to chemical penetration, the method comprising: (a) blending one or more Aramid fibers, one or more moisture-wicking fabrics, and elastane to prepare a plurality of blended fabrics; (b) preparing a plurality of yarns, each comprising one or more blended fabrics of the plurality of blended fabrics; (c) preparing the chemical-resistant fabric by weaving or knitting the plurality of yarns; and (d) applying a protective coating on a surface of the chemical-resistant fabric, wherein the protective coating includes at least one of a durable water repellent (DWR) coating or a chemical-repellent coating.

7. The method of claim 6, wherein the one or more Aramid fibers comprises an aromatic polyamide.

8. The method of claim 6, wherein the one or more moisture-wicking fabrics comprise at least one of polyester, nylon, or polypropylene.

9. The method of claim 6, wherein the step (c) comprises: knitting, by a knitting machine, the plurality of yarns by adjusting a tension of the knitting machine to at least 70% of a maximum tension provided by the knitting machine;

10. The method of claim 6, further comprising: after the step (c), dyeing the chemical-resistant fabric.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] These and other aspects and features of the present embodiments will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying figures, wherein:

[0005] FIG. 1 is an example flowchart for performing a process of manufacturing a chemical-resistant fabric, according to some embodiments.

[0006] FIG. 2 is a diagram illustrating an example chemical-resistant fabric, according to some embodiments.

[0007] FIG. 3A and FIG. 3B are diagrams illustrating example garments made from a chemical-resistant fabric, according to some embodiments.

[0008] FIG. 4A and FIG. 4B are diagrams illustrating an example chemical-resistant fabric, according to some embodiments.

DETAILED DESCRIPTION

[0009] According to certain aspects, implementations in the present disclosure relate to a chemical-resistant fabric and methods for manufacturing the same.

[0010] In one aspect, exposure to chemicals is a significant risk in many environments (e.g., in a laboratory). The need for a protective garment is critical for people who work in these environments (e.g., biologists, chemists, or chemical engineers, etc.). For example, in an educational lab setting where exposure to chemicals frequently occurs, the need for a protective garment is critical. A chemical problem accident can occur at any moment, and without adequate protection against chemicals, students and educators face significant risks. When chemicals penetrate a standard lab coat, it highlights the stark lack of protection and the urgent need for improved solutions. To prevent these risks, it would be preferable to have garments designed specifically for protection against chemical penetration, ensuring safety and peace of mind in the lab.

[0011] To address this problem, some embodiments of the present disclosure can provide a chemical-resistant fabric that can be used for making specially designed garments, e.g., advanced lab coats or garments with chemical protection. Some embodiments can provide materials and methods for manufacturing a garment with chemical protection. In some embodiments, a garment with chemical protection (e.g., a lab coat) can be manufactured using a protective or chemical-resistant fabric or textile designed to enhance chemical protection while ensuring elevated comfort and exclusive fashion. In some embodiments, the chemical-resistant fabric can enhance increase a protection barrier against chemical penetration to skin. For example, the chemical-resistant fabric can provide a longer barrier in time against chemical penetration to skin (e.g., 15 seconds) than that of a conventional lab coat fabric (e.g., 5 seconds). In some embodiments, the chemical-resistant fabric can be composed of a material for chemical resistance (e.g., Aramid fibers), a water-resistant material (e.g., polyester), and/or any sustainable, eco-friendly materials.

[0012] In some embodiments, the chemical-resistant fabric can include one or more blended fabrics (e.g., one or more blended textiles, one or more blended yarns). In some embodiments, the one or more blended fabrics can include (1) one or more Aramid fibers for chemical resistance, (2) a moisture-wicking material for comfort, and/or (3) elastane for flexibility. Aramid fibers refer to aromatic polyamide fibers, containing more than 85% amide bonds directly connected with aryl groups (e.g., two aryls). This kind of fiber has the following advantages: lightweight, high-strength, high-modulus, high-temperature resistance, and excellent corrosion resistance. In some embodiments, the moisture-wicking material can be at least one of polyester, nylon, or polypropylene.

