Claims:

1. A composite thermal barrier layer of a protective composite ensemble comprising:
at least two fabric layers, a first inner layer made from thermally resistant fibres having a weight about 50 to 500 GSM and a second layer made from thermally resistant fibres and its blends that include fibres selected from inherently fire-retardant fibres and/or chemically modified fibres having a weight about 50 to 500 GSM; and
a quilting thread made of high crystalline non-melting inherently fire-retardant thread (yarn/filament) having a direct count ranges from 30-150Tex for quilting said first and second layers to form a predefined quilting pattern in such a way that with said quilting, said composite thermal barrier layer, post five washes has a relative washing shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 6330: 2012, and a relative thermal shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 17493.

2. The composite thermal barrier layer as claimed in claim 1, wherein said high crystalline non-melting inherently fire-retardant thread (yarn/filament) is a para-aramid thread is having direct count of 50 Tex and runs in a straight-line path at an angle from both sides of a selvedge of said thermal barrier layer.

3. The composite thermal barrier layer as claimed in claims 1-2, wherein said first layer is a woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having weight about 150 GSM.

4. The composite thermal barrier layer as claimed in claims 1-3, wherein said second layer is a nonwoven layer made of 100% meta-aramid having weight about 160 GSM.

5. A process of manufacturing a composite thermal barrier layer of a protective composite comprising the steps of:
a) providing a first inner layer made from thermally resistant fibres having a weight about 50 to 500 GSM;
b) providing a second layer made from thermally resistant fibres and its blends that include fibres selected from inherently fire-retardant fibres and/or chemically modified fibres having a weight about 50 to 500 GSM; and
c) quilting said first and second layers with a quilting thread made of high crystalline non-melting inherently fire-retardant thread (yarn/filament) having a direct count ranges from 30-150Tex to form a predefined quilting pattern, in such a way that with said quilting, said composite thermal barrier layer, post five washes has a relative washing shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 6330: 2012 and a relative thermal shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 17493.

6. The process as claimed in claim 5, wherein said high crystalline non-melting inherently fire-retardant thread (yarn/filament) is a para-aramid thread having a direct count of 50 Tex and runs in a straight-line path at an angle from both sides of a selvedge of said thermal barrier layer.

7. The process as claimed in claims 5-6, wherein said first layer is a woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM.

8. The process as claimed in claims5-7, wherein said second layer is a nonwoven layer made of 100% meta-aramid having weight about 160 GSM.

9. A protective composite ensemble comprising:
an outer layer made from thermally resistant fibre and its blends having a weight about 80 to 500 GSM;
a moisture barrier layer made from thermally resistant fibre and its blends, laminated from a fire and a water-resistant barrier membrane, having a weight about 50 to 500 GSM; and
a composite thermal barrier layer including:
a first inner layer made from thermally resistant fibres having a weight about 50 to 500 GSM;
a second layer made from thermally resistant fibres and its blends having a weight about 50 to 500 GSM; and
a quilting thread made of high crystalline non-melting inherently fire-retardant thread (yarn/filament) having a direct count ranges from 30-150Tex for quilting said first and second layers to form a predefined quilting pattern in such a way that said protective composite ensemble complies requirements of EN 469:2005, which defines the performance requirement for protective clothing for firefighters, for following test standards: EN ISO 9151:2016, EN ISO 6942: 2002, EN ISO 6530: 2005 and EN ISO 11092: 2014.

10. The ensemble as claimed in claim 9, wherein said outer layer is a woven/knitted, oil and water-resistant layer made from thermally resistant fibres and its blends having a weight about 220 GSM.

11. The ensemble as claimed in claims 9-10, wherein said moisture barrier layer is a nonwoven/knitted/woven layer having a weight about 145 GSM is laminated with a PU/PTFE membrane.

12. The ensemble as claimed in claims 9-11, wherein said first layer of said thermal barrier layer is a woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM.

13. The ensemble as claimed in claims 9-12, wherein said second layer of said thermal barrier layer is a nonwoven layer made of 100% meta-aramid having weight about 160 GSM.

