Patent Grant
11337473
Various different types of protective garments exist that are designed to protect the wearer in the environment in which the garment is worn. For instance, various protective garments exist that are intended to be fire resistant. Such garments are worn by military personnel, industrial workers, pilots, rescue personnel, and firefighters.
Firefighter garments, for instance, are intended to not only protect the firefighter from exposure to fires but are also designed to be water resistant. Firefighter garments typically include multiple layers of materials. For example, firefighter garments typically include an outer shell attached to an inner lining or face cloth. The firefighter garment may include intermediate layers, such as a moisture barrier layer and/or a thermal barrier layer. Each layer can be made from fire resistant materials, such as fire resistant fibers and yarns.
Many protective garments, such as firefighter garments, are intended not only to protect the wearer from fire and other elements, but the garments should also be comfortable to wear. For example, firefighter garments that do not provide water resistance may absorb water during use and increase in weight thereby increasing the load on the wearer.
The inner lining of protective garments as described above should also display high lubricity characteristics. A low friction inner lining, for instance, makes it much easier to don the garment and to take the garment off later. A low friction inner lining also can substantially increase the comfort of the garment during use, especially when the wearer is actively moving. Ultimately, a low friction inner lining can reduce the amount of stress imposed on the wearer, especially when worn in harsh environments.
In this regard, those skilled in the art in the past have attempted to produce inner linings for protective garments that are not only fire resistant but also have excellent lubricity characteristics. For example, inner linings made from multi-filament yarns and spun yarns are disclosed in U.S. Pat. Nos. 6,247,179 and 5,858,888, which are both incorporated herein by reference. The inner linings disclosed in the above patents have provided great advancements in the art demonstrated by significant commercial success. U.S. Pat. No. 5,539,928 and U.S. Patent Publication No. 2009/0255038, which are also both incorporated herein by reference, also disclose inner liners having high lubricity characteristics.
The present disclosure is directed to further improvements in the construction of protective garments and particularly in the construction of high lubricity liners for protective garments.
In general, the present disclosure is directed to protective garments having an inner lining with high lubricity and high strength characteristics. In one embodiment, the protective garment and the inner lining may be constructed so as to provide protection to a wearer against fires, open flames, incendiary devices, and the like.
In one embodiment, the protective garment includes an outer shell having an exterior surface and an inside surface. An inner lining is positioned on the inside surface of the outer shell. For instance, the inner lining can be directly affixed to the outer shell or may be attached to a garment subassembly that is then connected to the outer shell.
The inner lining comprises a woven fabric having first yarns and second yarns. The inner lining has an interior surface positioned to face a wearer and an opposite outside surface. The interior surface of the inner lining has greater lubricity characteristics than the outside surface. In accordance with the present disclosure, the first yarns used to produce the inner lining comprise spun yarns, while the second yarns comprise para-aramid filament yarns. The second yarns occupy a greater surface area than the first yarns on the interior surface and provide the inner lining with the desired lubricity characteristics. The filament yarns also provide strength to the inner lining. For instance, the fabric that comprises the inner lining may have a tensile strength in at least one direction according to ASTM Test D5034 of greater than about 400 lbsf, such as greater than about 450 lbsf, such as greater than about 500 lbsf, such as greater than about 550 lbsf, such as greater than about 600 lbsf.
The para-aramid filament yarns, in one embodiment, can have a denier of from about 100 to about 400. Of particular advantage, the filament yarns made from the para-aramid filaments may not need to be twisted prior to weaving the fabric. For instance, the second yarns contained in the inner lining may have less than about five twists per inch, such as less than about three twists per inch, such as even less than about one twist per inch. Reducing the number of twists per inch not only simplifies the manner in which the fabric is formed, but may also lead to improved properties in certain embodiments, such as improved fire resistant properties and improved lubricity properties.