[0013] In some embodiments, the one or more blended fabrics can include (1) one or more Aramid fibers and (2) a moisture-wicking material. In some embodiments, the one or more blended fabrics can include (1) one or more Aramid fibers, (2) polyester, and (3) elastane. In some embodiments, the one or more Aramid fibers may include a aromatic polyamide which is lightweight, high-temperature resistant, and high sustainable.

[0014] In some embodiments, the chemical-resistant fabric can include a protective coating (e.g., a protective coating layer) on a surface of the one or more blended fabrics (e.g., one or more blended textiles, one or more blended yarns). In some embodiments, the protective coating can be a durable, water-repellent (DWR) coating that further enhances the resistance of the chemical-resistant fabric to chemical penetration. In some embodiments, the DWR coating can include a water-repellent agent that includes fluoropolymers like polytetrafluoroethylene (PTFE or Teflon) or silicone-based compounds, and a solvent to dissolve the water-repellent agent. In some embodiments, the protective coating can be a chemical-repellent coating, serving as the first line of defense against chemical permeation. The chemical-repellent coating may include at least one of fluoropolymer-based coatings (e.g., Polytetrafluoroethylene (PTFE) or Teflon, Perfluorinated compounds (PFCs)), silicone-based coatings (e.g., Polydimethylsiloxane (PDMS)), sol-gel derived coatings, organosilane and silica-based sol-gel coatings, nanoparticle-based coatings (e.g., Titanium Dioxide (TiO.sub.2) and Zinc Oxide (ZnO) nanoparticles), and/or Polyurethane-based coatings (e.g., Polyurethane (PU) coatings).

[0015] In some embodiments, the chemical-resistant fabric can include eco-friendly, sustainable materials (e.g., recycled polyester, Econyl, Tencel, etc.) that meet industry standards for environmental impact (e.g., Occupational Safety and Health Administration (OSHA), ASTM (American Society for Testing and Materials)).

[0016] In some embodiments, a process of manufacturing a garment (e.g., lab coat) can include textile production, e.g., a process of manufacturing a chemical-resistant fabric, and design and construction of the garment. In some embodiments, the process of manufacturing a chemical-resistant fabric can include (step S1) obtaining, sourcing, or selecting fibers (e.g., high-performance fibers), (step S2) blending the selected fibers to create a blended fiber or a yarn (as a base material for the chemical-resistant fabric), (step S3) weaving or knitting the blended fiber or yarn into a tight knit fabric or a woven fabric, (step S4) dyeing the knit fabric or the woven fabric, and/or (step S5) applying a protective coating. Each step can be controlled to ensure the final product (e.g., the garment or the chemical-resistant fabric) has the desired properties (e.g., chemical/water resistance, flexibility) and appearance (e.g., adjustable appearance to accommodate different body types).

[0017] In some embodiments, in step S1, the selected fibers can include (1) one or more Aramid fibers (that can provide chemical resistance), (2) polyester (that can offer moisture management), and/or (3) elastane (that can adds flexibility). In some embodiments, in step S2, the selected fibers can be blended by (1) opening fibers (e.g., the selected fibers) and preparing for blending, (2) carding (or brushing to align) the opened fibers to remove any impurities, (3) mixing (or blending) the carded fibers together in desired proportions, (4) roving (or drawing out and twisting) the blended fibers to form a roving (e.g., a long, continuous strand of fiber), and/or (5) spinning the roving into yarn or thread (e.g., a single, blended fiber) ready for use in textiles.

[0018] In some embodiments, in step S3, a plurality of blended fibers or yarns can be woven into a woven fabric, ensuring durability and strength. In some embodiments, a plurality of blended fibers or yarns can be knitted into a tight knit fabric. In some embodiments, a knitting machine can knit the plurality of blended fibers or yarns to produce a tight knit fabric by adjusting a tension of the knitting machine to at least 70% of a maximum tension provided by the knitting machine.

