Protective Clothing Having A Thermally Reflective Liner

Abstract

Protective clothing for environments having high radiant heat loads and/or high conductive heat loads is described. Protective clothing including, but not limited to, coats and pants and methods of making such protective clothing are provided. Protective clothing may include a thermally reflective liner positioned internal to an outer layer or shell, the thermally reflective liner having a reflective surface facing the outer layer or shell.

Description

RELATED APPLICATION

[0001] This application claims the benefit under 35 U.S.C. .sctn.119(e) of U.S. application Ser. No. 61/475,774 filed Apr. 15, 2011, the entire content of which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The invention relates to protective clothing and, in particular, to thermally reflective clothing for use in environments where high radiant heat loads and/or high conductive heat loads may be encountered.

BACKGROUND

[0003] Firefighters and other emergency responders can be exposed to a variety of hazardous conditions such as flame, smoke, and high heat. Clothing used by these professionals may be designed to protect against one or more of these specific conditions.

[0004] Clothing, such as pants and coats may also be specifically designed and can be, for example, abrasion resistant, flame resistant, thermally resistant, waterproof, and/or fire resistant. As one example, gear designed for use in proximity firefighting must be able to withstand extreme heat and should be capable of protecting the responder as provided in NFPA 1971: "Standard on Protective Ensembles for Structural Fire Fighting and Proximity Fire Fighting."

SUMMARY OF THE INVENTION

[0005] According to an aspect of the invention, a thermally resistant coat for protecting a responder against thermal hazards is provided. The coat includes a) a flame and abrasion resistant outer shell, that may include a torso portion and two sleeve portions; and b) a thermally reflective liner positioned in the thermally resistant coat internal to the resistant outer shell, and that includes a thermally reflective surface facing the resistant outer shell. In some embodiments, the thermally reflective liner also includes two sleeve portions. In certain embodiments, the coat further includes a means for connecting the thermally reflective liner to the coat. In some embodiments, the means for connecting the thermally reflective liner to the coat includes a means for connecting the thermally reflective liner to the resistant outer shell. In some embodiments, the means for connecting the thermally reflective liner to the resistant outer shell is a means for connecting one or more regions of the thermally reflective liner to one or more regions of the resistant outer shell. In certain embodiments, the thermally reflective liner is connected to the resistant outer shell at a sleeve region of each. In some embodiments, the thermally reflective surface includes a metalized surface. In some embodiments, the metalized surface is an aluminized surface. In certain embodiments, the thermally reflective liner further includes a knit, woven, or non-woven substrate. In some embodiments, the thermally reflective liner further includes a knit substrate. In some embodiments, the substrate includes polybenzimidazole and poly-paraphenylene terephthalamide. In certain embodiments, the substrate weighs between 2 and 8 ounces per square yard. In some embodiments, the thermally reflective liner includes at least one vent. In some embodiments, the thermally reflective surface is positioned throughout the torso of the thermally reflective liner. In some embodiments, the thermally reflective surface is positioned throughout the torso and sleeves of the thermally reflective liner. In certain embodiments, the thermally reflective liner is removably connected to the resistant outer shell. In some embodiments, the thermally reflective liner is waterproof. In some embodiments, the coat further includes an insulating liner. In some embodiments, the insulating liner is positioned in the thermally resistant coat internal to the thermally reflective liner. In certain embodiments, the insulating liner is a removable insulating liner. In some embodiments, the coat also includes a moisture barrier liner. In some embodiments, the moisture barrier liner is positioned in the thermally resistant coat internal to the thermally reflective liner. In some embodiments, the moisture barrier liner is a removable moisture barrier liner. In certain embodiments, the means for connecting the thermally reflective liner to the resistant outer shell is a means for removably connecting the reflective liner to the resistant outer shell. In some embodiments, the thermally reflective liner includes a front left panel, a front right panel, a back panel, and sleeves. In some embodiments, the means for connecting includes hook and loop, zipper, buttons, adhesive, stitching, bonding, or snaps. In certain embodiments, two or more of the same or different types of fasteners are included.

[0006] According to another aspect of the invention, an emergency responder's ensemble is provided and the ensemble complies with at least one of NFPA Standards Meeting Section 7.1 Protective Garment Elements Performance Requirements for Both Ensembles, Section 7.3 Additional Performance Requirements for Proximity Fire Fighting Protective Garment Elements Only, and the ensemble includes aforementioned embodiment of a thermally resistant pair of coat.

