AA812-PCT
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[NAME OF DOCUMENT] SPECIFICATION
[TITLE OF THE INVENTION] Layered Heat-Proof Protective
Clothing
Technical Field
5 [0001]
The present invention relates to layered heat-proof
protective clothing, and more specifically it relates to
heat-proof protective clothing having a layered structure
with not only excellent chemical resistance and
10 breathable waterproofness, but also a high heatinsulating
property, lightweight properties, and
flexibility.
Background Art
[0002]
15 The fibers used to compose heat-proof protective
wear worn by firemen during extinguishing operations have
conventionally been noncombustible asbestos fiber, glass
fiber and the like, but heat-proof flame retardant
organic fibers such as aramid fibers, polyphenylene
20 sulfide fibers, polyimide fibers, polybenzimidazole
fibers and polybenzoxazole fibers have come to be most
commonly used in recent years because of environmental
problems, and for greater mobility.
In order to prevent radiant heat into fabrics as
25 well, many products are surface-treated by coating, vapor
deposition, sputtering or plating of metallic aluminum or
the like, and these are used as front fabric layers.
Heat-insulating properties against radiant heat have been
improved considerably by such methods.
30 In recent years, especially, as preventing radiant heat
has become an extremely important specification. Approach
A of ISO 11613 assigns specifications of at least 13
seconds and at least 18 seconds for a flame exposure test
(ISO 9151) and a radiant heat exposure test (ISO 6942-
35 2002), respectively.
Furthermore, in order not only to provide heat
resistance but also to prevent heat stroke by heat stress
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during work activities in the summer season, methods used
in recent years have included those that employ ice packs
in inner layers, and ensuring air permeability by sewing.
Lightweightness is another means of reducing heat stress
5 that has become an issue of interest in recent years.
Such heat-proof protective wear includes protective
wear with a two-layer structure as disclosed in Japanese
Unexamined Patent Publication No. 2006-16709, and front
fabric layers composed of differential-shrinkage spun
10 yarn, as disclosed in Japanese Unexamined Patent
Publication No. 2009-280942, but the necessary
performance has often been inadequate, or sufficient
lightweightness has not been achieved, and as a result
the heat-proof protective clothing has not been fully
15 satisfactory.
Citation List
Patent Literature
[0003]
[Patent document 1] Japanese Unexamined Patent
20 Publication No. 2006-16709
[Patent document 2] Japanese Unexamined Patent
Publication No. 2009-280942
[Disclosure of the Invention]
Problems to be Solved by the Invention
25 [0004]
It is an object of the invention to solve the
aforementioned problems of the prior art by providing
layered heat-proof protective clothing that not only has
excellent heat-proof chemical resistance and breathable
30 waterproofness, but is also lightweight and has a high
heat-insulating property, meeting the specifications of
lightweightness, and the flame exposure test (ISO 9151)
and radiant heat exposure test (ISO 6942-2002) of
Approach A and B of ISO 11613.
35 Means for Solving the Problems
[0005]
As a result of much diligent research on these
- 3 -
problems, the present inventors have solved them by the
layered heat-proof protective clothing described below,
and have thereupon completed this invention.
Specifically, the invention provides layered heat-
5 proof protective clothing comprising a front fabric
layer, and a breathable waterproof interlayer and/or
heat-shielding layer, the layered heat-proof protective
clothing having a thickness of 2.5 mm or greater after 5
washings according to ISO 6330, and a time to temperature
10 increase by 24°C (RHTI24) of 18 seconds or longer in a
heat transfer (radiant heat exposure) test (ISO 6942-
2002) in European Approach A (Section 4) according to ISO
11613.
Effect of the Invention
15 [0006]
The layered heat-proof protective clothing of the
invention not only has excellent heat-proof chemical
resistance and breathable waterproofness, but is also
lightweight and has a high heat-insulating property,
20 meeting the specifications of the flame exposure test
(ISO 9151) and radiant heat exposure test (ISO 6942-2002)
of Approach A and B of ISO 11613, and can therefore be
used as layered heat-proof protective clothing with low
heat stress.
25 Brief Description of the Drawings
[0007]
Fig. 1 is a graph showing the relationship between
lattice spacing and temperature increase for a double
weave fabric composing the front fabric layer of layered
30 heat-proof protective clothing according to the
invention.
Fig. 2 is a graph showing the relationship between
lattice spacing and thickness variation for a double
weave fabric composing the front fabric layer of layered
35 heat-proof protective clothing according to the
invention.