14. The ensemble as claimed in claims 9-13, wherein said high crystalline non-melting inherently fire-retardant quilting thread (yarns/filaments) is a para-aramid thread having a direct count of 50 Tex that runs in a straight-line path at an angle from both sides of a selvedge of said thermal barrier layer.

15. The ensemble as claimed in claims 9-14, wherein at least said chemically modified fibres are selected from the group of polynosic rayon, fire resistant polynosic rayon, viscose rayon, fire resistant viscose rayon, fire resistant cotton, acetate, fire resistant polyester, wool, and fire-resistant wool.

16. The ensemble as claimed in claims 9-15, wherein at least said inherently fire-retardant fibres are selected from the group of meta-aramids, para-aramids and other aramids, Aromatic Polyamide co-polymers, aromatic polyetser, Polybenzimidazole, Polyetherimide, polyimide, polyamide, polyimide- amidepolyethersulfone, polyetherekentone, polyolefins, carbon, modacrylic, acrylic, melamine, glass, Polyvinyl chloride, Polyvinlydene chloride, Polyvinyl alcohol (PVA), and polytetrafluoroethylene.

17. The ensemble as claimed in claims 9-16, wherein said quilting thread is selected from the group of polybenzimidazole, aromatic polyester (Vectran), Aromatic polyamides and polyimides that include PBO, PBI, Oxidized acrylics, and PANOX.

18. The composite thermal barrier layer as claimed in claims 1-4, wherein at least said chemically modified fibres are selected from the group of polynosic rayon, fire resistant polynosic rayon, viscose rayon, fire resistant viscose rayon, fire resistant cotton, acetate, fire resistant polyester, wool, and fire-resistant wool.

19. The composite thermal barrier layer as claimed in claims 1-4, wherein at least said inherently fire-retardant fibres are selected from the group of meta-aramids, para- aramids and other aramids, Aromatic Polyamide co-polymers, aromatic polyetser, Polybenzimidazole, Polyetherimide, polyimide, polyamide, polyimide- amidepolyethersulfone, polyetherekentone, polyolefins, carbon, modacrylic, acrylic, melamine, glass, Polyvinyl chloride, Polyvinlydene chloride, Polyvinyl alcohol (PVA), and polytetrafluoroethylene.

20. The composite thermal barrier layer as claimed in claims 1-4, wherein said quilting thread is selected from the group of polybenzimidazole, aromatic polyester (Vectran), Aromatic polyamides and polyimides that include PBO, PBI, Oxidized acrylics, and PANOX.
, Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
[See section 10. Rule 13]

A COMPOSITE THERMAL BARRIER LAYER OF A PROTECTIVE COMPOSITE ENSEMBLE AND MANUFACTURING PROCESS THEREOF;

ARVIND LIMITED,
A COMPANY INCORPORATED UNDER THE COMPANIES ACT, 1956, WHOSE ADDRESS IS NARODA ROAD, AHMEDABAD - 380025, GUJARAT, INDIA,

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED;
TECHNICAL FIELD OF THE INVENTION
[1] The present invention relates to protective garments and more particularly to a composite thermal barrier layer of protective composite ensemble for the protective garments and a process of manufacturing the same.

BACKGROUD OF THE INVENTION
[2] Fire and arc protective fabrics/garments are designed to provide protection against heat, direct fire and water ingress, thus prevent burn injury to a wearer. A firefighter protective garment provides thermal comfort and further assist the firefighter to perform his tasks efficiently. Such a garment generally consists of three or more layers of fire-resistant textile materials. These different layers individually or collectively work together to provide protection to the firefighter during a fire incident.
[3] Such firefighting garments manufactured from conventional methods, subject to post wash and after use, tend to shrink, adversely the percentage of shrinkage is also high. A lower thermal and washing shrinkage is always preferred in the firefighter protective garment as it plays a major role in magnitude or extent of burn injury to the wearer. Lower shrinkage results in low probability of burn injury thereby enhancing chances of survival of wearer. Further, such garments need to be impermeable to hazardous liquid chemicals and have good breathability ratings for making it safer and comfortable to wear.
[4] Alternatively, conventional methods teach about usage of lower thermal shrinkage fibres and yarns during fabric manufacturing process to prevent break-open and thermal shrinkage of the fabric.
[5] Further, conventional methods teach also about developing thermally stable fibres i.e. the fabric may include a flame-resistant fibre and a cellulosic fibre may include a flame-resistant compound, which in the manufacturing process are either mixed at fibre stage or yarn stage or fabric stage or in all stages. However, still the drawback of lower thermal and a washing shrinkage after post washing operation is persistent, as the flame-resistant fibre and cellulosic fibre containing flame resistant compoundare complex to deal with, are more expensive than usual fabric blends and their shrinkage performance adversely gets affected post washing cycle and as the garment ages. On the other hand, lower thermal shrinkage fibres and yarns do not have effective flame-resistant properties.
[6] Therefore, there is a need to overcome one or more abovementioned drawbacks.