The spun yarns contained within the inner lining may contain flame resistant fibers, such as inherently flame resistant fibers alone or in combination with cellulose fibers that have been treated with aflame retardant composition. In general, the inner lining can have a basis weight of from about 2 osy to about 5 osy, such as from about 2.5 osy to about 4 osy. In one particular embodiment, the inner lining may comprise a fabric having a twill weave. The fabric can have from about 70 to about 90 ends per inch and from about 60 to about 80 picks per inch.
Inner linings made according to the present disclosure can have excellent flame resistant properties, even after being laundered. For instance, the inner lining may display a char length of less than about 40 mm, such as less than about 30 mm, such as even less than about 20 mm in at least one direction when tested according to ASTM Test D6413 and after being subjected to five laundry cycles.
In one embodiment, the inner lining can further be treated with an odor control agent. The odor control agent may comprise, for instance, a silver ion. In one embodiment, for instance, the odor control agent may comprise a silver zeolite.
Other features and aspects of the present disclosure are discussed in greater detail below.
A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure.
In general, the present disclosure is directed to protective garments that include an inner liner. In one embodiment, the protective garment is flame resistant and thus protects the wearer from exposure to fire, including flash fires. In accordance with the present disclosure, the inner liner is not only flame resistant but also has high lubricity characteristics. In comparison to lining materials used in the past, the inner liner has improved strength properties and may also have improved fire resistant properties.
In general, the inner liner of the present disclosure is made from a woven fabric that includes at least two different types of yarns. The first yarn comprises a spun yarn that contains inherently fire resistant fibers, such as meta-aramid fibers. The second yarns, on the other hand, comprise multifilament yarns made from para-aramid filaments. The yarns are woven together so that the second yarns occupy a majority of the surface area on one surface of the fabric which forms an interior surface of the protective garment. The use of multifilament para-aramid yarns as the second yarns has been found to provide numerous advantages and benefits. Although para-aramid filaments are known to have good strength characteristics, the increase in strength of the fabric when using the para-aramid filament yarns is unexpectedly high in comparison to a similar fabric containing other types of filament yarns. For instance, the strength of the fabric can, in some applications, be twice as much as the strength of previous liner fabrics. In addition to strength characteristics, the fire resistant properties of the fabric may be significantly enhanced. In addition, it was discovered that when using multifilament yarns made from a para-aramid, the amount of twists placed into the yarn in order to weave the yarn may be minimized. In fact, in one embodiment, the fabric may be woven without having to twist the multifilament yarns. In the past, for instance, meta-aramid yarns were typically twisted prior to weaving. The yarns were twisted in order to prevent breakage. In accordance with the present disclosure, however, the para-aramid multifilament yarns may have a minimal amount of twists which not only simplifies the manufacturing process and saves labor costs, but also may enhance the fire resistant properties of the fabric or various other properties.
In addition to the above advantages, the fabric of the present disclosure also produces garments having excellent seam strength.
In the illustrated embodiment, liner assembly 14 is constructed as a separate unit that may be removed from outer shell 12. A zipper 16 is provided in this case to maintain liner assembly 14 in position within outer shell 12 as shown. It should be appreciated, however, that other suitable means of attachment, such as various hook and pile arrangements, may also be utilized for this purpose.
The construction of liner assembly 14 may be most easily explained with reference to
Typically, lining layer 20 will be adjacent the wearers body during use, whereas lining layer 22 will be immediately inside of outer shell 12. As will be described more fully below, lining layers 20 and 22 are made from a textile material having a first side of higher lubricity and a second side of lesser lubricity. The higher lubricity sides are directed outwardly such that the outer surface of liner assembly 14 will be relatively “slick.” This construction desirably reduces the friction that may otherwise be produced by rubbing against the wearers clothing. Friction between the liner assembly 14 and outer shell 12 may also be reduced in this manner.
In the illustrated embodiment, an aramid felt, such as a felt produced from meta-aramid fibers, is utilized to provide thermal barrier layer 24. The felt functions as an insulator to inhibit transfer of heat from the ambient environment to the wearer.
