The present invention is directed to a protective garment, and more particularly to a protective garment having padding able to withstand relatively high temperatures.
Protective or hazardous duty garments are used in a variety of industries or settings to protect the wearer from hazardous conditions such as heat, smoke, cold, sharp objects, chemicals, liquids, fumes and the like. Such protective or hazardous duty garments are often used in adverse conditions, such as high heat, exposure to smoke or chemicals and the like. In addition, the wearers of such garments are often required to crouch or crawl to assume a defensive/protective position, and are often required to carry relative heavy items.
Accordingly, various areas of the garment, such as knee, elbow, shoulder, hip or other regions may be padded to provide comfort and protection. In addition, these (or other) areas of the garment may be compressed, such as when a wearer crawls on his or her knees, rests on his or her elbows or hips, or carries a load on his or her shoulders. When the garment is compressed in this manner, the heat protection of the garment may be reduced in that area. Thus, locating protective pads on these areas may provide additional heat protection and load absorbing protection to the wearer and the garment.
However, existing padding material can add additional bulk and/or weight to the garment. In addition, some padding materials may be prone to absorbing moisture which can increase the weight of the garment. In particular, the clothing may be exposed to moisture during use (i.e., when using water during firefighting), from perspiration of a wearer, during cleaning of the garment or the like. The absorption of moisture can also reduce the thermal/heat protection provided by the garment and add discomfort to the wearer. Accordingly, there is a need for a protective garment having improved pads.
In one embodiment, the invention is directed to a protective garment having pads which are relatively lightweight, non-bulky, and resist absorption of moisture. In particular, in one embodiment, the invention is a garment including an outer shell configured to be worn on at least part of a body of a wearer and a pad directly or indirectly coupled to a selected location of the outer shell to provide padding at the selected location. The pad includes an open cell foam padding material which resists melting, dripping or igniting when exposed to a temperature of 500 degrees Fahrenheit for five minutes. The padding material has a sealant located thereon to reduce the absorption of moisture therein. The pad further includes an abrasion resistant material coupled to the padding material by the sealant.
In another embodiment the invention is a garment including an outer shell configured to be worn on at least part of a body of a wearer, and a pad directly or indirectly coupled to a selected location of the outer shell to provide padding at the selected location. The pad includes an open cell melamine resin foam padding material with a sealant located thereon to limit the absorption of moisture. The pad further includes an abrasion resistant material coupled to the open cell foam by the sealant.
The coat 10 may include various layers through its thickness to provide various heat, moisture and abrasion resistant qualities to the coat 10 so that the coat 10 can be used as a protective, hazardous duty, or firefighter garment. For example, the coat 10 may include an outer shell 26, a moisture barrier 28 located inside of and adjacent to the outer shell 26, a thermal liner or barrier 30 located inside of and adjacent to the moisture barrier 28, and an inner liner or face cloth 32 located inside of and adjacent to the thermal liner 30.
The outer shell 26 may be made of or include a variety of materials, including a flame, heat and abrasion resistant material such as a compact weave of aramid fibers and/or polybenzarnidazole fibers. Commercially available aramid materials include NOMEX and KEVLAR fibers (both trademarks of E.I. DuPont de Nemours & Co., Inc. of Wilmington, Del.), and commercially available polybenzamidazole fibers include PBI fibers (a trademark of PBI Performance Fabrics of Charlotte, N.C.). Thus, the outer shell 26 may be an aramid material, a blend of aramid materials, a polybenzamidazole material, a blend of aramid and polybenzamidazole materials, or other appropriate materials. The materials of the outer shell 26 may have a weight of, for example, between about 6-10 oz/yd2.
The moisture barrier 28 and thermal liner 30 may be generally coextensive with the outer shell 26, or spaced slightly inwardly from the outer edges of the outer shell 26 (i.e., spaced slightly inwardly from the outer ends of the sleeves 24, the collar 34 and from the lower edge of the coat 10) to provide moisture and thermal protection throughout the coat 10. The moisture barrier 28 may include a semi-permeable membrane layer 28a and a substrate 28b. The membrane layer 28a may be generally moisture vapor permeable but generally impermeable to liquid moisture.
The membrane layer 28a may be made of or include expanded polytetrafluoroethylene (“PTFE”) such as GORE-TEX or CROSSTECH materials (both of which are trademarks of W.L. Gore & Associates, Inc. of Newark, Del.), polyurethane-based materials, neoprene-based materials, cross-linked polymers, polyamid, or other materials. The membrane layer 28a may have microscopic openings that permit moisture vapor (such as water vapor) to pass therethrough, but block liquids (such as water) from passing therethrough. The membrane layer 28a may be made of a microporous material that is either hydrophilic, hydrophobic, or somewhere in between. The membrane layer 28a may also be monolithic and may allow moisture vapor transmission therethrough by molecular diffusion. The membrane layer 28a may also be a combination of microporous and monolithic materials (known as a bicomponent moisture barrier), in which the microporous or monolithic materials are layered or intertwined.