SUMMARY OF THE INVENTION
[7] Accordingly, an aspect of the present invention discloses a composite thermal barrier layer of a protective composite ensemble comprising at least two fabric layers, a first inner layer made from thermally resistant fibres having a weight about 50 to 500 GSM and a second layer made from thermally resistant fibres and its blends that include fibres selected from inherently fire-retardant fibres and/or chemically modified fibres having a weight about 50 to 500 GSM; and a quilting thread made of high crystalline non-melting inherently fire-retardant threads (yarns/filaments) having a direct count ranges from 30-150Tex for quilting said first and second layers to form a predefined quilting pattern in such a way that with said quilting, said composite thermal barrier layer, post five washes has a relative washing shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 6330: 2012 when compared to existing fabrics available in the market and a relative thermal shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 17493 when compared to existing fabrics available in the market.
[8] According to an embodiment, said high crystalline non-melting inherently fire-retardant quilting thread (yarn/filament) is a para-aramid thread is having direct count of 50 Tex and runs in a straight-line path at an angle from both sides of a selvedge of said thermal barrier layer.
[9] In said embodiment, said first layer is a woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM.
[10] In said embodiment, said second layer is a nonwoven layer made of 100% meta-aramid having weight about 160 GSM.
[11] According to another aspect, the present invention discloses a process of manufacturing a composite thermal barrier layer of a protective composite comprising the steps of:
a) providing a first inner layer made from thermally resistant fibres having a weight about 50 to 500 GSM;
b) providing a second layer made from thermally resistant fibres and its blends that include fibres selected from inherently fire-retardant fibres and/or chemically modified fibres having a weight about 50 to 500 GSM; and
c) quilting said first and second layers with a quilting thread made of high crystalline non-melting inherently fire-retardant threads (yarns/filaments) having a direct count ranges from 30-150Tex to form a predefined quilting pattern, in such a way that with said quilting, said composite thermal barrier layer, post five washes has a relative washing shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 6330: 2012 when compared to existing fabrics available in the market and a relative thermal shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 17493 when compared to existing fabrics available in the market.
[12] According to an embodiment, said high crystalline non-melting inherently fire-retardant quilting thread (yarn/filament) is a para-aramid thread having a direct count of 50 Tex and runs in a straight-line path at an angle from both sides of a selvedge of said thermal barrier layer.
[13] In said embodiment, said first layer is a woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM.
[14] In said embodiment, said second layer is a nonwoven layer made of 100% meta-aramid having weight about 160 GSM.
[15] According to still another aspect, the present invention discloses a protective composite ensemble comprising an outer layer made from thermally resistant fibre and its blends having a weight about 80 to 500 GSM; a moisture barrier layer from thermally resistant fibre and its blends, laminated from a fire and a water-resistant barrier membrane, having a weight about 50 to 500 GSM; and a composite thermal barrier layer including a first inner layer made from thermally resistant fibres having a weight about 50 to 500 GSM; a second layer made from thermally resistant fibres and its blends having a weight about 50 to 500 GSM; and a quilting thread made of high crystalline non-melting inherently fire-retardant threads (yarns/filaments) having a direct count ranges from 30-150Tex for quilting said first and second layers to form a predefined quilting pattern in such a way that said protective composite ensemble complies requirements of EN 469:2005, which defines the performance requirement for protective clothing for firefighters, for following test standards: ISO 6330: 2012C, ISO 17493, EN ISO 9151:2016, EN ISO 6942: 2002, EN ISO 6530: 2005 and EN ISO 11092: 2014.
[16] According to an embodiment, said outer layer is a woven/knitted, oil and water-resistant layer made from thermally resistant fibres and its blends having a weight about 220 GSM.
[17] In said embodiment, the moisture barrier layer is a nonwoven layer having a weight about 145 GSM is laminated with a PU/PTFE membrane.
[18] In said embodiment, the first layer of said thermal barrier layer is a woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM.
[19] In said embodiment, the second layer of said thermal barrier layer is a nonwoven layer made of 100% meta-aramid having weight about 160 GSM.
[20] In said embodiment, said high crystalline non-melting inherently fire-retardant quilting thread (yarns/filaments) is a para-aramid thread having a direct count of 50 Tex that runs in a straight-line path at an angle from both sides of a selvedge of said thermal barrier layer.
