THERMAL LINER FOR PROTECTIVE GARMENTS

Abstract

A nonwoven for use in a thermal liner for protective apparel includes 1-45 wt % of a first inherently heat resistant fiber excluding an aramid, and a balance of a second heat resistant fiber. The nonwoven excludes wool and has a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm). In another embodiment, the insulating layer for protective apparel includes a nonwoven including an inherently flame resistant fiber and fibers being inherently resistant to moisture absorption. The inherently flame resistant fiber is different from said inherently resistant to moisture absorption fiber. The nonwoven has an equivalent or better thermal protective performance (TPP) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both.

Claims

1. A thermal liner for protective apparel comprising: a nonwoven having 15-30 wt % of a polybenzimidazole fiber, the remaining balance being an aramid fiber, the nonwoven excluding wool and cellulosic fibers, and having a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm).

2. The thermal liner of claim 1, wherein the polybenzimidazole fiber is a first inherently heat resistant fiber and the aramid fiber is a second heat resistant fiber.

3. The thermal liner of claim 2, wherein the first inherently heat resistant fiber and the second heat resistant fiber have a water retention of less than 15%, as measured by ASTM D2402 (2012).

4. The thermal liner of claim 1, wherein the protective apparel being a firefighter's turnout gear.

5. The thermal liner of claim 1, wherein said nonwoven being a spunlaced and an apertured nonwoven.

6. The thermal liner of claim 1, further comprising a facing fabric affixed to said nonwoven.

7. The thermal liner of claim 1, further comprising multiple nonwovens.

8. A protective garment comprising a thermal liner according to claim 1.

Description

DESCRIPTION OF THE DRAWINGS

[0018] For the purpose of illustrating the invention, there is represented in the figures data from various embodiments of the invention; it being understood, however, that this invention is not limited to the data shown and that this data is not necessarily been optimized, but instead only indicates the possibilities for the inventive materials.

[0019] FIG. 1 is an illustration of a protective garment, parts broken away.

[0020] FIG. 2 is an exploded view of the layers of the protective garment shown in FIG. 1.

DESCRIPTION OF THE INVENTION

[0021] Referring to the Figures, wherein like numerals refer to like elements, there is shown in FIG. 1, a protective garment 10. Specifically, protective garment 10 is the jacket of a firefigther's turnout suit. It is understood, however, that the invention is not limited to firefighter's turnout gear. The invention may be used in other types of protective gear, as will be apparent to those of ordinary skill. Such other types of protective suits include, but are not limited to, suits for industrial workers (including, for example, arc flash apparel), wildlands firefighters, race car drivers, airplane pilots, military personnel, and the like.

[0022] As indicated in FIGS. 1 and 2, the protective garment 10 may have a multi-layer construction that includes an outer shell 20, a moisture barrier 40, and a thermal liner 60. The outer shell 20 is typically constructed of a flame and abrasion resistant material that comprises flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof. The outer shell 20 may be treated with a water-resistant finish (for example, a perfluorohydrocarbon) to prevent or reduce water absorption from the outside environment. The weight of the outer shell material may be within the range of about 6-8 ounces per square yard (osy).

[0023] The moisture barrier 40 may be constructed of a non-woven or woven flame resistant fabric 42 comprising flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof. The moisture barrier 40 may be laminated with a water-impermeable layer 44 of material such as, for instance, a layer of polytetrafluoroethylene (PTFE) or polyurethane (PU). When such an impermeable layer 44 is provided, it usually is provided on the moisture barrier 40, so as to face the thermal liner 60. The weight of the moisture barrier material is typically within the range about 4-6 osy.

[0024] The thermal liner 60 may, optionally, include both an insulation layer 62 and a facecloth layer 64, which may be quilted together. In alternative embodiments, however, the insulation layer 62 alone may be used. The insulation layer 62 is discussed in greater detail below. When it is used, the facecloth layer 64 may be constructed of woven material comprising flame resistant fibers made of, for example, aramid (meta-aramid or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, flame resistant (FR) cellulosics, modacrylic, carbon, or the like, and blends thereof. The facecloth layer 64 may be, optionally, finished with a hydrophilic finish that draws perspiration off of the firefighter's body, if desired. The weight of the facecloth layer material is normally in the range of about 1-6 osy.