Moisture barrier layer 26 is preferably a suitable polymeric membrane that is impermeable to liquid water but is permeable to water vapor. As such, exterior water (such as from a firefighter's water hose) will not penetrate the interior of garment 10, but perspiration from the firefighter can escape. Suitable membranes of this type are distributed by W. L. Gore & Associates under the trademark Gore-Tex.
As described above, the higher lubricity side of lining layer 20 forms an outer surface of liner assembly 14. Thus, the membrane of moisture barrier layer 26 is adhered to the lower lubricity side of lining layer 20. This is advantageous because membranes of this type will generally adhere more readily to a rougher surface than to one which is smooth.
In addition to being used in coats and jackets as shown in
As described above, at least one set of yarns used to produce the lining layers 20 and 22 is made from para-aramid filaments. The use of para-aramid filament yarns has been found to produce numerous advantages and benefits. For example, the tensile strength of the fabric in the direction parallel to the filament yarns is significantly increased. For example, in the direction of the filament yarns, the fabric can have a tensile strength measured according to ASTM Test D5034 of greater than 400 lbsf, such as greater than 500 lbsf, such as even greater than 600 lbsf. The tensile strength is generally less than 1200 lbsf and can be from about 400 lbsf to about 800 lbsf for a fabric having a basis weight of from about 2 osy to about 6 osy, such as from about 2 osy to about 5 osy, such as from about 2 osy to about 2.5 osy to about 4 osy.
Another unexpected advantage is that the para-aramid filament yarns can be woven without having to be twisted. In the past, similar filament yarns typically had to be twisted so that the yarns could be more easily woven. Filament yarns of the present disclosure, however, can have a minimal amount of twisting without compromising the weaving process. For example, filament yarns can be twisted less than five twists per inch, such as less than four twists per inch, such as even less than three twists per inch. In one embodiment, for instance, the filament yarns may not have any appreciable twisting. By not having to twist the filament yarns, the lubricity of the resulting fabrics can actually be enhanced in certain embodiments.
The use of para-aramid filament yarns may also appreciably increase the flame resistant properties of the fabric in certain embodiments. In fact, it is believed that, in some applications, the flame resistant properties of the fabric are enhanced because the filament yarns are not twisted. For instance, fabrics made in accordance with the present disclosure, even after being laundered five laundry cycles, can have a char length in a direction perpendicular to the filament yarns when tested according to ASTM Test D6413 (AATCC 135) of less than about 50 mm, such as less than about 40 mm, such as even less than about 30 mm. The char length, for instance, can be generally from about 5 mm to about 50 mm. In one particular embodiment, the char length in a direction perpendicular to the filament yarns can be less than about 15 mm.
The weight of the para-aramid filament yarns can vary depending upon the particular application, the desired weight of the fabric, and various other factors. In general, the filament yarns can have a weight of greater than about 100 denier, such as greater than about 140 denier, such as greater than about 180 denier. The denier of the filament yarns is generally less than about 500 denier, such as less than about 400 denier. In one embodiment, the filament yarns have a denier of from about 150 to about 250, such as from about 180 to about 220.
In addition to the filament yarns, the fabric can also include spun yarns. The spun yarns contain flame resistant fibers. In one embodiment, all of the fibers contained in the spun yarns comprise inherently flame resistant fibers, such as meta-aramid fibers.
In one embodiment, the spun yarns may be made from a blend of fibers. For instance, in one embodiment, the spun yarns may comprise meta-aramid fibers blended with para-aramid fibers. For instance, the para-aramid fibers may be present in an amount less than the meta-aramid fibers, such as in an amount less than about 15% by weight, such as from about 1% to about 15% by weight, such as from about 3% to about 10% by weight.
The spun yarns can contain the meta-aramid fibers in an amount greater than about 30% by weight, such as in an amount from about 30% by weight to about 100% by weight. The meta-aramid fibers may be present in the spun yarns in an amount greater than about 40% by weight, such as in an amount greater than 60% by weight, such as in an amount greater than about 80% by weight.