Fig. 3 is a weave diagram showing an example of a
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woven fabric composing the heat-shielding layer of
layered heat-proof protective clothing according to the
invention.
Fig. 4 is a weave diagram showing another example of
5 a woven fabric composing the heat-shielding layer of
layered heat-proof protective clothing according to the
invention.
Fig. 5-1 is a weave diagram showing another example
of a woven fabric composing the heat-shielding layer of
10 layered heat-proof protective clothing according to the
invention.
Fig. 5-2 is a weave diagram showing another example
of a woven fabric composing the heat-shielding layer of
layered heat-proof protective clothing according to the
15 invention.
Fig. 5-3 is a weave diagram showing another example
of a woven fabric composing the heat-shielding layer of
layered heat-proof protective clothing according to the
invention.
20 Fig. 5-4 is a weave diagram showing another example
of a woven fabric composing the heat-shielding layer of
layered heat-proof protective clothing according to the
invention.
Fig. 5-5 is a weave diagram showing another example
25 of a woven fabric composing the heat-shielding layer of
layered heat-proof protective clothing according to the
invention.
Fig. 5-6 is a weave diagram showing another example
of a woven fabric composing the heat-shielding layer of
30 layered heat-proof protective clothing according to the
invention.
Fig. 5-7 is a weave diagram showing another example
of a woven fabric composing the heat-shielding layer of
layered heat-proof protective clothing according to the
35 invention.
Fig. 5-8 is a weave diagram showing another example
of a woven fabric composing the heat-shielding layer of
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layered heat-proof protective clothing according to the
invention.
Fig. 6 is a schematic cross-sectional view showing
shape deformation before and after flame exposure, for
5 layered heat-proof protective clothing according to the
invention.
Best Mode for Carrying Out the Invention
[0008]
Embodiments of the invention will now be explained
10 in detail.
The layered heat-proof protective clothing of the
invention is composed of a front fabric layer, and a
breathable waterproof interlayer and/or heat-shielding
layer, and it may be used as a union woven or knitted
15 fabric with the front fabric layer, interlayer and heatshielding
layer all consisting of para-aramid fibers or
meta-aramid fibers alone, or as blended or combined
filaments, such other blendable or combinable filaments
including polyphenylene sulfide fibers, polyimide fibers,
20 polybenzimidazole fibers, polybenzoxazole fibers,
polyamideimide fibers, polyetherimide fibers,
polyetherimide fibers or flame-retardant acrylic fibers,
with polychlal fibers, flame-retardant polyester fibers,
flame-retardant cotton fibers, flame-retardant rayon
25 fibers, flame-retardant vinylon fibers, flame-retardant
wool fibers, Pyromex, carbon fibers and the like.
However, so long as flame retardance of the fabric can be
satisfied, there is no problem with blending, combining
or union weaving or knitting of highly flammable fibers.
30 [0009]
Also, the para-aramid fibers are preferably fibers
composed of polyamide which has aromatic rings in the
main chain, and it may be poly-p-phenylene
terephthalamide (PPTA), or copolymerization-type
35 copolyparaphenylene-3,4'-oxydiphenylene terephthalamide
(PPODPA).
In particular, the front fabric layer must have
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properties such as heat-proofness, flame retardance, cut
resistance, high strength and high tensile strength, and
it is formed using meta-aramid fibers and para-aramid
fibers and some antistatic fibers although there is no
5 limitation to these, while the fabric form may be a
knitted or woven fabric or a nonwoven fabric, with woven
fabrics being preferred in practice.
Fibers such as meta-aramid fibers and para-aramid
fibers may be used as filaments, composite yarn, or spun
10 yarn composed of staple fibers, but in order to achieve
both resistance to hole burning in knitted/woven fabrics
during flame exposure and practical knitted/woven fabric
properties, the content of para-aramid fibers is, as a
recommendation, preferably 1 to 70 mass%.
15 The front fabric layer may be either a single weave
fabric or a double weave fabric. Double weave fabrics
have more excellent flame exposure resistance and radiant
heat exposure resistance for the same basis weight, and
double weave fabrics are especially preferred to satisfy
20 requirements for lightweightness and high heat-insulating
properties.
In other words, in order to minimize temperature
increase at sections corresponding to the skin side when
worn, it is considered effective to increase the
25 difference in thickness of the front fabric layer before
and after flame exposure, and in the case of a double
weave fabric, for example, this is accomplished because
fibers with different shrinkage factors are used to form
textures on the front and back, and the bundle spacing on
30 the front and back is varied to easily allow variation in
thickness.