The membrane layer 28a may be bonded or adhered to a substrate 28b of a flame and heat resistant material to provide structure and protection to the membrane layer 28a. The substrate 28b may be or include aramid fibers similar to the aramid fibers of the outer shell 26, but may be thinner and lighter in weight. The substrate 28b may be woven, non-woven, spunlace or other materials. In the illustrated embodiment, the membrane layer 28a is located between the outer shell 26 and the substrate 28b. However, the orientation of the moisture barrier 28 may be reversed such that the substrate 28b is located between the outer shell 26 and the membrane layer 28a.
The thermal liner 30 may be made of any suitable material that provides sufficient thermal insulation. In one embodiment, the thermal liner 30 may include a relatively thick (i.e. between about 1/16″- 3/16″) batting, felt or needled non-woven material 30a which can include aramid fiber batting (such as NOMEX batting), aramid needlepunch material, an aramid non-woven material, an aramid blend needlepunch material, an aramid blend batting material, an aramid blend non-woven material, or foam (either open cell or closed cell) materials. The batting 30 may trap air therein and possesses sufficient loft to provide thermal resistance to the coat 10.
The batting 30a is typically quilted to a thermal liner face cloth 30b which can be a weave of a lightweight aramid material. Thus, either the batting 30a alone, or the batting 30a in combination with the thermal liner face cloth 30b, may be considered to constitute the thermal liner 30. In one embodiment, the thermal liner 30 may have a thermal protection performance (“TPP”) of at least about twenty, or of at least about thirty-five.
In the illustrated embodiment, the batting 30a is located between the outer shell 26 and the thermal liner face cloth 30b. However, the orientation of the thermal liner 30 may be reversed such that the thermal liner face cloth 30b is located between the outer shell 26 and the batting 30a. If desired, the thermal liner 30 may be treated with a water-resistant or water-repellent finish. In addition, although the moisture barrier 28 is shown as being located between the outer shell 26 and the thermal liner 30, the positions of the moisture barrier 28 and thermal liner 30 may be reversed such that the thermal liner 30 is located between the outer shell 26 and the moisture barrier 28.
The face cloth 32 may be the innermost layer of the coat 10, located inside the thermal liner 30. The face cloth 32 can provide a comfortable surface for the wearer and protect the thermal liner 30 and/or moisture barrier 28 from abrasion and wear.
Each layer of the coat 10, and the coat 10 as a whole, may meet the National Fire Protection Association (“N.F.P.A.”) 1971 standards for protective firefighting garments (“Protective Clothing for Structural Firefighting”), which are entirely incorporated by reference herein. The NFPA standards specify various minimum requirements for heat and flame resistance and tear strength. For example, in order to meet the NFPA standards, the outer shell 26, moisture barrier 28 and thermal liner 30 must be able to resist igniting, burning, melting, dripping and/or separation at a temperature of 500° F. for at least five minutes. Furthermore, in order to meet the NFPA standards, all combined layers of the coat 10 must provide a thermal protective performance rating of at least thirty-five.
As shown in
The garments 10, 40 may include one or more pads 50 positioned at selected, discrete and spaced apart locations on the garment. As best shown in
The padding material 52 may be relatively soft and pliable to provide shock absorption and load distribution qualities. For example, the padding material 52 may be easily compressed when pressed down upon by a user's finger, and generally return to its original shape when the pressing force is removed. The padding material 52 can have a variety of thicknesses, for example, at least about 3 mm, or about 6 mm.
Because the padding material 52 is made of open cell foam, it may be desired to locate a sealant 54 on the foam to generally seal the open cells and eliminate, reduce or limit the absorption of moisture into and through the padding material 52. The sealant 54 generally covers and seals the open cells of the padding material 52 that are contacted by the sealant 54. In one embodiment, the sealant 54 is a urethane coating although the sealant 54 can be made of other materials which provide the desired sealing and adhesive properties. The sealant 54 can have a variety of thicknesses, such as between about 1 and 10 mils, and more particularly between about 2 and 5 mils (with the drawings not necessarily being to scale).
In the illustrated embodiment, the padding material 52 is a generally planar and flat sheet-like material having a pair of opposed major surfaces 56. In this case, the sealant 54 may cover substantially both of the opposed major surfaces 56 to seal substantially the entire padding material 52. However, if desired, and under certain circumstances, only one of the major surfaces 56 or even only part thereof, may be covered by the sealant 54. In addition, it may be desired to seal the peripheral end or edge surfaces 58 of the padding material 52 to provide complete moisture protection to the padding material 52. The sealant 54 may not necessarily provide complete waterproofing to the pad 50. Instead, in one case the sealant 54 may primarily protect from “hot moisture” such as steam or the like from penetrating into or through the pad 50. Such hot moisture can quickly heat a wearer of a garment, and therefore the protection provided by the sealant 54 can be quite useful.