The meta-aramid fibers contained in the spun yarns can be substantially amorphous, crystalline, or a mixture of both. Amorphous meta-aramid fibers generally have a crystallinity of less than about 10%. Crystalline fibers, on the other hand, have a crystallinity greater than about 10%, such as greater than about 25%, such as having a crystallinity of from about 25% to about 40%.
In addition to meta-aramid fibers and/or para-aramid fibers, the spun yarns may contain various other inherently flame resistant fibers. Such fibers may include, for instance, polybenzimidazole fibers, such as poly[2,2′-(m-phenylen)-5,5′bibenzimidazole].
In addition to inherently flame resistant fibers or instead of inherently flame resistant fibers, the spun yarns may also contain other fibers treated with a flame retardant composition. For instance, in one embodiment, the spun yarns may contain flame resistant cellulose fibers.
As used herein, flame resistant cellulose fibers refers to cellulose fibers that have been treated with a flame resistant composition or flame retardant. The inclusion of cellulose fibers in the fiber blend can make the resulting fabric softer, more breathable, and less expensive. Examples of flame resistant cellulose fibers that may be incorporated into the fabric include FR cotton, FR rayon, FR acetate, FR triacetate, FR lyocell, and mixtures thereof. In one particular embodiment, FR rayon fibers are incorporated into the fiber blend. FR rayon fibers are available from various different sources. FR rayon fibers, for instance, are sold under the name LENZING by Lenzing Fibers of Austria. LENZING FR fibers are viscous fibers that have been treated with a flame retardant composition. In one embodiment, the flame resistant rayon fibers are made by spinning reconstituted cellulose from beech trees. Such fibers are more water absorbent than cotton fibers.
The amount of flame resistant cellulose fibers present in the spun yarns may depend upon various different factors and the particular application. In one embodiment, for instance, the flame resistant cellulose fibers may be present in the spun yarns in an amount from about 20% to about 100% by weight. In one particular embodiment, for instance, the flame resistant cellulose fibers may be present in the spun yarns in an amount from about 30% to about 50% by weight.
As described above, flame resistant cellulose fibers comprise fibers that have been treated with aflame retardant composition. The flame retardant composition can be incorporated into the fibers using various methods and techniques. For instance, the flame retardant composition can be incorporated into the fibers during spinning, can be coated on the fibers, or can be absorbed into the fibers. The flame retardant composition may contain, for instance, a phosphorus compound, a halogen compound, or any other suitable flame resistant agents.
Similar to the filament yarns, the weight of the spun yarns can also vary depending upon the particular application. The spun yarns, for instance, can have a weight of from about 20/1 to about 50/1. For instance, the spun yarns can have a weight of 26/1, 37/1, 40/1, 18/2, or 26/3.
In general, the spun yarns and filament yarns are woven together such that the filament yarns comprise more than about 50% of the surface area of one side of the fabric. For instance, the filament yarns may comprise greater than about 60%, such as greater than about 70%, such as even greater than about 80% of one side of the fabric. The side of the fabric with more exposed filament yarns is then used as the interior face of the garment. The filament yarns provide a fabric with high lubricity characteristics.
In one embodiment, the warp yarns 32 and the fill yarns 34 are woven together using a twill weave. For example, the twill weave may be a 2×1 or a 3×1 weave. Of particular advantage, a twill weave has been found to be more resistant to velcro damage than other weave patterns.
In another embodiment, warp yarns 32 and fill yarns 34 are woven together utilizing a satin weave in order to achieve the desirable qualities discussed above. In a satin weave, the interlacing of each warp yarn is at least one fill yarn apart from the interlacing of either of the two warp yarns next to it. The points of interlacing do not produce an unbroken line (such as with a twill weave), but are scattered about over the weave. The interlacings of the warp yarns are thus hidden by adjacent floats.
As a result of either of the above weaves, warp yarns 32 will mostly appear on one side of textile material 30, whereas fill yarns 34 will mostly appear on the backside thereof. These two sides may be referred to as the warp side and fill side, respectively.