[0007] According to yet another aspect of the invention, a thermally resistant pair of pants for protecting a responder against thermal hazards is provided. The pair of pants includes a pair of full length pants legs each having a long dimension extending from the top to the bottom of the leg, each pair of pants including a) a flame and abrasion resistant outer shell, and b) a thermally reflective liner, wherein the thermally reflective liner is positioned in the pair of pants internal to the resistant outer shell and includes a thermally reflective surface facing the resistant outer shell. In some embodiments, the pair of pants also includes a means for connecting the thermally reflective liner to the pair of pants. In some embodiments, the means for connecting is hook and loop, zipper, buttons, adhesive, stitching, bonding, or snaps. In some embodiments, two or more of the same or different types of fasteners are included. In certain embodiments, the pair of pants also includes a means for connecting the thermally reflective liner to the resistant outer shell of the pair of pants. In some embodiments, the thermally reflective surface includes a metalized surface. In some embodiments, the metalized surface is an aluminized surface. In certain embodiments, the thermally reflective liner includes a knit, wove, or non-woven substrate. In some embodiments, the substrate includes polybenzimidazole and poly-paraphenylene terephthalamide. In some embodiments, the substrate weighs up to 8 ounces per square yard. In certain embodiments, the substrate weighs between 2 and 8 ounces per square yard. In some embodiments, the thermally reflective liner includes at least one vent. In some embodiments, the thermally reflective surface is positioned throughout the pair of pants. In some embodiments, the thermally reflective liner is removably connected to the resistant outer shell. In certain embodiments, the thermally reflective liner is waterproof. In some embodiments, the pair of pants also includes an insulating liner. In some embodiments, the insulating liner is positioned in the pair of pants internal to the thermally reflective liner. In some embodiments, the insulating liner is a removable insulating liner. In certain embodiments, the pair of pants also includes a moisture barrier liner. In some embodiments, the moisture barrier liner is positioned in the pair of pants internal to the thermally reflective liner. In some embodiments, the moisture barrier liner is a removable moisture barrier liner. In some embodiments, the means for connecting the thermally reflective liner to the resistant outer shell is a means for removably connecting the reflective liner to the resistant outer shell. In certain embodiments, the pair of pants also includes a torso-covering portion. In some embodiments, the torso-covering portion includes a flame and abrasion resistant outer shell and a thermally reflective liner, wherein the thermally reflective liner is positioned inside the torso-covering resistant outer shell and has a thermally reflective surface facing the resistant outer shell.

[0008] According to another aspect of the invention, an emergency responder's ensemble is provided and the ensemble complies with at least one of NFPA Standards Meeting Section 7.1 Protective Garment Elements Performance Requirements for Both Ensembles, Section 7.3 Additional Performance Requirements for Proximity Fire Fighting Protective Garment Elements Only, and the ensemble includes any aforementioned embodiment of a thermally resistant pair of pants.

[0009] According to yet another aspect of the invention, a thermally reflective liner for use as part of an emergency responder's clothing article is provided. The liner includes a thermally reflective surface; wherein the liner is constructed in a manner to be positioned in the clothing article internal to a flame and abrasion resistant outer shell with the thermally reflective surface facing the resistant outer shell, and wherein the clothing article is a coat or a pair of pants. In some embodiments, the thermally reflective liner is constructed in a manner to be connected to the clothing article. In certain embodiments, the thermally reflective liner is constructed in a manner to be connected to the resistant outer shell of the clothing article. In some embodiments, the connection is a removable connection. In some embodiments, the clothing article is a coat and the thermally reflective liner includes a thermally reflective surface that includes a torso portion and two sleeve portions; and the liner is constructed in a manner to be positioned in the coat internal to a flame and abrasion resistant outer shell with the thermally reflective surface facing the resistant outer shell. In certain embodiments, the thermally reflective liner is constructed in a manner to be connected to the coat. In some embodiments, the thermally reflective liner is constructed in a manner to be connected to the resistant outer shell of the coat. In some embodiments, the connection of the reflective liner with the outer shell of the coat is between one or more regions of the reflective liner and the outer shell of the coat. In some embodiments, the connection is a removable connection. In certain embodiments, the thermally reflective liner includes a front left panel, a front right panel, a back panel, and sleeves. In some embodiments, the connection is by means of a fastener. In some embodiments, the fastener is hook and loop, zipper, buttons, adhesive, stitching, bonding, or snaps. In some embodiments, two or more of the same or different types of fasteners are included. In certain embodiments, the thermally reflective surface is positioned throughout the torso and sleeves of the thermally reflective liner. In some embodiments, the thermally reflective surface is positioned throughout the thermally reflective liner. In some embodiments, the clothing article is a pair of pants. In certain embodiments, the pair of pants further includes a torso-covering portion. In some embodiments, the torso-covering portion includes a flame and abrasion resistant outer shell and a thermally reflective liner, wherein the thermally reflective liner is positioned in the pair of pants and the torso portion internal to the resistant outer shell and has a thermally reflective surface facing the resistant outer shell. In some embodiments, the thermally reflective surface includes a metalized surface. In some embodiments, the metalized surface is an aluminized surface. In certain embodiments, the thermally reflective liner also includes a knit, woven, or non-woven substrate. In some embodiments, the substrate includes polybenzimidazole and poly-paraphenylene terephthalamide. In some embodiments, the substrate weights between 2 and 8 ounces per square yard. In certain embodiments, the substrate weighs up to 7 ounces per square yard. In some embodiments, the thermally reflective liner includes at least one vent. In some embodiments, the thermally reflective liner is removably connected to the resistant outer shell. In some embodiments, the thermally reflective liner is waterproof.