[0025] The insulation layer 62 comprises a nonwoven material that comprises a plurality of flame resistant fibers, discussed in greater detail below. The insulation layer 62 may comprise a single layer of nonwoven, or two layers of nonwoven, or multiple layers of nonwoven. In one embodiment, the insulation layer has two layers of nonwoven material, and each of these layers may have a different basis weight. The nonwoven material may be a weight range of about 0.75-8 osy. In one embodiment, the nonwoven material may be in a weight range of about 1.0-3.0 osy. In another embodiment, the nonwoven material may be in a weight range of 1.2-2.5 osy. In yet another embodiment, the nonwoven material may be in a weight range of 1.2-2.0 osy. In still another embodiment, the insulation layer may comprise two nonwoven layer, one layer having a basis weight of about 1.4 osy and the other layer having a basis weight of about 1.8 osy. In one embodiment, the nonwoven material may have a thickness of less than 3 mm. In another embodiment, the nonwoven material may have a thickness of less than 2 mm. In yet another embodiment, the nonwoven material may have a thickness of less than 1 mm. The nonwoven material, in all embodiments, should have a minimum thickness of 0.25 mm. In still another embodiment, the nonwoven material may have a thickness in the range of about 0.75-1.25 mm. The nonwoven material may be made by any nonwoven process. Such processes include, but are not limited to, wet laid, air laid, carding, felting, needlepunching, and hydroentangling (spunlaced). In one embodiment, the nonwoven may be spunlaced. The nonwoven material may be flat (i.e., without apertures), apertured (see U.S. Pat. No. 5,136,723 incorporated herein by reference), dimpled (see U.S. Pat. No. 7,676,855 incorporated herein by reference), or a combination of any of the foregoing.

[0026] The nonwoven may comprise a plurality of flame resistant fibers. The nonwoven may exclude any wool and/or cellulosic fibers and/or natural fibers (i.e., any non-synthetic or non-man-made fibers). The nonwoven may be characterized has having an equivalent or better thermal protective performance (TPP per NFPA 1971 (2007)) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both, for example—E89.

[0027] In one embodiment, the flame resistant fibers may also be characterized as non-water absorbing fibers. Non-water absorbing fiber does not refer to the moisture regain of the fiber. Moisture regain, as used herein, refers to percentage of atmospheric moisture in a textile material brought into equilibrium with a standard atmosphere after partial drying, calculated as a percentage of the moisture-free weight. Instead, non-water absorbing fiber refers to the fibers ability, when placed in contact with liquid water, to swell, absorb, and retain that water. The water absorbency of fibers may be measured according to ASTM D2402 (2012). The maximum water retention that may be tolerated is about 15%, preferably about 10% or below.

[0028] In one embodiment, the nonwoven material comprises a first inherently heat resistant fiber and a second heat resistant fiber. The first fiber may be different from the second fiber. The first heat resistant fiber may comprise 1-45 wt % of the nonwoven and the balance may be the second fiber. The first heat resistant fiber may comprise 10-40 wt % of the nonwoven and the balance may be the second fiber. The first heat resistant fiber may comprise 15-30 wt % of the nonwoven and the balance may be the second fiber.

[0029] The first inherently heat resistant fiber of the nonwoven material may selected from the group consisting of polybenzimidazoles, polyamideimides, polyetherim ides, polyacrylates, aromatic copolyimides, polyacrylonitriles, polyetherketones, polysulfones, polyethersulfones, melamines, polybenzoxazole, and combinations thereof. In one embodiment, the first inherently heat resistant fiber may be selected from the group consisting of polybenzimidazoles, melamines, polybenzoxazole, and combinations thereof. In another embodiment, the first inherently heat resistant fiber may be selected from the group consisting of polybenzimidazoles, polybenzoxazole, and combinations thereof. The first inherently heat resistant fiber may exclude aramids and/or melamines.

[0030] The second heat resistant fiber of the nonwoven material may be selected from the group of aramids (meta- and/or para-aramids), polybenzimidazoles, polyamideimides, polyetherim ides, polyacrylates, aromatic copolyimides, polyacrylonitriles, polyetherketones, polysulfones, polyethersulfones, melamines, polybenzoxazole, and combinations thereof. The second heat resistant fiber of the nonwoven material may be selected from the group of aramids (meta- and/or para-aramids), melamines, polybenzoxazole, and combinations thereof. The second heat resistant fiber of the nonwoven material may be selected from the group of meta-aramids, para-aramids, and combinations thereof. The second fiber may exclude FR cellulosics.

EXAMPLES

[0031] The following examples further illustrate the invention; it being understood, however, that this invention is not limited to the precise formulations set forth.

