Flash fire and chemical resistant fabric and garments

Abstract

A flash fire and chemical barrier composite fabric, comprising a flame resistant fibrous basic layer; a radiant heat and chemical permeation barrier, the barrier including a metalized polymeric chemical permeation resistant layer film; and a clear heat sealable outer film layer overlying the radiant barrier and forming a heat sealable outer surface of the composite fabric.

I claim: 
     
       1. A flash fire and chemical barrier composite fabric, comprising:
 a flame resistant fibrous basic layer having a side configured to face the skin of a wearer and an opposing side, the flame resistant fibrous basic layer comprising flame resistant fibers chosen from fiberglass, carbonized fibers, rayon, cotton, wool and aramid fibers, aromatic polyamide, polyester, or blends thereof, wherein the flame resistant fibrous basic layer is a woven, nonwoven, or knit; 
 a radiant heat and chemical permeation barrier layer, the bonded to the opposing side of the flame resistant fibrous basic layer, the radiant heat and chemical permeation barrier including comprising a metalized chemical permeation resistant polymeric film;, comprising one or more layers of polyolefin, a tie layer, and a clear heat sealable outer film bonded to the tie layer; wherein the radiant heat and chemical permeation barrier layer is structured such that the clear heat sealable outer film is the outermost layer providing a heat sealable outer surface thereon 
 an intumescent material positioned between the radiant heat and chemical permeation barrier layer and the flame resistant fibrous basic layer; and 
 a clear heat sealable outer film layer overlying the radiant barrier layer providing a heat sealable outer surface thereon. 
 
     
     
       2. The composite fabric of  claim 1 , wherein the flame resistant fibers are chosen from fiberglass, carbonized fibers, rayon, cotton, wool and aramid fibers, aromatic polyamide, polyester, or blends thereof. 
     
     
       3. The composite fabric of  claim 1 , wherein the radiant heat and chemical permeation barrier layer includes at least one component chosen from polyvinylidene chloride, ethylene vinyl acetate, chlorinated polyethylene, polyethylene, low density polyethylene, linear low density polyethylene, high density polyethylene, nylon, polyvinyl alcohol, polyester, polytetrafluoroethylene, fluorinated ethylene propylene, propylene, polyvinyl chloride copolymer, acrylic, acrylonitrile, and ethylene vinyl alcohol. 
     
     
       4. The composite fabric of  claim 3 , wherein the radiant heat and chemical permeation barrier layer includes a co-extruded polymeric chemical permeation resistant film. 
     
     
       5. The composite fabric of  claim 3 , wherein the radiant heat and chemical permeation barrier layer is a mono-layer film with the metalized layer adhered to the top and/or bottom thereof. 
     
     
       6. The composite fabric of  claim 4 , wherein the radiant heat and chemical permeation barrier layer is a co-extruded multilayer film with the metalized layer adhered to the top and/or bottom thereof. 
     
     
       7. The composite fabric of  claim 1 , wherein the flame resistant fabric is a woven, nonwoven, or knit. 
     
     
       8. The composite fabric of  claim 1 , wherein the sealable outermost surface of the outer film layer is an extruded layer of polyolefin chosen from LDPE, LLDPE, HDPE, EVA, EAA, and blends thereof. 
     
     
       9. The composite fabric of  claim 1 , wherein the sealable outermost surface of the outer film layer is a clear polyolefin film laminated to the metalized barrier film with a and the tie layer is selected from a group consisting of EVA, EMA, and EAA. 
     
     
       10. The composite fabric of  claim 1 , wherein sealable outermost surface of the outer film layer is a clear polyurethane film. 
     
     
       11. The composite of  claim 1 , further comprising a flame resistant adhesive between the radiant heat and chemical permeation barrier layer and the flame resistant fibrous basic layer, wherein the flame resistant adhesive contains the intumescent. 
     
     
       12. The composite of  claim 11 , wherein the adhesive comprises a hot melt polymer. 
     
     
       13. The composite of  claim 11 , wherein the adhesive comprises a thermal set polymer. 
     
     
       14. The composite fabric of  claim 1 , wherein the radiant heat and chemical permeation barrier layer blocks 14 of the 15 liquid chemicals specified in ASTM F1001 99a (2006) for a period of 8 hours when tested per ASTM F739 (2007). 
     
     
       15. The composite fabric of  claim 1 , wherein the radiant heat and chemical permeation barrier layer metalized chemical permeation resistant polymeric film is a metalized polyester film. 
     