[0019] In some embodiments, in step S4, the woven fabric or the tight knit fabric (as a result of step S3) can be dyed by (1) preparing the woven/knit fabric in hot water with a high concentration of fixative, (2) preparing a dye (or a dye mixture) by dissolving dye in hot water, (3) placing the woven/knit fabric in a container with enough water to cover the fabric and adding the prepared dye mixture to evenly distribute the dye mixture over the woven/knit fabric, (4) slowly heating a dye bath to a desired temperature, and/or (5) cooling and rinsing the woven/kit fabric in the dye bath.

[0020] In some embodiments, in step S5, a protective coating (e.g., a DWR coating, a chemical-repellent coating) can be applied to the woven/knit fabric. In some embodiments, the woven/knit fabric can be treated a protective coating to enhance chemical resistance. In some embodiments, the protective coating can be applied using a dip-and-dry method to ensure even distribution and maximum protection (by apply coatings to various substrates). The dip-and-dry method for a protective coating can be performed by (1) dipping or submerging the woven/knit fabric in a coating solution (e.g., DWR coating solution, chemical-repellent coating solution), (2) letting the woven/knit fabric remain in the solution for a specific period to ensure proper wetting and adhesion, (3) removing excess of the coating solution by letting excess coating solution drain off, (4) drying the coated woven/knit fabric using techniques such as air drying, baking, or using a drying oven to set the coating.

[0021] In some embodiments, in step S5, a protective coating (e.g., a DWR coating, a chemical-repellent coating) can be applied using a spray by (1) laying the woven/knit fabric flat on a clean surface, (2) holding the spray about 6-8 inches away from the fabric and spraying on the fabric evenly, covering the entire surface of the woven/knit fabric, and/or (3) letting the woven/knit fabric (with the protective coating) dry for a desired time.

[0022] In some embodiments, in step S5, a protective coating (e.g., a DWR coating, a chemical-repellent coating) can be applied by adding the protective coating to a washing machine during a gentle cycle with cold water (a wash-in method).

[0023] In some embodiments, the process of design and construction of a chemical-resistant garment (e.g., a lab coat) from the chemical-resistant fabric can include (1) pattern design, (2) cutting and sewing, and/or (3) customization. In some embodiments, a pattern design of a garment can incorporate ergonomic considerations for comfort and mobility. Special attention can be given to fit, with adjustable features to accommodate different body types. For example, the pattern design of the garment can incorporate elements like drawstrings, elastic waistbands, adjustable straps, and buttons to allow for size customization. In some embodiments, the cutting and sewing can be performed by cutting the chemical-resistant fabric into part fabrics according to the designed patterns and sewing the part fabrics together using reinforced stitching techniques to ensure durability. In some embodiments, the reinforced stitching can include at least one of double stitching, backstitching, interlocking stitches, using stronger threads, adding interfacing (e.g., corners or high-stress points), or incorporating materials like patches or tapes at critical points to provide additional support. In some embodiments, the customization can be optionally performed by adding logos, names, and other branding elements through embroidery or printing.

[0024] After manufacturing the chemical-resistant garment (e.g., a lab coat), a user can wear the lab coat by ensuring the lab coat fits properly, for example, by adjusting the cuffs, collar, and waist for a snug but comfortable fit. The user can also wear the lab coat by fastening all buttons or zippers securely to ensure full coverage and protection.