The pad 50 may further include an abrasion resistant material 60 coupled to the padding material 52 by the sealant 54. The abrasion resistant material 60 may be coupled to part or all of the major surfaces 56, or end surfaces 58 as desired. The abrasion resistant material 60 provides protection to the padding material 52, since the padding material may be relatively fragile and prone to ripping, tearing, puncturing and the like.
In one embodiment, the abrasion resistant material 60 may be a fabric, such as a woven fabric or a non-woven (including spun-lace) fabric, such as E-89™ or (Nomex E-89™), or E-88™ or (Nomex E-88™), both sold by E. I. du Pont de Nemours and Company of Wilmington, Del. However, the abrasion resistant material 60 can be made of nearly any other materials which provide the desired protection and strength. The abrasion resistant material 60 may be relatively thin, such as between about 5 mils and about 30 mils. In addition, the abrasion resistant material 60 may be relatively lightweight, and in one case has a weight of about 1.5 ounces per square yard.
As noted above, in one embodiment the abrasion resistant material 60 may be coupled to the padding material 52 by the sealant 54. The abrasion resistant material 60 may be securely attached such that the abrasion resistant material 60 cannot be removed without tearing the padding material 52. Thus, the sealant 54 may serve the dual purpose of both sealing the open cell foam padding material 52, and adhering, bonding or coupling the abrasion resistant material 60 to the padding material 52.
The padding material 52 may be made of a material which resists melting, dripping or igniting, and which generally fully retains its flexibility when exposed to temperatures of 500° F. for five minutes. In addition, the pad 50 as a whole (i.e., including the padding material 52, sealant 54 and abrasion resistant material 60) may be relatively heat resistant and be able to resist melting, dripping and/or igniting when exposed to temperatures of 500° F., or 1000° F. for five minutes.
In order to form the pad 50, the padding material 52 may first be provided, such as in relatively large sheet form. The sealant 54, such as urethane, is located on the major surface(s) 56 (and/or end surfaces 58 if desired) of the padding material 52. The sealant 54 can be applied in sheets (i.e., in solid form) which are laid on the padding material 52, or can be brushed on (i.e., in liquid form). The padding material 52/sealant 54 is then heated until the sealant 54 becomes sufficiently tacky to adhere the sealant 54 to the padding material 52, and to adhere the abrasion resistant material 60 to the sealant 54. In one embodiment, the sealant 54 is exposed to a temperature of between about 300° F. and 375° F. for about two or about three minutes.
The abrasion resistant material 60 is then located on top of the heated, tacky sealant 54. The sealant 54 is then allowed to cool to thereby secure the abrasion resistant material 60 thereto. If desired, only one major surface 56 of the padding material 52 may receive the sealant 54 and/or abrasion resistant material 60 thereon at a time. Alternately, if desired, both sides or major surfaces 56 of the padding material 52 can simultaneously receive the sealant 54 and/or abrasion resistant material 60. The larger sheet of pad material can then be cut to size to provide pads 50 of the desired size and shape. If desired, and if not done earlier, sealant 54 and/or abrasion resistant material 60 can then be located on the end surfaces 58.
When used as padding material at selected portions of a garment, the pads 50 can be located at various locations of the garment. In addition, although not necessarily shown herein, the “pads” 50 may be significantly larger than the shape shown herein and cover nearly all of the surfaces of the garment (i.e., cover substantially the same portion as the outer shell 26 of the coat 10, trousers 40 or the like). When located at select locations, the pads 50 can be located on areas of the garment 10/40 where relatively high loads and/or compression and/or abrasion and/or high heat exposure are expected, such as on the elbows, knees, shoulders and/or hips of the garment.
The pads 50 can be coupled to the garment in a variety of manners. For example, as shown in
The pads 50 need not necessarily be located outside of the outer shell 26 and could instead be located inside the outer shell 26 (i.e., between the outer shell 26 and the wearer of the garment). In the embodiment shown in
The pad 50 can be located at any location in the thickness of the garment 10/40 (i.e., between the outer shell 26 and the thermal liner 30, between the outer shell 26 and the moisture barrier 28, between the moisture barrier 28 and the thermal liner 30, between the moisture barrier 28 and the inner liner 32, between the thermal liner 30 and the inner liner 32, between the outer shell 26 and the inner liner 32, etc.). In addition, if desired more than one pad 50 can be located at a single location of the garment. For example, if extra padding is desired (i.e. at the knee) then one pad 50 can be located outside of the outer shell 26 at the knee, and a second pad 50 can be located inside of the outer shell 26 at the knee. Thus, it can be seen that the pads 50 can be located in a variety of positions and used in a variety of manners to provide lightweight, moisture resistant pads to protect a wearer and/or the garment.
Having described the invention in detail and by reference to the preferred embodiments, it will be apparent that modifications and variations thereof are possible without departing from the scope of the invention.
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