[0032] In Table 1, there are shown several representative embodiments of the instant invention compared to the certain industry standard materials. These embodiments illustrate a range of thickness and basis weights that may be useful in the manufacture of turnout gear. Fiber blends A-B represent the inventive embodiments and fiber blend C represents an industry standard material.

TABLE-US-00001 TABLE 1 Basis Weight Fiber Blend Structure (gsm) [osy] Thickness (mm) (mm/gsm) .Math. 100 A Apertured 56.9 [1.68] 0.89 1.56 A Apertured 66.5 [1.96] 0.97 1.46 A Apertured 84.6 [2.50] 1.10 1.30 B.sup.1 Apertured 48.1 [1.42] 0.74 1.54 B.sup.1 Apertured 62.0 [1.83] 0.93 1.50 B Apertured 77.7 [2.29] 1.07 1.38 B Apertured 85.0 [2.50] 1.19 1.40 C.sup.2 Flat 50.0 [1.47] 0.70 1.40 C.sup.3 Flat 80.0 [2.36] 0.87 1.09 C Dimpled 80.0 [2.36] 1.22 1.53 A: 47 wt % m-aramid/33% p-aramid/20% PBI B: 80 wt % m-aramid/20% PBI C: 67 wt % m-aramid/33% p-aramid Apertured: spunlaced nonwoven with apertures, US513723 incorporated herein by reference. Flat: spunlaced nonwoven without apertures. Dimples: spunlaced nonwoven without apertures but having dimples, U.S. Pat. No. 7,676,855 incorporated herein by reference. Also referred to in the industry as ‘3D.’ Conversion: (gsm/33.9) = osy. .sup.1Exemplary embodiment. .sup.2Industry standard - 1.5 osy spunlace. .sup.3Industry standard - 2.3 osy spunlace.

[0033] In TABLE 2, there are shown several full composite comparisons of the instant invention industry standards. The full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner. The outer shell was PBI MATRIX® available from Safety Components, Inc of Greenville, S.C. The moisture barrier was CROSSTECH 2C available from W.L. Gore & Associates of Elkton, Md. The thermal barrier was unquilted and made with a NOMEX face cloth and the insulation layers set forth in TABLE 2. The first two listed materials are existing industry standard constructions and the remaining are examples of the instant invention.

TABLE-US-00002 TABLE 2 Full Composite basis TPP/ Fiber Blend Insulation Layers Weight (osy) TPP.sup.4 osy 33 wt % p-aramid/ 1.5 osy flat 19.99 35.5 1.78 67% m-aramid.sup.1 2.3 osy flat 33 wt % p-aramid/ 1.5 osy flat 19.55 36.4 1.86 67% m-aramid.sup.2 2.3 osy dimpled 20 wt % PBI/ 1.4 osy apertured 18.89 36.2 1.92 80% m-aramid.sup.3 1.8 osy apertured 47 wt % m-aramid/ 1.7 osy apertured 18.95 34.7 1.83 33% p-aramid/20% PBI 1.7 osy apertured 47 wt % m-aramid/ 2.0 osy apertured 19.27 36.7 1.90 33% p-aramid/20% PBI 1.7 osy apertured 20 wt % PBI/ 1.4 osy apertured 19.39 37.2 1.92 80% m-aramid 2.3 osy apertured 20 wt % PBI/ 1.8 osy apertured 19.41 36.6 1.89 80% m-aramid 1.8 osy apertured Apertured: spunlaced nonwoven with apertures, US513723 incorporated herein by reference. Flat: spunlaced nonwoven without apertures. Dimples: spunlaced nonwoven without apertures but having dimples, U.S. Pat. No. 7,676,855 incorporated herein by reference. .sup.1Industry standard .sup.2Industry standard .sup.3Exemplary embodiment .sup.4TPP-Thermal Protection Performance per NFPA1971 (2007).

[0034] In TABLE 3A-D, there is shown several full composite comparisons of the instant invention to various industry standard full composites. The full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner. The outer shell was varied as indicated. The moisture barrier was varied as indicated. The thermal barrier was quilted and varied as indicated.