     
       16. The composite fabric of  claim 15 , wherein the metalized polyester film is between about 10 and 100 gauge in thickness. 
     
     
       17. The composite fabric of  claim 1 , wherein the heat sealable outer layer is a polyolefin layer laminated to the metalized barrier film with a tie layer of EAA. 
     
     
       18. The composite fabric of  claim 1 , wherein the fabric is configured to pass ASTM F1358 (2005) flammability test. 
     
     
       19. The composite fabric of  claim 1 , wherein the fabric passes flammability when tested per ASTM D6413 (2008). 
     
     
       20. The composite fabric of  claim 1 , wherein the composite fabric provides a flash fire barrier when exposed to a flash fire, the composite fabric providing an interior surface temperature of less than about 275 degrees Fahrenheit. 
     
     
       21. A protective garment made from the fabric of  claim 1 . 
     
     
       22. The garment of  claim 21 , comprising exterior seams, wherein a heat sealable chemical resistant tape welds the exterior seams. 
     
     
       23. The garment of  claim 22 , configured to pass the ASTM F1052 97 (2002) vapor tight integrity test. 
     
     
       24. The composite of  claim 1 , further comprising at least one additional chemical barrier layer laminated to the skin facing side of the flame retardant fabric. 
     
     
       25. The composite of  claim 24 , wherein the additional layer is chosen from polyvinylidene chloride, ethylene vinyl acetate, chlorinated polyethylene, polyethylene, low density polyethylene, linear low density polyethylene, high density polyethylene, nylon, polyvinyl alcohol, polyester, metalized polyester, polytetrafluoroethylene, fluorinated ethylene propylene, propylene, polyvinyl chloride copolymer, acrylic, acrylonitrile, and ethylene vinyl alcohol. 
     
     
       26. The composite  claim 25 , wherein the additional layer is a co-extruded multi-layer. 
     
     
       27. The composite fabric of claim  24  1, wherein the radiant heat and chemical permeation barrier layer is configured to hold out at least 17 of the 21 liquid and gaseous chemicals specified in ASTM F1001 99a (2006) for a period of 8 hours when tested per ASTM F739 (2007). 
     
     
       28. A flash fire and chemical protective garment made from the fabric of  claim 24 . 
     
     
       29. A flash fire and chemical protective garment of  claim 28 , comprising exterior seams and interior seams welded with a heat sealable chemical resistant tape. 
     
     
       30. A flash fire and chemical protective garment of  claim 28 , the garment configured to pass ASTM F1052 vapor tight integrity test. 
     
     
       31. A flash fire and chemical protective garment comprising a composite fabric, the composite fabric comprising:
 a chemical barrier layer comprising co-extruded linear low density polyethylene layers with multiple nylon layers, the chemical barrier layer having an outermost layer of linear low density polyethylene configured for facing the wearer; 
 a flame resistant fibrous basic layer having an inner surface configured for contact with a wearer bonded to the chemical barrier layer, and an outer surface, the flame resistant fibrous basic layer comprising flame resistant fibers chosen from fiberglass, carbonized fibers, rayon, cotton, wool and aramid fibers, aromatic polyamide, polyester, or blends thereof, wherein the flame resistant fibrous basic layer is a woven, nonwoven, or knit; 
 a radiant heat and chemical permeation barrier, the barrier including a metalized chemical permeation resistant polymeric film; 
 a radiant heat and chemical permeation barrier layer bonded to the outer surface of the flame resistant fibrous basic layer, the radiant heat and chemical permeation barrier comprising a metalized chemical permeation resistant polymeric film comprising one or more layers of a polyolefin, a tie layer, and a clear heat sealable outer film bonded to the tie layer; wherein the radiant heat and chemical permeation barrier layer is structured such that the clear heat sealable outer film is the outermost layer providing a heat sealable outer surface thereon; 
 an adhesive layer between the outer surface of the flame resistant fibrous basic layer and the radiant heat and chemical permeation barrier, the adhesive layer comprising a protective amount of intumescent sufficient to expand upon absorbing radiant heat energy when exposed to a flash fire; and 
 a clear heat sealable layer deposited over the outer surface of the metalized chemical permeation resistant polymeric film; 
 wherein the metalized chemical permeation resistant polymeric film radiant heat and chemical permeation barrier layer is capable of reflecting a protective amount of radiant heat energy passing through the clear heat sealable layer. 
 