[21] In said embodiment, said at least said chemically modified fibres are selected from the group of polynosic rayon, fire resistant polynosic rayon, viscose rayon, fire resistant viscose rayon, fire resistant cotton, acetate, fire resistant polyester, wool, and fire-resistant wool or combinations thereof.
[22] In said embodiment, said at least said inherently fire-retardant fibres are selected from the group of meta-aramids, para-aramids and other aramids, Aromatic Polyamide co-polymers, aromatic polyetser, Polybenzimidazole, Polyetherimide, polyimide, polyamide, polyimide-amidepolyethersulfone, polyetherekentone, polyolefins, carbon, modacrylic, acrylic, melamine, glass, Polyvinyl chloride, Polyvinlydene chloride, Polyvinyl alcohol (PVA), and polytetrafluoroethylene or combinations thereof.
[23] In said embodiment, said quilting thread may be selected from the group of polybenzimidazole, aromatic polyester (Vectran), Aromatic polyamides and polyimides that include PBO, PBI, Oxidized acrylics, and PANOX or combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS:
The various aspects, features, and advantages of the embodiment of the present invention, hereinafter more particularly described, will be more apparent from the following description taken in conjunction with the drawings, in which:
Figure 1 shows an enlarged view of a composite thermal barrier layer according to an aspect of the present invention; and
Figure 2 shows detailed views of a protective composite ensemble manufactured as a firefighting jacket having different fabric layers according to another aspect of the present invention.
Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure.
Throughout the drawings, it should be noted that like reference numbers depict the same or similar elements, features, and structures.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION:
[24] In general, the present invention discloses a composite thermal barrier layer of a protective composite ensemble comprising at least two fabric layers, first layer woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM; a second layer, nonwoven layer made of 100% meta-aramid having weight about 160 GSM and a quilting thread made of 100% a para-aramid thread of 50Tex for quilting said first and second layers to form a predefined quilting pattern in such a way that with said quilting, said composite thermal barrier layer, post five washes has a relative washing shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 6330: 2012 when compared to existing fabrics available in the market and a relative thermal shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 17493 when compared to existing fabrics available in the market.
[25] According to another aspect, the present invention discloses a process of manufacturing said composite thermal barrier layer comprising the steps of:
a) providing a first inner woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM.
b) providing a nonwoven second layer made of 100% meta-aramid having weight about 160 GSM; and
c) quilting said first and second layers with a quilting thread made of 100% a para-aramid thread of 50Tex to form a predefined quilting pattern, in such a way that with said quilting, said composite thermal barrier layer, post five washes has a relative washing shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 6330: 2012 when compared to existing fabrics available in the market and a relative thermal shrinkage reduction of at least 10% in a wrap direction and at least 10% in a weft direction when tested pursuant to ISO 17493 when compared to existing fabrics available in the market.
[26] According to still another aspect, the present invention discloses a protective composite ensemble comprising woven/knitted, oil and water-resistant outer layer made from thermally resistant fibres and its blends having a weight about 220 GSM; a nonwoven moisture barrier layer from thermally resistant fibre and its blends, laminated with a PU/PTFE membrane, having weight about 145 GSM; and a composite thermal barrier layer including a first layer woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 150 GSM; a second layer, nonwoven layer made of 100% meta-aramid having weight about 160 GSM and a quilting thread made of 100% a para-aramid thread of 50Tex for quilting said first and second layers to form a predefined quilting pattern in such a way that said protective composite ensemble complies requirements of EN 469:2005, which defines the performance requirement for protective clothing for firefighters, for following test standards: EN ISO 9151:2016, EN ISO 6942: 2002, EN ISO 6530: 2005 and EN ISO 11092: 2014.
Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.
The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