[0010] According to another aspect of the invention, an emergency responder's ensemble is provided and the ensemble complies with at least one of NFPA Standards Meeting Section 7.1 Protective Garment Elements Performance Requirements for Both Ensembles, Section 7.3 Additional Performance Requirements for Proximity Fire Fighting Protective Garment Elements Only, and includes any aforementioned embodiment of a thermally reflective liner.

[0011] According to yet another aspect of the invention, methods of making a thermally resistant clothing article for protecting a responder against thermal hazards are provided. The methods include positioning a thermally reflective liner in the clothing article internal to a flame and abrasion resistant outer shell, wherein the thermally reflective liner includes a thermally reflective surface that faces the resistant outer shell, and wherein the clothing article is a pair of pants or a coat for protecting the responder. In some embodiments, the methods also include connecting the thermally reflective liner to the clothing article. In certain embodiments, the methods also include connecting the thermally reflective liner to the flame and abrasion resistant outer shell. In some embodiments, the clothing article is a coat and the thermal reflective surface includes a torso portion and two sleeve portions. In some embodiments, connecting the thermally reflective liner to the resistant outer shell includes connecting a portion of the thermally reflective liner to a portion of the resistant outer shell. In certain embodiments, the thermally reflective liner is connected to the resistant outer shell at one or more regions of each. In some embodiments, connecting the thermally reflective liner to the resistant outer shell is removably connecting the thermally reflective liner to the resistant outer shell. In some embodiments, the thermally reflective liner includes a front left panel and a front right panel. In some embodiments, the connection between the thermally reflective liner and the resistant outer shell includes a fastener. In certain embodiments, the fastener is hook and loop, zipper, buttons, adhesive, stitching, bonding, or snaps. In some embodiments, two or more of the same or different types of fasteners are included. In certain embodiments, the thermally reflective surface is positioned throughout the torso and sleeves of the thermally reflective liner. In some embodiments, the thermally reflective surface is positioned throughout the thermally reflective liner. In some embodiments, the clothing article is a pair of pants. In certain embodiments, the pair of pants also includes a torso-covering portion, which may also include arm-covering portions. In some embodiments the pair of pants is part of a pair of overalls. In some embodiments, the torso-covering portion includes a flame and abrasion resistant outer shell and a thermally reflective liner, wherein the thermally reflective liner is positioned in the pair of pants and in the torso portion internal to the resistant outer shell and has a thermally reflective surface facing the resistant outer shell. In some embodiments, the thermally reflective surface includes a metalized surface. In some embodiments, the metalized surface is an aluminized surface. In certain embodiments, the thermally reflective liner also includes a knit, woven, or non-woven substrate. In some embodiments, the substrate includes polybenzimidazole and poly-paraphenylene terephthalamide. In some embodiments, the substrate weights up to 8 ounces per square yard. In certain embodiments, the substrate weighs between 2 and 8 ounces per square yard. In some embodiments, the thermally reflective liner includes at least one vent. In some embodiments, the method also includes positioning an insulating liner in the clothing article, internal to the resistant outer shell. In some embodiments, the insulating liner is positioned in the clothing article internal to the thermally reflective liner. In certain embodiments, the insulating liner is a removable insulating liner. In some embodiments, the method also includes positioning a moisture barrier liner in the clothing article, internal to the resistant outer shell. In some embodiments, the moisture barrier liner is positioned in the clothing article internal to the thermally reflective liner. In some embodiments, the moisture barrier liner is a removable moisture barrier liner. In certain embodiments, the thermally reflective liner is removably connected to the resistant outer shell. In some embodiments, the thermally reflective liner is waterproof.

[0012] According to another aspect of the invention, an emergency responder's ensemble is provided that complies with at least one of NFPA Meeting Section 7.1 Protective Garment Elements Performance Requirements for Both Ensembles, Section 7.3 Additional Performance Requirements for Proximity Fire Fighting Protective Garment Elements Only, and the ensemble includes a thermally resistant clothing article made with the method of any aforementioned embodiment.

[0013] The subject matter of this application may involve, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of a single system or article.

[0014] The present invention is not intended to be limited to a system or method that must satisfy one or more of any stated objects or features of the invention. It is also important to note that the present invention is not limited to the exemplary or primary embodiments described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 shows a front view of one embodiment of a thermally resistant coat of the invention.

[0016] FIG. 2 shows a front view of one embodiment of a thermally reflective coat liner of the invention. The thermally reflective surface 116 is external to substrate 118, which is shown in a cutaway view.

[0017] FIG. 3 shows an exploded and cutaway front view of one embodiment of a thermally resistant pair of pants of the invention.

[0018] FIG. 4 shows an exploded and cutaway front view of one embodiment of a thermally reflective pair of pants liner of the invention.

[0019] FIG. 5 shows a section of thermally reflective liner materials according to one embodiment of the invention.

[0020] FIG. 6 shows a section of thermally reflective liner materials having vents according to one embodiment of the invention.

[0021] FIG. 7 shows views of layers of materials of the invention. FIG. 7A shows an exploded view of an outer layer or shell, an inner liner, and a thermally reflective liner according to one embodiment of the invention. FIG. 7B shows an outer layer, an inner liner, and a thermally reflective liner in contact with one another according to one embodiment of the invention.

