MULTI-LAYER PROTECTIVE FABRIC FOR FIREFIGHTER SUIT

Abstract

The existing firefighter suits made from Nomex and Kcvlar provide adequate thermal insulation for most scenarios, withstanding temperatures up to 370°C and 420°C, respectively. However, in industrial settings where fires can reach extremely high temperatures, these materials aren't practical to withstand temperature above 400°C. This project introduces a multilayered suit material, HiCL (High Silica, Ceramic, Linen). designed to withstand temperatures up to 850°C, significantly enhancing firefighter protection. HiCL's three-layer structure provides superior thermal resistance: the outer layer of high silica fabric shields against initial heat. the ceramic blanket middle layer acts as a critical thermal barrier, and the linen inner layer offers comfort. This design ensures no heat transfer to the firefighter's body, even in extreme conditions. Industrial fires, pOlrticularly in petroleum and chemical industries, present unique challenges due to their intensity and complexity. The HiCL suit's advanced thermal protection allows firefighters to operate safely and effectively in these high-risk environments, where existing suits are inadequate. To validate its performance, the composite material undergoes Thermogravimetric Analysis (TGA) to assess thermal stability. Field tests in controlled environments further ensure the suit's reliability. By incorporating advanced materials and design, this project aims to revolutionize firefighter protective suit, enhancing safety and operational effectiveness in the most demanding situations ..