Figures discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way that would limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged environment. The terms used to describe various embodiments are exemplary. It should be understood that these are provided to merely aid the understanding of the description, and that their use and definitions in no way limit the scope of the invention. Terms first, second, and the like are used to differentiate between objects having the same terminology and are in no way intended to represent a chronological order, unless where explicitly stated otherwise.
[27] Referring Figure 1 shows an enlarged view of a composite thermal barrier layer according to an aspect of the present invention. Accordingly Figure 1 shows, a composite thermal barrier layer ensemble (100) of two or more different textile layers for a thermal barrier layer. The composite thermal barrier layer ensemble (100) comprises a first inner layer (101) made from thermally resistant fibres having a weight about 50 to 500 GSM and a second layer (102) made from thermally resistant fibres and its blends that include fibres selected from inherently fire-retardant fibres and/or chemically modified fibres or combination thereof having a weight about 50 to 500 GSM.
[28] According to an embodiment, the first inner layer (101) is a woven/knitted layer made of meta-aramid and fire-retardant (FR) viscose in a 50:50 ratio having a weight about 100 to 200 GSM and more preferably150 GSM.
[29] According to the embodiment, the second layer (102) is a nonwoven layer made of 100% meta-aramid having weight about 160 GSM.
[30] According to the embodiment, a quilting thread (103) is made of a high crystalline non-melting inherently fire-retardant threads (yarns/filaments) of 30 Tex -150 Tex, more preferably, 50 Tex, for diagonally quilting said inner woven layer (101) and nonwoven layer (102) composite thermal barrier layer (100) to form predetermined shapes of predetermined sizes. According to the present invention, the quilting thread is made of 100% para-aramid of 50 Tex.
[31] In one embodiment, the composite thermal barrier layer (100) may be quilted form the top in such a way that lines of said quilting thread (103) run a straight-line path at an angle from both sides of a selvedge of said composite thermal barrier layer (100) for achieving lower washing and thermal shrinkage post wash.
[32] Referring Figure 2 shows detailed views of a protective composite ensemble manufactured as a firefighting jacket having different fabric layers according to another aspect of the present invention. According to one embodiment, a structural firefighting protective composite ensemble (200) is disclosed. The structural firefighting protective composite ensemble (200) may comprise an oil and water-resistant and Inherent FR or treated FR Fabric outer layer (201), a nonwoven felt moisture barrier layer (202) having thermally resistant fibres or its blend laminated with a PU/PTFE membrane and a composite thermal barrier layer (203) for a thermal protection.
[33] In one embodiment, the composite thermal barrier layer (203) includes an inner woven layer (204) made from a blend of a meta-aramid and a FR viscose fibres, a nonwoven layer (205) made of a meta-aramid fibres and a quilting thread (206) made of a para-aramid thread, for predefined quilting pattern said inner woven layer (204) and nonwoven layer (205) composite thermal barrier layer (203) to form predetermined shapes of predetermined sizes in such a way that lines of said quilting thread (206) run a straight-line path at an angle from both sides of a selvedge of said composite thermal barrier layer (203), said quilting achieves lower thermal shrinkage post wash and provides structural support to constituent composite thermal barrier layer (203).
[34] According to the present invention, the outer layer, moisture barrier layer, non-woven layer and inner woven/knitted layer fabrics may be selected from the group of chemically modified fibres that include but not limited to polynosic rayon, fire resistant polynosic rayon, viscose rayon, fire resistant viscose rayon, fire resistant cotton, acetate, fire resistant polyester, wool, and fire-resistant wool or combinations thereof.
[35] Further, fibres may be selected from the group of inherently fire resistant fibres that include but not limited meta-aramids, para- aramids and other aramids, Aromatic Polyamide co-polymers, aromatic polyetser, Polybenzimidazole, Polyetherimide, polyimide, polyamide, polyimide- amide, polyethersulfone, polyetherekentone, polyolefins, carbon, modacrylic, acrylic, melamine, glass, Polyvinly chloride,Polyvinlydene chloride, all kinds of Polyvinyl alcohol (PVA) and their derivatives, and polytetrafluoroethylene or combinations thereof.
[36] According to the present invention, the outer layer fabrics can be woven or knit, and moisture barrier layer fabrics can be woven, knit or nonwoven fabric which are further coated or laminated. As shown in fig: 1, (100) composite thermal barrier layer (101) can be woven or knitted, layer (102) is nonwoven and woven and knit.
[37] The quilting thread (103) could be filament or yarn consisting of high crystalline non-melting inherent fire-retardant yarns/filaments such as polybenzimidazole, aromatic polyester (Vectran), Aromatic polyamides and polyarimids like PBO, PBI, Oxidized acrylics or PANOX or combination thereof.