[0010]
For example. Fig. 1 shows the relationship between
temperature increase (AT) on the section corresponding to
35 the skin side, and bundle spacing on the front and back
of the front fabric layer, after a lapse of 40 seconds
following 8 seconds of flame exposure in a (radiant heat
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+ flame exposure) test (ISO 17492) of the North American
Approach B (Section 5) according to ISO 11613, for
layered heat-proof protective clothing having the same
construction as Example 1 described below, and the graph
5 shows that there is an optimum value of the bundle
spacing for inhibition of temperature increase.
[0011]
Fig. 2 shows the relationship between thickness
variation of the front fabric layer and bundle spacing on
10 the front and back of the front fabric layer, after a
lapse of 40 seconds following 8 seconds of flame exposure
under the same conditions described above, and the graph
indicates that with a small bundle spacing, despite
thickness variation occurring by differential shrinkage
15 of the front and back fabrics, the gain is limited and a
sufficient temperature increase-inhibiting effect is not
exhibited. If the bundle spacing is too large, however,
there is a gain in thickness, but it may not be possible
to maintain an effective form for inhibiting temperature
20 increase, and therefore, as with the bundle spacing,
there is an optimal value of the thickness for inhibiting
temperature increase.
With layered heat-proof protective clothing having
the construction described above, the preferred front
25 fabric layer thickness variation is 2 mm or greater
(under a 3 g/cm^ load), and the preferred bundle spacing
is 15 to 45 mm and more preferably 15 to 30 mm.
Most preferably, the front fabric layer is composed
of a double weave fabric, the front fabric layer used
30 having a front side fabric and back side fabric whose TMA
shrinkage factor difference at 400°C (I50°C/min increase)
is at least 4%, and the variation in thickness of the
double weave fabric after 8 seconds of flame exposure
from the front side fabric side following ISO 17492 (TPP)
35 being 2 mm or greater.
Also, the double weave fabric of the front fabric
layer preferably has higher cut resistance in the back
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side fabric than the front side fabric.
In order to provide protective clothing with even
higher water resistance and chemical resistance, the
front fabric layer is preferably treated for water-
5 repellency and oil-repellency, with the treatment method
being coating, dipping, spraying, bath immersion or the
like.
By using an interlayer which is a woven or knitted
fabric mentioned above further subjected to laminating or
10 coating with a breathable waterproof layer film made of
polytetrafluoroethylene or the like, it is possible to
impart excellent breathable waterproof functioning and
chemical resistance.
The interlayer and/or heat-shielding layer with a
15 breathable waterproof function may be either separate or
integrated.
A separated 3-layered structure has more interlayer
air layers (heat-insulating layers) and is therefore
advantageous for the heat-insulating property, but it
20 will likely not exhibit any significantly different heatinsulating
property if the layering thickness is the
same.
The heat-shielding layer thickness is preferably
1.80 mm or greater, and the basis weight is preferably
25 110 to 150 g/m^
The heat-shielding layer is preferably obtained by
mixing high-shrinkage fibers at 2 to 20%, and exposing
the heat-shielding layered structure to wet and dry heat
conditions of 80°C or higher to cause shrinkage, to form a
30 heat-shielding layer with increased thickness (high
bulk). In order to obtain a heat-shielding layer of even
greater bulk, for example, they are used as warp yarn for
a woven fabric (in a design arrangement), so that
shrinkage is generated in the warp direction upon
35 exposure to wet and dry heat conditions of 80°C or higher,
and a heat-shielding layer of very high bulk is obtained,
or they are alternatingly arranged with non-high-
9 -
shrinkage fibers to obtain a knitted/woven fabric such as
an insulating shock-absorbing material (air packing).
In this case, in order to maintain pressure
resistance/form retention (during washing and wearing) in
5 the direction of thickness (bulk), for example, when an
insulating shock-absorbing material (air packing) is to
be obtained, a high effect is obtained by single/double
alternating arrangement or arrangement in a bordered or
striped fashion in the knitted/woven fabric. For a
10 bordered pattern (single/double alternating arrangement),
it is very useful for shrinkage-resistant or nonshrinkage
fibers to occupy the front side of the double
sections, with a greater percentage on the front side of
the double section than on the back side (for example,
15 frontrback ratio of 2:1), in order to exhibit a stable
and durable thickness.