[0025] The user can practice maintenance and care of the chemical-resistant garment (e.g., a lab coat) by cleaning, drying, and/or reapplication of a protective coating (e.g., a DWR coating, a chemical-repellent coating) as follows. The lab coat can be machine washed on a gentle cycle using mild detergent. It can be avoided to use bleach or fabric softeners, as these can degrade the protective coating. The user can air dry or tumble dry the lab coat on low heat to preserve the chemical-resistant fabric's integrity and protective properties. After multiple washes of the lab coat, the user can practice reapplication of the protective coating by reapplying the protective coating using commercially available sprays (e.g., DRW sprays, chemical-repellent sprays), following the manufacturer's instructions. The user can store the lab coat in a cool, dry place away from direct sunlight and harsh chemicals to prevent degradation of the fabric and coating.

[0026] In some embodiments, a chemical-resistant fabric with improved resistance to chemical penetration, may include a plurality of yarns and a protective coating (e.g., a durable water repellent (DWR) coating, a chemical-repellent coating) on a surface of the plurality of yarns. Each of the plurality of yarns may include one or more blended fabric. Each blended fabric may include one or more Aramid fibers, one or more moisture-wicking fabrics, and elastane.

[0027] In some embodiments, the one or more Aramid fibers may include an aromatic polyamide. In some embodiments, the one or more moisture-wicking fabrics may include at least one of polyester, nylon, or polypropylene.

[0028] In some embodiments, the chemical-resistant fabric may be a tight knit fabric. In some embodiments, the plurality of yarns may be dyed.

[0029] Embodiments in the present disclosure have at least the following advantages and benefits. First, embodiments in the present disclosure can provide useful techniques for efficiently protect skin against chemical penetration by wearing a chemical-resistant garment (e.g., a lab coat) made using (1) textile blend (e.g., blended fabric/yarn) and (2) protective coating that can offer superior resistance to chemical penetration, reducing the risk of exposure.

[0030] Second, embodiments in the present disclosure can provide useful techniques for elevating comfort in wearing the chemical-resistant garment. The combination of moisture-wicking fibers and flexible materials (e.g., elastane) can ensure that the lab coat is comfortable to wear for extended periods.

[0031] Third, embodiments in the present disclosure can provide useful techniques for creating exclusive fashion. Flexible materials (e.g., elastane) in the chemical-resistant fabric can ensure that the lab coat can be designed with style in mind, offering a modern look that allows wearers to maintain a professional appearance without compromising on protection.

[0032] Fourth, embodiments in the present disclosure can provide a dual protection model. For example, the coating can act as the first level of protection (e.g., chemical-repellent surface barrier). The engineered textile itself can function as the second level of protection, with defense mechanisms built directly into the fiber structure.

[0033] Fifth, embodiments in the present disclosure can provide significant environmental and user safety benefits. By embedding protective properties directly at the fiber level, the need for excessive chemical finishing treatments is minimized. This approach results in materials that are safer for the environment and safer/gentler on the user's skin, as it reduces direct exposure to chemical additives or chemical treatments while maintaining a high level of chemical resistance.

[0034] FIG. 1 is an example flowchart for performing a process 100 of manufacturing a chemical-resistant fabric with improved resistance to chemical penetration, according to some embodiments. In some implementations, the process 100 includes more, fewer, or different steps than shown in FIG. 1.

[0035] At step (a), one or more Aramid fibers, one or more moisture-wicking fabrics, and elastane may be blended to prepare a plurality of blended fabrics. In some embodiments, the one or more Aramid fibers may include an aromatic polyamide. In some embodiments, the one or more moisture-wicking fabrics may include at least one of polyester, nylon, or polypropylene.

[0036] At step (b), a plurality of yarns may be prepared such that each of the plurality of yarns can include one or more blended fabrics of the plurality of blended fabrics.

[0037] At step (c), the chemical-resistant fabric may be prepared by weaving or knitting the plurality of yarns.

[0038] In some embodiments, the step (c) may include knitting, by a knitting machine, the plurality of yarns by adjusting a tension of the knitting machine to at least 70% of a maximum tension provided by the knitting machine. In some embodiments, the method may include after the step (c), dyeing the chemical-resistant fabric.