Specification

DESCRIPTION
The primary motivation for this project is to provide firefighters with better equipment, ensuring
their safety in the most hazardous environments. Despite the critical and lifecsaving nature of
their work, frrefighter suits in Tamil Nadu, INDIA, have remained unchanged for over 30 years.
This project aims to introduce significant improvements to these suits, offering enhanced
protection and ultimately saving lives.
Firefighters are often exposed to extreme conditions, including high temperatures, flames, and
hazardous materials. Their safety gear must provide not only protection from heat but also
comfort and flexibility to allow them to perform their duties effectively. The traditional suits
currently in use have several limitations, including insufficient thermal resistance and lack of
advanced materials that can provide enhanced protection in extremely critical fire accident·
situation where only frre bats are used , where in certain situation the fire bats become not
practical for putting off the fire.
The core idea of this project is to enh~·nce the thermal resistance of firefighter suits by creating
a composite fabric that binds multiple advanced materials together. This innovative approach
aims to offer better heat resistance and durability compared to individual fabric components. By
doing so, we can allow tirefighters to endure more dangerous environments with minimal
damage fi·om high flames.
The proposed suit material is a three layered Thermal resistant fabric where High silica fabric is
the outer most layer which is directly exposed to the high temperature that withstands the most
of the thermal insulation, then the middle layer is composed of Ceramic blanket that is an
additional thermal insulation that effectively block heat transfer and finally the inner most layer
is Linen that offer comfort and we arability for the fire fighters .
FIELD OF INVENTION
The existing firefighter suits, predominantly made from Nomex and Kevlar, have been the instance, can withstand temperatures up to approximately 370°C, while Kevlar can endure
up to about 420°C. This level of thermal resistance has been adequate for most firefighting
operations, allowing firefighters to safely combat the flames they face in various scenarios.
However, as fires become more severe, particularly in industrial settings, the need for more
advanced protection has become evident. In this project, we aim to introduce a multilayered
suit material that significantly enhances the thermal resistance capabilities of firefighter suits,
pushing the boundaries of safety and protection. Our proposed suit design can withstand
temperatures up to 850°C, a substantial improvement· over the existing Nomex and Kevlar
suits. This enhancement provides a significant advantage for firefighters, especially when
dealing with critical fire accidents in high-risk environments such as petroleum and chemical
industries. These industrial fires present unique and daunting challenges compared to
domestic fires. In a typical house fire, once the primary source of ignition is identified and
addressed, the flames can often be extinguished relatively quickly. However, in industrial
settings, the intensity and complexity of the tires are far greater. Fires in petroleum and
chemical industries can reach extremely high temperatures, and the presence of volatile
substances can exacerbate the situation, making it incredibly difficult to control and
extinguish the flames. The enhanced thermal resistance offered by our multilay!'!red suit
design allows firefighters to operate in more hazardous environments with reduced risk of
injury. This is particularly important in industrial fire scenarios, where the intensity of the
flames can be tremendous. In such situations, the ability to withstand higher temperatures
can make the difference between life and death, both for the firefighters aud the victims they
are trying to rescue. Thermogravimetric analysis (TGA) was conducted to assess the thermal
stability and resistance of the composite fabric. Field testing in controlled environments will
simulate real-life conditions to verify the suit's performance. Feedback from fu·efighters will
be gathered to make necessary adjustments and improvements, ensuring that the final product
meets their needs and expectations.
BACKGROUND OF INVENTION
This project focuses on the domain of thermal protective clothing for firefighters. The currently
used materials, Nomex and Kevlar, have long been standards in firefighter protective gear. These
materials are highly regarded for their excellent thermal insulation properties. Nomex can
withstand temperatures up to approximately 3 70°C, while Kevlar can endure up to about 420°C.
Their effectiveness has been validated through extensive testing and refinement, as detailed in
0 · the "Mechanical properties of No even more advanced protective materials, especially given the increasingly severe nature of
fires, particularly in industrial settings.
The primary objective of this project is to develop a new composite material that offers
significantly greater thennal resistance than both Nomex and Kevlar. The proposed multilayered
suit material is designed to withstand temperatures up to 850°C, providing a substantial
improvement in protection. This enhancement is particularly crucial for firefighters operating in
critical situations, such as those encountered in petroleum and chemical industries. These
environments can present extremely high temperatures and complex fire scenarios that make
traditional protective materials insufficient.
In a typical house fire, identifying and addressing the primary source of ignition can often lead
to quickly extinguishing the flames. However, industrial fires are markedly different. They
involve much higher temperatures and the presence of volatile substances that can rapidly
escalate the intensity and complexity of the fire. This makes it incredibly challenging to control
and extinguish the flames, even after identifYing the main cause. In such scenarios, the ability
to withstand higher temperatures becomes vital for both firetlghter safety and the successful
rescue of victims.
Our project aims to address these challenges by introducing a multilayered suit design composed
ofhigh-performance materials. The outer layer of the suit is made from high silica fabric, known
for its excellent thermal resistance ancl durability. This layer serves as the first line of defense,
protecting the inner layers from direct exposure to extreme heat and flames. The middle layer is
constructed from a ceramic blanket, which is renowned for its superior insulation properties .
This layer acts as a critical barrier against heat transfer, ensuring that the innermost layer remains
unaffected by the extemal temperatures. Finally, the inner layer of the suit is made from linen,
a natural fiber that offers comfort, breathability, and moisture-wicking prope11ies. This
combination of materials provides unparalleled thermal protection while maintaining the
comfort and flexibility needed for effective frrefighting operations.
The enhanced thermal resistance offered by our multilayered suit design allows firefighters to
operate in more hazardous environments with a reduced risk of injury. This is especially
important in industrial fire scenarios, where the intensity of the flames can be tremendous. In
~ such situations, the ability to withstand higher temperatures can make the difference het.ween
N o life and death for both the firefighters and the victims they are trying to rescue.
material can surpass the thermal resistance of existing firefighter suits. The new suit design not
only enhances the safety of firefighters but also improves their ability to perform their duties
effectively in high-risk environments. By incorporating advanced materials and innovative
design, we provide firefighters with the tools they need to tackle even the most severe fire
scenanos.
In conclusion, this project represents a significant advancement in firefighter safety and
protection. By developing a new composite material that can withstand temperatures up to