Examples of design drawings for such a woven texture
are shown in Fig. 3 to Fig. 5. Fig. 5 shows an example
of an alternating arrangement, and the density and
20 alternating pitch may be varied to freely vary the
thickness or the thickness durability.
When a heat-shielding layer obtained in this manner
is to be used in layered heat-proof protective clothing,
either the front or back may be used as the flame side
25 (or the wearing (body) side), but considering that the
fireproof piece of the layered heat-proof protective
clothing is to be worn, it is important that it not be
hooked by toe tips or roughened fingertips, in which case
the wearing (body) side is preferably the side with fewer
30 irregularities; however, this is not a limitation if a
high heat-insulating property is the priority, and
irregularities (random, alternating or on one side) such
as found in insulating shock-absorbing materials (air
packings) may be present either on the front or back.
35 The layered heat-proof protective clothing of the
invention undergoes an alteration in cross-sectional form
as shown in Fig. 6, before and after flame exposure, and
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exhibits the excellent heat resistance described below.
Specifically, the layered heat-proof protective
clothing of the invention must have a thickness of 2.5 mm
or greater after 5 washings according to ISO 6330, and a
5 time to temperature increase by 24°C (RHTI24) of 18
seconds or longer in a heat transfer (radiant heat
exposure) test (ISO 6942-2002) in European Approach A
(Section 4) according to ISO 11613.
[0012]
10 If the time to temperature increase by 24°C (RHTI24)
in the radiant heat exposure test (ISO 6942-2002) is not
within this range it may not be possible to obtain an
adequate heat-insulating property, the weight of the
protective clothing may be excessively increased, and it
15 may not be possible to reduce heat stress.
[0013]
The following properties are also preferred
according to the invention.
(1) A time to temperature increase by 24°C (HTI24) of
20 13 seconds or longer in a heat transfer (flame exposure)
test (ISO 9151) in European Approach A (Section 4)
according to ISO 11613.
(2) A difference of at least 4 seconds between the
time to temperature increase by 24°C (RHTI24) and the time
25 to temperature increase by 12°C (RHTI12), in a heat
transfer (flame exposure) test (ISO 9151) in European
Approach A (Section 4) according to ISO 11613.
(3) A time to temperature increase by 24°C (TPP) of
at least 17.5 seconds in a (radiant heat + flame
30 exposure) test (ISO 17492) in North American Approach B
(Section 5) according to ISO 11613.
[0014]
The layered heat-proof protective clothing of the
invention obtained in this manner preferably has a basis
35 weight of 400 to 600 g/m^, and more preferably 450 ±50
g/m^.
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The layered heat-proof protective clothing of the
invention also preferably has a 2nd + 3rd degree burn
rate of no greater than 10%, according to ISO 13506.
[Examples]
5 [0015]
The invention will now be explained in greater
detail by the following examples. The evaluation methods
used in the examples were the following.
(1) ISO 6942-2002: RHTI24 (sec)
10 The time to 24°C increase (RHTI24) of a copper sensor
after initiating radiant heat exposure with heat flux of
40 kW/m^ was determined according to ISO 6942(2002).
(2) ISO 9151: HTI24 (sec)
The time to 24°C increase (HTI24) of a copper sensor
15 after initiating flame exposure was determined according
to ISO 9151.
(3) ISO 17492: TPP time (sec)
The time to 24°C increase (second degree burn) (TPP
time (sec)) after start of testing was determined
20 according to ISO 17492.
(4) ISO 13506: 2nd + 3rd degree burn rate (%)
The 2nd + 3rd degree burn rate was calculated
according to ISOI3506. In this case, however, the head
protector was not worn, and therefore measurement and
25 calculation was performed only for the body without the
head. For the evaluation, 100% cotton upper and lower
body underwear and uniform slacks were donned first, and
then the heat-proof protective clothing was worn and the
test was conducted.
30 (5) Thickness (mm)
Washing was conducted 5 times according to ISO 6330,
and the front fabric layer and the interlayer and/or
heat-shielding layer were layered. The thickness was
then measured under 3 g/cm^ according to JISL1018 (pilose
35 fabrics) .
[Example 1]
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The front fabric layer was a two-layer structure
woven fabric, using on the front side of the two-layer
structure a spun yarn comprising polymetaphenylene
isophthalamide fiber (product of Teijin Techno Products
5 Co., Ltd., Teijin Conex, mass-colored filament grade,
c/#NB32.2T51) and coparaphenylene 3,4'-oxydiphenylene
terephthalamide fiber (product of Teijin Techno Products
Co., Ltd., Technora, grade: T330BK1.7T51) (blending
ratio: meta 90:para 10, yarn count: 40/1).