DETAILED DESCRIPTION

[0022] There are two major types of thermally protective clothing worn by emergency responders such as firefighters and other personnel working near fires: proximity protective clothing and structurally protective clothing. Proximity protective clothing is designed to be worn by responders working close to large open flame fires such as those caused by aviation fuel fires. Proximity protective clothing requires specialized thermal protection due to the high radiant heat loads that can be encountered. Structural protective clothing is the most commonly utilized thermally protective clothing and is utilized by responders to make entry into burning buildings. Structural protective clothing provides limited thermal protection, provides a moderate level of physical hazard protection, and may clothing with an outer layer (also referred to herein as a "shell") that is flame and abrasion resistant.

[0023] In a conventional construction, proximity protective clothing of the type satisfying NFPA 1971 has a metalized external surface to reflect radiant heat away from the responder. The metalized surface may be mechanically less durable than other materials used on the exterior of protecting clothing, such as abrasion-resistant materials, and may be more susceptible to punctures, cuts, and abrasions thus resulting in a shorter useful life for the protective clothing. Also, the external metalized surface can be difficult to keep clean because scrubbing the material can cause extensive wear and degradation of the surface. Unfortunately, when the metalized surface is damaged and/or becomes dirty, it loses its ability to reflect heat, and the responder's life and physical safety is put at greater risk. In addition, clothing having a metalized exterior surface may be less favored by responders when given a choice of a coat or pants with a flame and abrasion-resistant outer surface or a coat or pants with a metalized outer surface.

[0024] Structural protective clothing, such as pants and coats, may have an external surface made of a flame and abrasion-resistant material. Compared to metalized materials, the external materials used in structural protective clothing such as pants and coats can be durable, easy to clean, and may be more comfortable to wear than clothing having a metalized outer surface. Structural protective clothing is generally better at withstanding many of the mechanical hazards encountered by responders that might otherwise damage a metalized outer surface on proximity protective clothing.

[0025] The thermally resistant protective clothing described herein, a coat or pair of pants for example, may be used by any person exposed to, or potentially exposed to, a heat source. Protective clothing of the invention may be worn by a responder or firefighter while extinguishing or controlling a fire or while performing a rescue from a burning structure or location. The clothing may also be used by an industrial worker, for example a kiln operator or maintenance person, to provide protection from intense heat and/or flame. As another example, thermally resistant clothing of the invention may be used by military servicemen exposed to a fire in the line of duty.

[0026] In one aspect of the invention, a protective clothing article is disclosed that has a thermally reflective liner located internal to an outer shell layer of the clothing, and not as the outermost layer of the clothing. The thermally reflective liner comprises a reflective surface that faces the outer shell layer of the clothing. The protective clothing of the invention may be any type of clothing such as a coat, jacket, pants, or overalls. Thus, a thermally resistant coat, jacket, pants, overalls, etc. of the invention includes a thermally reflective liner that is internal to an outer shell layer of the clothing, and the thermally reflective liner's thermally reflective surface is not the external surface of the coat, jacket, pants, or overalls, etc. To an observer, the clothing may appear to be conventional structural turnout gear. Much of the description herein is directed to a thermally reflective liner and it is understood that the liner may be removably included with other layers such as a substantially non-reflective outer shell and/or an inner thermal liner to provide a coat or pants suitable for use by firefighters, emergency responders, or others in a high-heat environment. A coat and/or pants of the invention may be part of a clothing ensemble that includes, for example, coat, pants, boots, and/or gloves for protection of the wearer. For example, an ensemble may include pants (also referred to as trousers) such as those described in U.S. patent application Ser. No. 11/615,262, entitled PROTECTIVE APPAREL FOR FIREFIGHTERS AND EMERGENCY RESPONDERS, but that include an internal, thermally reflective liner.

[0027] In an embodiment of the invention, a thermally protective coat or pair of pants can be a structural protective coat or pair of pants that includes a thermally reflective liner inside a substantially non-reflective external shell, wherein the thermally reflective liner has a metalized, reflective surface facing the outer shell of the coat or pair of pants. A structural protective coat or pair of pants having an internal, thermally reflective liner, can be durable and easy to clean, and can provide a responder, firefighter, or other wearer with the proper fit and capacity for ease of movement. The gear can be surprisingly reflective even though the reflective layer is not the outermost layer. A protective coat or pair of pants of the invention can satisfy the requirements of NFPA 1971 (2007) for proximity firefighting.

Overview of Coat Features

[0028] In one aspect of the invention, a thermally resistant coat for protecting a responder against thermal hazards comprises (a) a flame and abrasion resistant outer shell having a torso portion and two sleeve portions; and (b) a thermally reflective liner having a thermally reflective surface. The thermally reflective liner may comprise a torso portion and two sleeve portions. The sleeve portion may be open and unfitted at the wrist or may be configured to be closed or closable around the wrist, for example with elastic, snaps or any suitable alternative means. The torso portion of a thermally reflective liner of the invention may comprise a front left panel, a front right panel and a back panel. In some embodiments of the invention, the coat can be donned as a pullover.