850°C, we can provide firefighters with enhanced protection that meets the demands of modern
firefighting. This itmovation has the potential to save lives and improve the overall effectiveness
of firefighting operations, pat1icularly in high-risk industrial environments. Through rigorous
testing and feedback, we aim to deliver a suit that not only meets but exceeds the expectations
of those who risk their lives to keep us safe.
SUMMARY OF THE INVENTION
Objective:
The HiCL material, abbreviated fi·om high silica, ceramic, and linen, is designed to enhance
heat isolation, allowing firefighters to withstand temperatures up to 850°C. This significant
improvement over existing materials like Nomex and Kevlar, which can withstand
approximately 370°C and 420°C respectively, makes HiCL an essential advancement for
handling critical fire situations in industrial environments such as petroleum and chemical
industries.
This project focuses on addressing the complexities and technical limitations faced by
fu·efightcrs. It aims to provide greater freedom to work under high temperatures above
700°C-conditions currently managed only by firefighting robots. While robots are useful,
they arc limited in their scope of tasks. Human firefighters, with their skill and experience,
are far more effective in rescuing victims in complex situations and handling the intricacies
of critical firt accidents.
The HiCL composite material stoit provides superior protection, enabling firefighters to
withstand high temperatures and find the root cause of fires in severe accidents. While
firetighting robots can assist, they often struggle with the operational challenges of locating
and extinguishing the fu·e. ln some scenarios, controlling such intense fifeS is nearly
impossible with existing firefighting robots alone .
By offering enhanced thermal resistance and durability, the HiCL suit significantly improves
the safety and effectiveness of firefighters. It allows them to pcrfonn their duties more
efficiently and safely, even in the most hazardous conditions. This innovation is a crucial step
forward in improving fire fighting capabilities and ensuring that firefighters can protect lives
more effectively in critical situations. The extensive Thermogravimetric Analysis (TGA)
confirms the superior thermal resistance of the HiCL material, proving its potential to surpass
current firefighter suit materials.
DESCRIPTION OF THE FIGURE BELOW
Figure I:
Thermogravimetric Analysis (TGA), following ASTM E 1131 standards, measures weight
changes of materials as a function of temperature or time under a controlled atmosphere. The
graph clearly indicates that the test material can withstand temperatures up to 850°C, with a mass
loss of only 6.15% of the test specimen. This demonstrates the material's substantial thermal
resistance and stability under extreme conditions.
Figure 2:
This image illustrates the composite material's arrangement: the outermost layer is high silica
fabric, the middle layer is ceramic fabric, and the innermost layer is linen. This layered structure
optimizes thermal resistance of the firefighters suit.
Detailed Description:
The selection of materials for this project is based purely on their thermal resistance, ensuring
each layer contributes effectively to resisting high external temperatures in a fire accident. Hi
silica fabric was chosen fi·om a variety of researched thermal-resistant materials, including
fiberglass fabric, leached silica fabric, silicon fiberglass fabric, Meta Aramide fabric, PTFE
(Teflon) fabric, and zirconia fabric. The choice was based on multiple factors:
I. Thickness: Ensuring the suit material does :1ot become too bulky, thus maintaining the
comfort and fi.mctionality of the fu·efighter suit.
2. Thermal Conductivity: The material must not only withstand high temperatures but also
prevent heat transfer to the next layer of the composite material, ensuring effective
insulation.
3. Weight and Structural Strength: The fabric must be robust and satisfy the durability
requirements of a firefighter suit without compromising mobility.
The second layer's main function is to completely halt thermal conductivity fi·om the first layer.
This is where the ceramic blanket comes into play. Ceramic fabric is highly capable of arresting
thermal conductivity and can withstand high temperatures simultaneously. It has the added
advantage of being less than 0. 75 inches thick, making it an effective structural barrier to heat
transfer.
The final layer of the composite material is linen, chosen for its ability to withstand high
temperatures and its comfort. Linen is breathable and lightweight, enhancing the wearability for
firefighters and ensuring the overall composite material remains light.
Together, these layers form the HiCL fabric material-high silica, ceramic, and linen-which
significantly enhances heat isolation. This allows firefighters to withstand temperatures up to
850°C,' which is impossible with current suits like Nomex and Kevlar. This innovation provides
firefighters with the pl'otection needed for critical rescue operations in extremely hightemperature
environments.
Process:
The project aims to develop a new composite material that is more thetmally resistant than the
current firefighter suits. This involves several key processes, stat1ing with fabricating the three
layers of materials by the sandwich method using conventional interlocking stitching. This
technique ensures that the high silica fabric, ceramic blanket, and linen layers are firmly held
together.
To verifY the thermal resistance of the proposed composite material, we conduct
Thermogravimetric Analysis {TGA). This test is crucial as it assesses the thermal stability by
analyzing the mass change of the material as a function of temperature. TGA is the primary test
to determine whether the new composite material outperforms existing materials like Nomex and
Kevlar.
The principle ofTGA involves gradually heating the fabric from zero to high temperatures and
recording the mass changes. The resulting TGA graph shows the relatic. ~shir between
temperature and weight loss. A sudden, drastic change in the graph indicates a significant thermal
event, such as decomposition or phase transition. By studying the graph patterns, specitically the
number of steps and the mass at each step corresponding to the temperature, we can evaluate the
material's performance.
The results from TGA provide critical data on how the r.ew composite material responds to high
temperatures. If the material exhibits stable mass retention at higher temperatures compared to
existing materials, it confirms the superior thermal resistance of the HiCL (high silica, ceramic,
linen) fabric. This enhanced thetmal protection is vital for firefighters working in extremely hightemperature
environments, allowing them to pertonn their duties more safely and effectively.
CLAIMS
We Claim:
I. The HiCL(High Silica Fabric; Ceramic Fibre; Linen Fabric) composite material
exhibits a thermal resistance that is 400°C higher thancurrently existing firefighter
suits. This significant increase ensures enhanced safety for firefighters operating in
extreme conditions.
2. The 1-liCL(I-Iigh Silica Fabric; Ceramic Fibre; Linen Fabric) material is composed of
three layers: High Silica fabric, Ceramic 131ankd, and Linen. In contrast, existing
firefighter suits typically have only one layer, which is structurally less effective in
providing thermal resistance.
3. The combination of High Silica fabric and Ceramic Blanket allows the HiCL
(High Silica Fabric; c~ran~ic Fibre; Linen Fabric) material to resist temperatures up
to 850°C. This multilayer stmcture ensures that no heat is transferred to the inner
Linen layer, which is in direct contact with the firefighter's body, thus maintaining
comfy and safety.
4. The proposed HiCL(High Silica Fabric; Ceramic Fibre; Linen Fabric) material is
designed to be sturdy and durable against prolonged exposure to extreme heat,
ensuring long-term reliability and protection for firefightersin high-risk environments.

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