10 On the back side there was used spun yarn composed
of coparaphenylene 3,4'-oxydiphenylene terephthalamide
fiber (product of Teijin Techno Products Co., Ltd.,
Technora, grade: T330BK1.7T51), and for the front and
back bundles, there was used on the front side, spun yarn
15 comprising metaphenylene isophthalamide fiber (product of
Teijin Techno Products Co., Ltd., Teijin Conex, masscolored
filament grade, c/#NB32.2T51) and coparaphenylene
3,4'-oxydiphenylene terephthalamide fiber (product of
Teijin Techno Products Co., Ltd., Technora, grade:
20 T330BK1.7T51), bundled with a lattice spacing of 15 mm,
and weaving with a warp x weft density of 96 x 86/inch.
The obtained greige was subjected to singeing,
desizing scouring and water-repellent/oil-repellent
treatment, by common processes. The basis weight of the
25 obtained fabric was 215 g/cm^, and the thickness was 0.80
mm (JISL1018).
For the interlayer there was used spun yarn
comprising polymetaphenylene isophthalamide fiber
(product of Teijin Techno Products Co., Ltd., Teijin
30 Conex, mass-colored filament grade, c/#NB32.2T51) and
coparaphenylene 3,4'-oxydiphenylene terephthalamide fiber
(product of Teijin Techno Products Co., Ltd., Technora,
grade: T330BK1.7T51) (blending ratio: meta 95:para 5,
yarn count: 40/1), and after weaving and finish cutting
35 by common methods, a polytetrafluoroethylene breathable
waterproofness film (product of Japan Goretex Co., Ltd.)
was laminated therewith to obtain a breathable waterproof
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layer with a basis weight of 120 g/cm^
For the heat-shielding layer there was used spun
yarn comprising polymetaphenylene isophthalamide fiber
(product of Teijin Techno Products Co., Ltd., Teijin
5 Conex, mass-colored filament grade, c/#NB32.2T51) and
coparaphenylene 3,4'-oxydiphenylene terephthalamide fiber
(product of Teijin Techno Products Co., Ltd., Technora,
grade: T330BK1.7T51) (blending ratio: meta 95:para 5,
yarn count: 40/1), and doubled yarn of this spun yarn
10 with polyester filaments with a BWS of 30% (product of
Teijin Fibers, Ltd., grade: TFYN301 SDC33T12) was
arranged in an alternating fashion as warp yarn, with
spun yarn as the weft yarn, and weaving at 88 warp/inch,
90 weft/inch in the pattern shown in Fig. 3, followed by
15 desizing scouring and finish cutting, to obtain a heatshielding
layer with a basis weight of 129 g/cm^ and a
thickness of 2.1 mm (JISL1018).
The obtained front fabric layer, interlayer and
heat-shielding layer were washed 5 times, the thickness
20 of the three layers was measured, and then the heatinsulating
and other properties were evaluated. The
results are shown in Table 1.
[Example 2]
The procedure was carried out in the same manner as
25 Example 1, except for using spunize filaments of
coparaphenylene 3,4'-oxydiphenylene terephthalamide fiber
(product of Teijin Techno Products Co., Ltd., Technora,
grade: GTN220T) for the back side of the front fabric
layer in Example 1.
30 [Example 3]
The procedure was carried out in the same manner as
Example 2, except that the weaving density of the front
fabric layer in Example 2 was changed to a warp x weft
density of 96 x 94/inch.
35 [Example 4]
The procedure was carried out in the same manner as
Example 1, except that the spun yarn count on the front
- 14 -
side of the front fabric layer in Example 1 was changed
to 36/1.
[Example 5]
The procedure was carried out in the same manner as
5 Example 1, except that the texture of the heat-shielding
layer in Example 1 was changed to the design shown in
Fig. 4.
[Example 6]
The procedure was carried out in the same manner as
10 Example 1, except that the heat-shielding layer in
Example 1 was changed to two attached single layers.
[Example 7]
The procedure was carried out in the same manner as
Example 1, except that the lattice spacing between front
15 and back bundles of the front fabric layer in Example 1
was changed to 30 mm.
[Comparative Example 1]
The procedure was carried out in the same manner as
Example 1, except that the thickness of the heat-
20 shielding layer in Example 1 was changed to 1.27 mm, and
the thickness of the 3 layers was changed to 2.4 mm.
[0016]
[Table 1]
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