[0039] At step (d), a protective coating (e.g., a DWR coating, a chemical-repellent coating) may be applied on a surface of the chemical-resistant fabric.

[0040] FIG. 2 is a diagram illustrating an example chemical-resistant fabric 200 as a result of a process of manufacturing a chemical-resistant fabric (e.g., process 100), according to some embodiments. The chemical-resistant fabric 200 can include a plurality of blended fabrics or yarns 201, 202, and a protective coating 210 (e.g., a DWR coating, a chemical-repellent coating). For example, each of the blended yarns 201, 202 can include one or more Aramid fibers, one or more moisture-wicking fabrics, and elastane.

[0041] FIG. 3A and FIG. 3B are diagrams illustrating example garments 300, 350 made from a chemical-resistant fabric, according to some embodiments. Chemical-resistant fabrics or garments lab coats can be used in laboratory settings (e.g., worn by chemists, researchers, and laboratory technicians who require high levels of chemical protection). However, the present disclosure are not limited to the use in laboratory settings. Chemical-resistant fabrics or garments lab coats can be used in industrial settings (e.g., suitable for use in environments where exposure to chemicals and hazardous materials is common) or educational institutions for providing protection for students and faculty in chemistry labs and other scientific settings.

[0042] In some embodiments, a chemical-resistant fabric may include one or more layers and a coating layer. In some embodiments, the one or more layers may include, as base fibers, plant-based fibers, low-chemical contents, or blends of the plant-based fibers and the low-chemical contents. Examples of plant-based fibers include at least one of hemp, jute, ramie, sisal, abaca, pineapple, kapok, coir, bamboo, soybean, and/or banana. Examples of fibers with low-chemical contents include at least one of wool, silk and/or linen (flax). In some embodiments, each layer may be constructed using different structural configurations. For example, each of the one or more layers may have a honeycomb foundation or a honeycomb-level structure of the base fibers. This honeycomb level structure can enhance the textile's ability to resist chemical penetration while maintaining flexibility and comfort. In some embodiments, each layer may be constructed using a plain weave structure. In some embodiments, the honeycomb foundation or honeycomb-level structure of the base fibers can be manufactured by organizing the fibers into a honeycomb pattern at the foundation level. This can be achieved by weaving or structuring the fibers into interconnected hexagonal cells, either through advanced weaving techniques or by using molds/templates during fiber formation.

[0043] Compared to traditional synthetics, the one or more layers may be selected or modified for their innate resistance properties, breathability, and/or compatibility with engineered layering techniques. For example, each of the one or more layers may contributes a specific function to the overall protective barrier, including chemical repellency, delayed permeation, and/or structural durability, while maintaining comfort for the wearer. In some embodiments, each layer may include at least one of plant-based fibers (which can have innate resistance, breathability, softness, skin-friendliness), a honeycomb structure (which can have chemical repellency, durability, flexibility, breathability), plain weave (which can have structural durability, layering, even texture, adaptability), or nanofiber/micro-structure fibers (which can have chemical repellency, delayed permeation, lightweight, flexibility). This layered structure (e.g., multiple layers) may incorporate nanofibers or micro-structured fiber arrangements which are designed to trap and slow the movement of harmful substances before they reach the skin. In some embodiments, the layered structure may incorporate both synthetic and natural fibers, with a primary focus on natural fibers (e.g., natural fibers having more than 50% of the layered structure by volume or weight). These natural fibers can have embedded nano-fabrication level protection, making them inherently resistant while minimizing additional chemical load. Examples of natural fibers include at least one of cellulose (e.g., cotton, wood pulp, bamboo), silk, wool, chitosan, and/or alginate.