     
     
       32. A method of protecting a wearer when exposed to a chemical and a flash fire, the method comprising:
 providing a flash fire and chemical protective garment, the garment comprising: 
 a flame resistant fibrous basic layer having an outer surface and an inner surface configured for contact with to face a wearer, the flame resistant fibrous basic layer comprising flame resistant fibers chosen from fiberglass, carbonized fibers, rayon, cotton, wool and aramid fibers, aromatic polyamide, polyester, or blends thereof, wherein the flame resistant fibrous basic layer is a woven, nonwoven, or knit; 
 a radiant heat and chemical permeation barrier overlaying the outer surface of the flame resistant fibrous basic layer,a radiant heat and chemical permeation barrier layer bonded to the outer surface of the flame resistant fibrous basic layer, the radiant heat and chemical permeation barrier comprising a metalized chemical permeation resistant polymeric film comprising one or more layers of polyolefin, a tie layer, and a clear heat sealable outer film bonded to the tie layer; wherein the radiant heat and chemical permeation barrier layer is structured such that the clear heat sealable outer film is the outermost layer providing a heat sealable outer surface thereon, the barrier including a metalized chemical permeation resistant polymeric filmradiant heat and chemical permeation configured to reflect an amount of radiant heat energy of a flash fire; 
 an adhesive layer between the outer surface of the flame resistant fibrous basic layer and the radiant heat and chemical permeation barrier the adhesive layer comprising an intumescent; and 
 a clear heat sealable layer deposited over the outer surface of the metalized chemical permeation resistant polymeric film 
 optionally, a second chemical barrier layer bonded to the inner surface of the flame resistant fibrous basic layer of the laminate, the chemical barrier layer comprising co-extruded linear low density polyethylene layers with multiple nylon layers, the second chemical barrier layer having an outmost layer of linear low density polyethylene configured to face the wearer; and 
 creating a flash fire barrier for the wearer upon exposure to a flash fire in the ambient atmosphere by at least one of: expanding the intumescent of the adhesive after absorbing an amount of radiant heat energy from the flash fire; and/or reflecting an amount radiant thermal heat from the flash fire off of the metalized chemical permeation resistant polymeric film. 
 
     
     
       33. The method of  claim 32 , wherein the flash fire and chemical protective garment provides, during exposure to a flash fire, chemical protection to the wearer in combination with at least two of:
 (i) expanding upon absorbing a protective amount of radiant heat energy from the flash fire; 
 (ii)(i) reducing the internal temperature rise inside the garment; 
 (ii) charring of the expanded intumescent and thermally insulating the wearer and/or reducing ignition of the fibrous basic layer; 
 (iv)(ii) reducing or eliminating combustion of the clear heat sealable layer deposited over the outer surface of the metalized layer; and 
 (v)(iii) reflecting an amount of radiant thermal heat from the flash fire. 
 
     
     
       34. The method of  claim 32 , wherein the intumescent is expanding graphite. 
     
     
       35. The composite of  claim 1 , wherein the intumescent material is expanding graphite. 
     
     
       36. A flash fire and chemical protective garment of claim 31, the garment configured to pass ASTM F1052 97 (2002) vapor tight integrity test. 
     
     
       37. A flash fire and chemical protective garment comprising a composite fabric, the composite fabric comprising:
 a flame resistant fibrous basic layer having an inner surface bonded to the outer surface of a chemical barrier layer, the flame resistant fibrous basic layer consisting of flame resistant fibers chosen from fiberglass, carbonized fibers, rayon, cotton, wool and aramid fibers, aromatic polyamide, polyester, or blends thereof, wherein the flame resistant fibrous basic layer is a woven, nonwoven, or knit;   a radiant heat and chemical permeation barrier layer bonded to the outer surface of the flame resistant fibrous basic layer, the radiant heat and chemical permeation barrier consisting of a metalized chemical permeation resistant polymeric film with one or more layers of a polyolefin, a tie layer, and a clear heat sealable outer film bonded to the tie layer; wherein the radiant heat and chemical permeation barrier layer is structured such that the clear heat sealable outer film is the outermost layer providing a heat sealable outer surface thereon; and   optionally, a second chemical barrier layer bonded to the inner surface of the flame resistant fibrous basic layer, the chemical barrier layer consisting of co-extruded linear low density polyethylene layers with multiple nylon layers, the second chemical barrier layer having an outermost layer of linear low density polyethylene configured for facing the wearer;   wherein the radiant heat and chemical permeation barrier layer is capable of reflecting a protective amount of radiant heat energy passing through the clear heat sealable layer;   the garment configured to pass ASTM F1052 97 (2002) vapor tight integrity test.