Example 1:
[38] Composite thermal barrier layer (100) 1: The inner layer (101) and non-woven layer (102) are quilted with quilted thread (103) made of 100% para-aramid thread of 50Tex to make a composite thermal barrier layer (100).
[39] Composite thermal barrier layer 2: The inner layer and thermal barrier layer quilted with a quilted thread made of 100% Meta -aramid thread of 50Tex to make a composite thermal barrier ensemble.
Table 1: Washing and thermal Shrinkage of Composite thermal barrier layer

Method
Composite
Layer After 5 washes ISO 6330 6N ISO 17493 - 5mins 180?C (After 5 wash)
Warp Weft Warp Weft
Meta-aramid Quilted -2.0% -1.0% -2.5% -1.0%
Para-aramid Quilted (Composite thermal barrier layer (100)) -1.5% -0.5% -2.0% 0.5%
Relative Reduction in shrinkage 25% 50% 20% 50%
[40] Pursuant to a comparative test analysis done in accordance with the requirements of ISO 5770 and ISO 17493 after five wash/dry cycle treatment according to the ISO 6330: 2012 procedure 6N at 60?C, as per requirements of EN469:2005 shows the following results:
[41] Comparative test analysis for both composite thermal barrier layer (1 and 2) post five washes according to ISO 6330: 2012 procedure 6N at 60?C from the table shows that the composite thermal barrier layer quilted with 100% para-aramid thread of 50Tex has a relative washing shrinkage reduction of at least 25% in a wrap direction and at least 50% in a weft direction comparing to the composite fabric layer ensemble quilted with 100% meta-aramid thread of 50Tex.
[42] Comparative test analysis for both composite thermal barrier layer (1 and 2) post five washes from the table shows that the composite thermal barrier layer quilted with 100% para-aramid thread of 50Tex has a relative thermal shrinkage reduction of at least 20% in a wrap direction and at least 50% in a weft direction, comparing to the composite thermal barrier layer quilted with 100% meta-aramid thread of 50Tex, when tested pursuant to ISO 17493 at 180?C for five minutes for post 5 washes ISO 6330: 2012 procedure 6N at 60?C.
[43] Therefore, it may be inferred that using a para-aramid thread during quilting operation of the composite thermal barrier layer along with inner liner may offer better fire borne injury protection than the quilted assembly using meta-aramid as a thread in quilting operation.