[0044] In some embodiments, the coating layer may include Polytetrafluoroethylene (PTFE) or Teflon, Perfluorinated compounds (PFCs), Polydimethylsiloxane (PDMS), sol-gel derived coatings, organosilane and silica-based sol-gel coatings, nanoparticle-based coatings (e.g., Titanium Dioxide (TiO.sub.2) and Zinc Oxide (ZnO) nanoparticles), and/or Polyurethane-based coatings (e.g., Polyurethane (PU) coatings). In some embodiments, following the identification of the base fiber, once the layer foundation (of the one or more layers) are complete, an additional coating stage may be considered to further enhance chemical resistance. In some embodiments, the coating layer may act as a first level of protection (e.g., chemical-repellent surface barrier), and the one or more layers (e.g., engineered textile) may function as the second level of protection with defense mechanisms built directly into the fiber structure. In some embodiments, the material of the one or more layers may build its protective capacity from the inside out.

[0045] FIG. 4A and FIG. 4B are diagrams illustrating an example chemical-resistant fabric, according to some embodiments. FIG. 4A shows a layer 400 including a honeycomb foundation or a honeycomb-level structure of base fibers. Referring to FIG. 4B, a chemical-resistant fabric may include one or more layers 400, 420 and a coating layer (not shown). In some embodiments, the one or more layers 400, 420 may include, as base fibers, plant-based fibers, low-chemical contents, or blends of the plant-based fibers and the low-chemical contents. The layer 400 may have a honeycomb foundation or a honeycomb-level structure of the base fibers as shown in FIG. 4A.

[0046] Referring to FIG. 4B, following the identification of the base fiber (e.g., plant-based fibers), once the layer foundation (of the one or more layers 400, 420) are complete, a coating machine (e.g., spray unit) 460 may apply a coating material to an outer surface of the one or more layers to form a coating layer (not shown). In some embodiments, the coating layer may act as a first level of protection, and the one or more layers 400, 420 (e.g., engineered textile) may function as the second level of protection. In some embodiments, the material of the one or more layers may build its protective capacity from the inside out.

[0047] The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects. Thus, the claims are not intended to be limited to the aspects shown herein, but is to be accorded the full scope consistent with the language claims, wherein reference to an element in the singular is not intended to mean one and only one unless specifically so stated, but rather one or more. Unless specifically stated otherwise, the term some refers to one or more. All structural and functional equivalents to the elements of the various aspects described throughout the previous description that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed as a means plus function unless the element is expressly recited using the phrase means for.

[0048] It is understood that the specific order or hierarchy of blocks in the processes disclosed is an example of illustrative approaches. Based upon design preferences, it is understood that the specific order or hierarchy of blocks in the processes may be rearranged while remaining within the scope of the previous description. The accompanying method claims present elements of the various blocks in a sample order, and are not meant to be limited to the specific order or hierarchy presented.

[0049] The previous description of the disclosed implementations is provided to enable any person skilled in the art to make or use the disclosed subject matter. Various modifications to these implementations will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of the previous description. Thus, the previous description is not intended to be limited to the implementations shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0050] The various examples illustrated and described are provided merely as examples to illustrate various features of the claims. However, features shown and described with respect to any given example are not necessarily limited to the associated example and may be used or combined with other examples that are shown and described. Further, the claims are not intended to be limited by any one example.

[0051] The foregoing method descriptions and the process flow diagrams are provided merely as illustrative examples and are not intended to require or imply that the blocks of various examples must be performed in the order presented. As will be appreciated by one of skill in the art the order of blocks in the foregoing examples may be performed in any order. Words such as thereafter, then, next, etc. are not intended to limit the order of the blocks; these words are simply used to guide the reader through the description of the methods. Further, any reference to claim elements in the singular, for example, using the articles a, an or the is not to be construed as limiting the element to the singular.

[0052] The preceding description of the disclosed examples is provided to enable any person skilled in the art to make or use the present disclosure. Various modifications to these examples will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to some examples without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the examples shown herein but is to be accorded the widest scope consistent with the following claims and the principles and novel features disclosed herein.