TABLE-US-00003 TABLE 3A Outer Shell: PBI MATRIX-Safety Components, Inc, Greenville, SC. Moisture barrier-CROSSTECH Black, W.L. Gore & Associates, Elkton, MD. Thermal Liner Fiber Blend Insulation Layers TPP.sup.3 TPP/osy Glide Araflo.sup.1 33 wt % p-aramid/ 1.5 osy apertured 38.9 1.93 67% m-aramid 2.3 osy flat Glide E89.sup.1 33 wt % p-aramid/ 1.5 osy flat 37.6 1.87 67% m-aramid 2.3 osy flat Caldura SL2.sup.2 33 wt % p-aramid/ 1.5 osy flat 37.6 1.90 67% m-aramid 2.3 osy flat Quantum 3D.sup.2 33 wt % p-aramid/ 1.5 osy flat 41.8 2.10 67% m-aramid 2.3 osy dimpled Glide.sup.1 20 wt % PBI/ 1.4 osy apertured 39.3 1.90 w/invention 80% m-aramid 1.8 osy apertured Apertured: spunlaced nonwoven with apertures, US513723 incorporated herein by reference. Flat: spunlaced nonwoven without apertures. Dimples: spunlaced nonwoven without apertures but having dimples, U.S. Pat. No. 7,676,855 incorporated herein by reference. .sup.1Available from Safety Components, Inc, Greenville, SC. .sup.2Available from TenCate, Union City, GA. .sup.3TPP-Thermal Protection Performance per NFPA1971 (2007).

TABLE-US-00004 TABLE 3B Outer Shell: PBI MATRIX-Safety Components, Inc, Greenville, SC. Moisture barrier-CROSSTECH Black, W.L. Gore & Associates, Elkton, MD. Thermal Liner Fiber Blend Insulation Layers TPP.sup.3 TPP/osy Glide Araflo.sup.1 33 wt % p-aramid/ 1.5 osy apertured 39.2 2.10 67% m-aramid 2.3 osy flat Glide E89.sup.1 33 wt % p-aramid/ 1.5 osy flat 39.7 2.07 67% m-aramid 2.3 osy flat Quantum 3D.sup.2 33 wt % p-aramid/ 1.5 osy flat 42.2 2.16 67% m-aramid 2.3 osy dimpled Glide1 20 wt % PBI/ 1.4 osy apertured 43.4 2.20 w/invention 80% m-aramid 1.8 osy apertured Apertured: spunlaced nonwoven with apertures, US513723 incorporated herein by reference. Flat: spunlaced nonwoven without apertures. Dimples: spunlaced nonwoven without apertures but having dimples, U.S. Pat. No. 7,676,855 incorporated herein by reference. .sup.1Available from Safety Components, Inc, Greenville, SC. .sup.2Available from TenCate, Union City, GA. .sup.3TPP-Thermal Protection Performance per NFPA1971 (2007).

TABLE-US-00005 TABLE 3C Outer Shell: GEMINI XT-TenCate, Union City, GA. Moisture barrier-CROSSTECH Black, W.L. Gore & Associates, Elkton, MD. Thermal Liner Fiber Blend Insulation Layers TPP.sup.3 TPP/osy Caldura SL2.sup.1 33 wt % p-aramid/ 1.5 osy flat 36.4 1.93 67% m-aramid 2.3 osy flat Glide.sup.2 20 wt % PBI/ 1.4 osy apertured 39.7 2.03 w/invention 80% m-aramid 1.8 osy apertured Apertured: spunlaced nonwoven with apertures, US513723 incorporated herein by reference. Flat: spunlaced nonwoven without apertures. .sup.1Available from TenCate, Union City, GA. .sup.2Available from Safety Components, Inc, Greenville, SC. .sup.3TPP-Thermal Protection Performance per NFPA1971 (2007).

TABLE-US-00006 TABLE 3D Outer Shell: GEMINI XT-TenCate, Union City, GA. Moisture barrier-CROSSTECH Black, W.L. Gore & Associates, Elkton, MD. Thermal Liner Fiber Blend Insulation Layers TPP.sup.3 TPP/osy Caldura SL2.sup.1 33 wt % p-aramid/ 1.5 osy flat 38.2 1.97 67% m-aramid 2.3 osy flat Quantum 3D.sup.1 33 wt % p-aramid/ 1.5 osy flat 41.3 2.00 67% m-aramid 2.3 osy dimpled Glide.sup.2 20 wt % PBI/ 1.4 osy apertured 40.3 2.03 w/invention 80% m-aramid 1.8 osy apertured Apertured: spunlaced nonwoven with apertures, US513723 incorporated herein by reference. Flat: spunlaced nonwoven without apertures. Dimples: spunlaced nonwoven without apertures but having dimples, U.S. Pat. No. 7,676,855 incorporated herein by reference. .sup.1Available from TenCate, Union City, GA. .sup.2Available from Safety Components, Inc, Greenville, SC. .sup.3TPP-Thermal Protection Performance per NFPA1971 (2007).

[0035] The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.