When the warp yarns 32 are multifilament yarns, the warp side will tend to have a lustrous surface of relatively high lubricity. The fill side will have a lesser lubricity, since it is dominated by the spun yarns. The “scattered” interlacings of a satin weave enhance the lubricity difference between the respective sides in relation to what would generally be achieved using, for example, a twill weave.
The construction illustrated in
Referring now to
The particular weave utilized in the illustrated case is referred to as a two by one (“2/1” or “2×1”) twill. In this weave, the warp passes over two fill yarns before interlacing with the third. The interlacings are offset along the diagonal, as shown, to produce characteristic twill lines. Fabric 30′ is preferably produced from multifilament warp yarns 32 and spun fill yarns 34 as described above.
Assuming a square weave and equal yarns in both directions, a five shaft satin will produce a fabric in which about eighty (80) percent of the surface area of the “warp side” will be contributed by the warp yarns. Likewise, about eighty (80) percent of the surface area of the fill side will be contributed by the fill yarns. A 2/1 twill weave will produce a fabric in which about two-thirds of the surface area of the “warp side” will be contributed by the warp yarns. About two-thirds of the fill side's surface area will be contributed by the fill yarns.
An even greater ratio of multifilament to spun surface may be achieved on the warp side if larger yarns are utilized for the warp yarns than are utilized for the fill yarns. Thus, in one embodiment, the filament yarns may have a size or weight greater than the spun yarns. In this regard, the filament yarns may comprise greater than 50% of the overall weight of the fabric, such as greater than about 55%, such as greater than about 60% of the overall weight of the fabric. In other embodiments, however, the spun yarns and filament yarns may be present in relatively equal amounts by weight.
In general, the fabric of the present disclosure may be treated with various finishes. In one particular embodiment, for instance, the fabric may be treated with an anti-odor agent. For instance, the anti-odor agent may comprise metal ions, such as silver ions. The silver ions may act as an antimicrobial agent for reducing odors. In one embodiment, the silver ions may be present in a compound or complex that also absorbs odors. For instance, in one embodiment, the silver ions may be present in a porous zeolite.
In one embodiment, the fabric of the present disclosure may be powder coated with an anti-odor agent. For instance, the anti-odor agent may be in the form of particles having a size of less than about 1 micron, such as from about 0.001 microns to about 1 micron. The anti-odor agent may be combined with a pre-polymer or polymer. The resulting particles may then be heated and applied to the fabric. The polymer or pre-polymer forms an attachment to the surface. The polymer or pre-polymer may comprise a thermoplastic polymer or a thermosetting polymer. The polymer may comprise, for instance, polyester resins, epoxy resins, acrylic resins, phenol resins, melamine resins, urea resins, urethane resins, vinylether resins, and the like. Other polymers include polyamides, polymethylmethacrylate, and polyolefins.
In an alternative embodiment, the anti-odor agent may be contained in a finish that is then applied to the fabric. The finish may include binders, leveling agents, adherents, thickeners, and the like. For instance, in one embodiment, a binder, such as a polyurethane or an acrylic-type resin may be combined with the anti-odor agent and applied to the fabric as a liquid. Once applied, the fabric may be dried.
The present disclosure may be better understood with reference to the following examples.
The following fabrics were produced and tested for various properties. As will be demonstrated below, fabrics containing filament yarns made from para-aramid filaments demonstrated better strength characteristics and better flame resistance without in any way compromising lubricity.
The above fabrics were then tested for various properties relating to strength and flame resistance. The following results were obtained:
As shown above, the use of para-aramid filament yarns dramatically increased the tensile strength of the fabric in the direction parallel to the filament yarns. The flame resistant properties of the fabric were also dramatically improved in a direction perpendicular to the filament yarns.
These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.
The present application is a continuation application of U.S. patent application Ser. No. 13/396,125, filed on Feb. 14, 2012, and which is incorporated herein by reference.
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