[0029] A thermally resistant coat of the invention may have a thermally reflective liner positioned in the coat internal to an abrasion resistant outer shell in a manner wherein the thermally reflective surface of the thermally reflective liner faces the outer shell of the coat. In some embodiments of the invention, the thermally reflective surface may be positioned throughout the torso and/or sleeves of the thermally reflective liner. In other embodiments of the invention, the thermally reflective surface may be positioned only in portions of the torso and/or sleeves of the thermally reflective liner. In some embodiments of the invention, the thermally reflective liner is positioned in one or more specific sections of the coat and is not positioned in all sections of the interior of the coat. In certain embodiments the thermally reflective liner is positioned throughout all sections of the interior of the coat, providing a barrier between the body and the exterior.

[0030] A thermally resistant coat of the invention may also include a means for connecting the thermally reflective liner to the coat, which may be a means for connecting the thermally reflective liner to the abrasion resistant outer shell or may be a means for connecting the thermally reflective liner to an alternative layer of the coat, such as an insulating liner and/or a moisture-resistant liner, and/or another liner.

[0031] In some embodiments, the portion of the thermally reflective liner that faces inwardly and contacts the wearer's skin may include a material chosen for comfort, e.g., synthetic fleece or other fabric, woven or non-woven, chosen to avoid irritation and to be comfortable. In some embodiments, there is only one point of attachment between the thermally reflective liner and the coat or outer shell, with the rest of the thermally reflective liner remaining unattached. If desired, the thermally reflective liner may be donned by the responder prior to donning the outer shell, and the shell may be removed by the responder without removing the thermally reflective liner.

[0032] In other embodiments, the thermally reflective liner may be attached to the outer shell at least at the sleeves or other region. Other regions where the thermally reflective liner may be attached to the outer shell include, but are not limited to at the back of the torso, at the neck, at the front of the torso, etc. For example, a thermally reflective liner can be permanently (e.g., sewn) or temporarily (e.g., zippered, buttoned, hook-and-looped, snapped, etc.) attached to the sleeve or other region of a coat. An attachment to a sleeve of a coat can be an attachment to one or both sleeves of the coat's outer shell. Attachment of a thermally reflective liner at the sleeves may or may not be accompanied by attachment at another region of the coat. If permanently attached at the sleeves or other region, the thermally reflective liner is not considered to be a removable thermally reflective liner. In such cases, the thermally reflective liner and the outer shell to which the thermally reflective liner is permanently attached may function as a single garment and may be donned and removed as one.

[0033] A thermally reflective liner of a coat of the invention may alternatively or additionally be connected to one or more liners that are within the outer shell of the coat. Examples of additional layers include, but are not limited to, an insulating layer, a moisture-resistant layer, etc.

[0034] A thermally resistant coat of the invention may include a hood that is comprised of a thermally reflective layer. Such a hood may be permanently attached (integral) to the torso portion of a thermally reflective liner or may be attached via a reversible fastener (modular). When not deployed, the hood may be stored in space between thermally reflective liner and the outer shell of the thermally protective coat. Although a pocket or storage area may be added, the hood may slide comfortably between the liner and the shell, being hidden and almost unnoticeable by the wearer. The lower portion of a protective coat of the invention may overlap a pair of protective pants, which may include an extension above the waist.

[0035] FIG. 1 provides a view of one aspect of a coat 100 that includes both a liner 110 and an outer shell 120. Outer shell 120 may be flame, water and/or abrasion resistant and may be made from known materials used to make outer shells. Thermally reflective liner 110 may be shaped and constructed similarly to a conventional jacket, pullover, anorak, or coat, having two sleeves and a torso section. The thermally reflective liner 110 is positioned internal to an outer resistant shell 120. The coat, when equipped with a thermally reflective liner, should incorporate enough of the liner that the wearer is protected from radiant heat. In some embodiments, the thermally reflective liner is at least adequate to provide a level of protection to meet NFPA standard 1971.

[0036] As shown in the non-limiting example of a thermally resistant coat of FIG. 1, liner 110 may include left front portion (panel) 112 and right front portion (panel) 114. The opening between front portions 112 and 114 need not extend the full length of the liner and may extend, for example, half way or less from the neck down resulting in a pullover type design. The thermally reflective liner includes an integral thermally reflective surface 116, which faces the outer shell of the coat. Fasteners, for example in the sleeves or torso area, may be used to secure the liner to the shell. Shell 120 may include shell zipper halves 142 and 144 and may also include flap 146 that can help to seal the zipper through the use of a hook and loop fastener, or other suitable fastener.

[0037] It will be understood that a thermally resistant coat 100 of the invention may optionally include one or more additional liners such as a moisture-resistant liner, or an insulating liner. The one or more additional liners can be positioned internal to an outer shell of a coat of the invention a position that is internal to or external to a thermally reflective liner of the invention.