Example 2
[44] A firefighting garment may be designed comprising the composite thermal barrier layer (203) of present invention. The garment ensemble consists of oil & water-resistant outer layer (201) having a 220 GSM made from a blend of 93% meta-aramid, 5% para-aramid and 2% anti-static fibres, a moisture barrier layer (202) having a 145±10 GSM made of 47% meta-aramid, and 23% para-aramid fibres laminated with a 30% PU/PTFE bi-component membrane and a composite thermal barrier layer (203).
[45] The composite thermal barrier layer (203) includes an inner woven layer (204) having a 150±10 GSM, made from a blend of meta-aramid and FR viscose fibres in a 50:50 ratio, a nonwoven layer (205) having a 160GSM made of 100% meta-aramid fibres, a quilting thread (206) made of 100% para-aramid thread of 50 Tex, for predefined quilting pattern said inner woven layer (204) and nonwoven layer (205) ensemble to form predetermined shapes of predetermined sizes in such a way that lines of said quilting thread (206) run a straight-line path at an angle from both sides of a selvedge of said composite thermal barrier layer (203).
[46] The protective composite ensemble is designed to be heat transfer (flame and radiation) according to the requirements of EN ISO 9151:2016 and EN ISO 6942: 2002, after pre-treatment of five wash/dry cycle treatment according to the ISO 6330: 2012 procedure 6N at 60?C. The test analysis shows the following results:
S. No Test Parameter Test Method Results
1 Heat Transfer (Flame)
After Pre-treatment EN ISO 9151: 2016
HTI24 = 22.7
HTI24-12 = 7.2
2 Heat Transfer (Radiation) After Pre-treatment EN ISO 6942: 2002 Method B at 40kW/m² RHTI24 = 31.1
RHTI24-12 = 9.4
wherein,
HTI12 (flame) and RHTI12 (radiation) refers to the time taken to rise in temperature by 12?C, correlating to threshold of pain of a human being (first degree burns).
HTI24 (flame) and RHTI24 (radiation) refers to the time taken to rise in temperature by 24?C, correlating to threshold of a second degree burns of the human skin (blisters).
HTI24-12 (flame) and RHTI24-12 (radiation) refers to the time taken to rise in temperature from 12?C to 24?C, corresponding to the time taken to raise from the threshold of pain to the second degree burn.
[47] Test analysis pursuant to EN ISO 9151:2016 for protective composite ensemble post five washes from the table shows that protective composite ensemble has a heat resistance (flame) time of at least 22.7 seconds for rise in temperature by 24?C correlating to threshold of a second degree burns of the human skin (blisters) and at least 7.2 seconds for rise in temperature from 12?C to 24?C corresponding to the time taken to raise from the threshold of pain to the second degree burn.
[48] Test analysis pursuant to EN ISO 6942: 2002 method B at 40 kW/m2 for protective composite ensemble post five washes from the table shows that protective composite ensemble has a heat resistance (radiation) time of at least 31.1 seconds for rise in temperature by 24?C correlating to threshold of a second degree burns of the human skin (blisters) and at least 9.4 seconds for rise in temperature from 12?C to 24?C corresponding to the time taken to raise from the threshold of pain to the second degree burn.
[49] The protective composite ensemble is designed to be hazardous liquid chemical penetration resistant and optimum water vapour resistant according to the requirements of EN ISO 6530: 2005 and EN ISO 11092: 2014. The test analysis shows the following results:
S. No Test Parameter Test Method Results
1 Resistance to
Penetration by
liquid Chemicals
(As Received) EN ISO 6530: 2005
1. 40% NaOH
2. 36% HCl
3. 30% H2SO4
4. 100% o-xylene Penetration Repellency
1. Nil 99.5%
2. Nil 98.0%
3. Nil 99.1%
4. Nil 93.1%
2 Water vapour Resistance EN ISO 11092: 2014 Ret = 39.7 m². Pa/W

[50] Test analysis pursuant to treatment of the protective composite ensemble in accordance with requirements of EN ISO 6530: 2005 has hazardous liquid chemical penetration resistance for NaOH, HCL, H2SO4 and o-xylene.
[51] Test analysis pursuant to treatment of the protective composite ensemble in accordance with requirements of EN ISO 11092: 2014 has a water vapour resistance of 39.7 m2. Pa/W.
[52] The present invention has been described in the context of a composite thermal barrier layer of a protective ensemble which is lighter and can be used as firefighting apparel. The invention discloses using para-aramid thread for achieving lower thermal and washing shrinkage post wash. However, the composite thermal barrier layer can be used in any type of protective ensemble for any fire-retardant applications such as home interiors, Electric Arc suits and fire blankets.
[53] In the foregoing detailed description of aspects embodiments of the invention, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the detailed description of aspects, embodiments of the invention, with each claim standing on its own as a separate embodiment.
[54] It is understood that the above description is intended to be illustrative, and not restrictive. It is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined in the appended claims. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” is used as the plain-English equivalent of the respective term “comprising” respectively.