[0038] FIG. 2 shows a thermally reflective liner 110 for a coat, the liner 110 having a thermally reflective surface 116. The cutaway view shows the substrate 118 that supports the thermally reflective surface 116. An embodiment of the invention such as that illustrated in FIG. 2 may also include a means to tighten and/or to fit the sleeves at the wearer's wrists. It will be understood that the sleeve portion of a thermally reflective liner of the invention may be open and unfitted at the wrist or may be configured to be closable around the wrist, for example with elastic, snaps, cording, or any suitable alternative means. A thermally resistant coat of the invention may, in addition to a thermally reflective liner of the invention, optionally include one or more additional liners such as a moisture-resistant liner, or an insulating liner. It will be understood that one or more additional liners can be positioned internal to an outer shell of a coat at a position that is internal to or external to a thermally reflective liner 110 of the invention.

[0039] Some aspects of the invention provide an emergency responder's ensemble that complies with NFPA Standard 1971, the ensemble comprising a thermally resistant coat that includes a thermally reflective liner positioned internal to an outer shell of the coat, wherein the thermally reflective liner comprises a thermally reflective surface that faces the outer shell of the coat.

Overview of Pant Features

[0040] A thermally resistant article of clothing of the invention may be a thermally resistant pair of pants for protecting a responder against thermal hazards. Pants of the invention may comprise a pair of full length pants legs each having a long dimension extending from the top to the bottom of the leg of the wearer. In some embodiments the pant leg length may be longer or shorter than the leg of the wearer. Pants of the invention may also comprise a seat, a front portion and a waist portion.

[0041] A pair of pants of the invention may comprise a flame and abrasion resistant outer shell, and a thermally reflective liner positioned in the pants internal to the outer shell, with the thermally reflective liner comprising a thermally reflective surface facing the resistant outer shell. In some aspects of the invention, a thermally resistant pair of pants may include a thermally reflective liner that comprises a thermally reflective surface disposed on the outside of the thermally reflective liner. In some embodiments of the invention, the thermally reflective surface may be positioned throughout the entirety of the pants. In other embodiments of the invention, the thermally reflective surface may be positioned only in portions of the pants, such as in the seat, front, and/or pant leg portion of the thermally reflective liner. In some embodiments of the invention, the thermally reflective liner is included in one or more specific sections of the pants and is not included throughout all sections of the interior of the pair of pants. In certain embodiments of the invention, the thermally reflective liner is included throughout all sections of the interior of the pants.

[0042] A thermally resistant pair of pants of the invention may also include a means for connecting the thermally reflective liner to the pants. A connecting means may be a means for connecting the thermally reflective liner to the resistant outer shell of the pants. A thermally reflective liner of a pair of pants of the invention may be permanently or removably connected to the pants. Thus, the means for connecting may be a permanent means (e.g., sewing, stitches, etc.) or may be a removable means, (e.g., snaps, zipper, buttons, hook-and-loop, etc.). In some embodiments, the either permanent or removable connection is a connection between the thermally reflective liner and the outer shell of the thermally resistant pants. A connection between the thermally reflective liner and an outer shell can be at one or more locations in the outer shell, such as at or near the bottom of a pant leg, along an inseam of a pant leg, at the waist of the pants, etc. For example, an outer shell of a thermally resistant pair of pants and a corresponding thermally reflective liner may be connected to each other around their peripheries or detachably connected with fastening means such as snap fasteners or hook and loop strips that can be located in spaced positionings around their corresponding peripheries. A thermally reflective liner of a pair of pants of the invention may alternatively or additionally be connected to one or more liners that are within the outer shell of the pants. Examples of additional layers include, but are not limited to, an insulating layer, a moisture-resistant layer, etc.

[0043] A thermally resistant pair of pants of the invention may also include a torso-covering portion. For example, with the torso-covering portion included, the pants may be a pair of overalls. A thermally resistant pair of pants, such as overalls may include a torso-covering portion that includes a flame and abrasion resistant outer shell and a thermally reflective liner. In such a thermally resistant pair of pants, the thermally reflective liner may be positioned inside the torso-covering resistant outer shell as well as in the pant section, with the thermally reflective liner including a thermally reflective surface that faces the resistant outer shell.

[0044] FIG. 3 provides a view of one aspect of a pair of pants 10 that includes both a thermally reflective liner 60 and an outer shell 20. Outer shell 20 may be flame, water and/or abrasion resistant and may be made from known materials used to make outer shells for protective clothing. Thermally reflective liner 60 may be shaped and constructed similarly to a conventional pair of pants, trousers, or overalls; e.g., having two legs, a front section, a seat section, a waist section, and in the case of overalls, also including a torso section. The thermally reflective liner 60 is positioned internal to an outer resistant shell 20. The pair of pants, when equipped with a thermally reflective liner, may incorporate enough of the liner that the wearer is protected from radiant heat. In some embodiments, the thermally reflective liner is at least adequate to provide a level of protection to meet NFPA standard 1971.

[0045] The non-limiting example of a thermally resistant pair of pants shown in FIG. 3 comprises an outer shell 20 made of a fire protective material and a removable liner 60 which includes an integral thermally reflective surface 70, which faces the outer shell of the pants. The thermally reflective liner 60 and the outer shell 20 can be permanently or removably connected to each other. A thermally resistant pair of pants 10 of the invention may optionally include one or more additional liners such as a moisture-resistant liner, or an insulating liner. An exemplary liner 80 is show internal to a thermally reflective liner 60. It will be understood that one or more additional liners can be positioned internal to an outer shell of a pair of pants at a position that is internal to or external to a thermally reflective liner of the invention.

[0046] FIG. 4 shows a non-limiting example of internal liners 90 that may be included in a thermally reflective pair of pants. A thermally reflective liner 60, which has a thermally reflective surface 70, is shown. Optional snap fasteners 64 may be included to connect the liner to the outer shell and/or to one or more additional liners. In addition to a thermally reflective liner, a thermally resistant pair of pants of the invention may optionally include one or more liners such as a moisture-resistant liner, or an insulating liner. An exemplary additional liner 80 is shown internal to a thermally reflective liner 60. It will be understood that one or more additional liners can be positioned internal to an outer shell of a thermally resistant pair of pants at a position that is internal to or external to a thermally reflective liner 60 of the invention.

[0047] Some aspects of the invention provide an emergency responder's ensemble that complies with NFPA Standard 1971, the ensemble comprising a thermally resistant pair of pants that includes a thermally reflective liner positioned internal to an outer shell of the pair of pants, wherein the thermally reflective liner comprises a thermally reflective surface that faces the outer shell of the pair of pants.

Clothing Articles--General Features

[0048] The outer shell of an article of clothing (e.g., coat, pair of pants, overalls, etc.) of the invention may be made of any flexible, heat resistant, and abrasion-resistant material and may be made from known materials used to make outer shells for protective clothing. Examples of materials from which an outer shell can be made include, but are not limited to, meta and para-aramids (NOMEX and KEVLAR), polybenzimidaxazole (PBI), polybenzobisoxazole (PBO), melamine (BASOFIL), and blends thereof. Additional materials suitable for making an outer shell for a thermally resistant article of clothing of the invention are available and known by those skilled in the art. An outer shell may include portions of light-reflective material for added visibility at night and in other dark conditions. An outer shell of an article of clothing of the invention is made of a material that is substantially non-thermally reflective.

[0049] A thermally reflective surface of a thermally reflective liner of the invention may be any appropriate thermally reflective material, such as a metalized material. For example, the thermally reflective liner may be a substrate supporting an aluminized film. The substrate may be a flexible material and in one embodiment the substrate is a combination of polybenzimidazole (PBI) and poly-paraphenylene terephthalamide, for example, (KEVLAR.RTM.). In a further embodiment, the substrate may be about 33 percent PBI and about 67 percent meta-aramid and weigh up to 2, 3, 4, 5, 6, 7, 8, or more ounces per square yard, including all weights in between the integers listed. A substrate in a thermally reflective liner of the invention can be a knit, woven, or non-woven substrate. The thermally reflective material can be applied to the substrate using any suitable means, including, but not limited to: coating, lamination, impregnation, casting, or depositing on the substrate. The thermally reflective material may weigh, for example, between 0.25 ounces and 2 ounces per square yard, including all weights between 0.25 and 2.

[0050] In some embodiments of the invention, the reflective liner may be a PBI and Kevlar knit substrate laminated with an aluminized film. The aluminized film may be of any weight and thickness that is capable of being used as a middle layer and is capable of reflecting or preventing the transfer of enough heat and thermal radiation to meet the requirements of NFPA 1971. The aluminized film may be coated or uncoated and may include a transparent coating. The reflective film itself may have a thickness of, for example, between about 0.01 and 0.5 mm. In some embodiments, the aluminum film may have a thickness between about 0.05 and 0.1 mm. In some cases, the film (void of any backing material) may weigh about two ounces per square yard, so that the combined weight of the knit substrate and aluminized film layer may be about 7.5 ounces per square yard (255 g/m.sup.2). In a further embodiment, the thermally reflective liner, including an aluminized film and a knit substrate, is about 0.9 mm thick. A suitable thermally reflective liner material is available from Gentex Corporation and is referred to as PA255 Jersey. It includes a GENTEX.RTM. Dual Mirror Aluminized Fabric on a PBI/Kevlar backing substrate.

[0051] A thermally reflective liner of the invention may be a reflector of radiant heat (infrared light) and can also serve to limit heat conduction. The reflective liner of the invention reflects heat, which as used herein, means to throw back or cast back heat from the thermally reflective liner. Different types of thermally reflective materials that can be used to form the thermally reflective liner may reflect more than 30%, more than 35%, more than 40%, more than 45%, more than 50%, more than 55%, more than 60%, more than 65%, more than 70%, more than 75%, more than 80%, more than 85%, more than 90%, or more than 95% of the radiant heat that is incident to the material. These materials can often be identified by their ability to reflect visible light and may reflect more than 50% of the visible light that is incident to the material. Examples of thermally reflective materials are metal coated fabrics and metallic foils. Thermally reflective materials may be flexible so that they can, for instance, conform to the movements of the clothing article, without cracking or restricting movement of the wearer. In some aspects of the invention, a thermally reflective liner of a thermally resistant article of clothing of the invention may be waterproof or moisture resistant.

[0052] In one embodiment a thermally resistant article of clothing as shown in FIG. 5, may include thermally reflective liner 150 made of an aluminized film 150a and a knit substrate 150b. Aluminized film 150a includes a reflective surface 190. When incorporated into thermally protective clothing of the invention, thermally reflective liner material 150 can be positioned with reflective surface 190 facing the exterior surface of the clothing.

[0053] FIG. 6 shows an embodiment of the invention in which thermally reflective liner 150 defines vents 210 to facilitate the flow of water vapor and other gases through thermally reflective liner 150. Vents 210 may be circular, as shown, but they may have any other shape, such as rectangular, square, or triangular, etc. and may be randomly placed or may be in a pattern. Vents may be of any appropriate size and may be as small as about 1 micron, and upward in size from 1 micron as appropriate. For example, a vent may be from one micron up to 4 mm or more across, including any size between 1 micron and 4 mm.

[0054] FIGS. 7A and 7B further illustrate materials used for construction of a portion of an article of clothing of the invention. FIG. 7A shows outer layer or shell 130 having an outer surface 160, inner liner 140, and thermally reflective liner material 150 separated from one another. The thermally reflective liner 150 is comprised of a thermally reflective layer 150a and a substrate material 150b. As indicated for this embodiment, a thermally reflective liner 150 is positioned between outer layer or shell 130 and inner liner 140. A thermally reflective surface 190 is shown on the external-facing surface of the thermally reflective liner 150. FIG. 7B shows outer layer or shell 130, having an outer surface 160, inner liner 140, and thermally reflective liner 150 in contact with one another. The thermally reflective liner 150 is comprised of a thermally reflective layer 150a and a substrate material 150b Inner liner 140 is optional and in some embodiments of the invention no inner liner is present and the clothing article includes an outer layer or shell and a thermally reflective liner, which may be separated or connected to one another.

[0055] Thermally resistant articles of clothing may be constructed using one or more materials illustrated in FIGS. 5-7 herein, such as a thermally resistant liner 150, an outer shell 130, an inner liner 140, etc.

[0056] A thermally resistant article of clothing of the invention may, in addition to the thermally reflective liner, also include an insulating liner and/or a moisture barrier liner, either or both of which may be positioned in the article of clothing of the invention. In some embodiments, an insulating and/or moisture barrier liner may be positioned internal to the thermally reflective liner. Such an insulating liner and/or moisture barrier liner may be removable from the thermally resistant clothing of the invention or may be permanently attached to the article of thermally resistant clothing.

[0057] Thus, an article of protective clothing of the invention may include one or more inner liners located between the thermally reflective liner and the interior of the clothing. The inner liner may be made of one, two, three, or more sub-layers that may be independent of each other, or may be adhered together. An inner liner may be either permanently or removably connected to the thermally reflective liner or may be independent of the thermally reflective liner and have no connection thereto. In some embodiments of the invention, the clothing may include one, two, three, or more independent, unbound, inner liners positioned between the thermally reflective liner and the interior of the clothing.

[0058] An inner liner may include one or more thermally insulating materials. As a non-limiting example, the inner liner may include one or more layers of non-woven fabric comprised of 65% meta-aramid material (such as NOMEX.RTM.) and about 35% poly-paraphenylene terephthalamide (such as KEVLAR.RTM.).

[0059] In some embodiments of the invention, an inner liner may include a moisture barrier. The moisture barrier liner may be facing outwardly. Additionally, the thickness of the inner liner may be similar to other thermal liners used in protective clothing. The thickness of internal liners can be achieved through the use of one, two, three or more thermal liners. Two or more thermal insulating liners may be separate from each other and can include an air layer between the two thermal insulating liners. This construction can provide light, flexible, comfortable thermally protective clothing that can be used in proximity firefighting, and other high-heat activities.

[0060] The thermally reflective liner may be physically attached to an outer liner and/or shell, and/or physically attached to an inner liner. In some embodiments the thermally reflective liner may be simply placed between the outer and inner layers (e.g. liner, shell) and may "float" between them. As used herein the term "float" means the layers are able to move independently of each other. If the thermally reflective liner is attached to an article of protective clothing of the invention, the thermally reflective liner may be fixed to either or both of an inner and outer layer using, for example, adhesive, stitching, staples, rivets, buttons, snaps, zipper, hook-and-loop, or other mechanical fasteners.

Methods of Making--Clothing

[0061] Methods of making thermally resistant clothing articles for protecting a responder or wearer, such as a high-heat worker, against thermal hazards are also described herein. Methods may include fabricating thermally reflective liner material, cutting the material to the desired shape for the article of clothing to be prepared, constructing from the material a liner shaped for the article of clothing, and positioning the thermally reflective liner in the clothing article internal to a flame and abrasion resistant outer shell. As described herein, the thermally reflective liner comprises a thermally reflective surface that faces the outer layer or shell. The clothing article so produced may be a pair of pants, overalls, a coat, etc. for protecting the responder. Methods of the invention may include connecting the thermally reflective liner to the clothing article. In some embodiments the connection between the thermally reflective liner and the clothing article is a connection between the thermally reflective liner and the flame and abrasion resistant outer shell. Methods of the invention may include removably connecting a thermally reflective liner to a resistant outer shell.

EXAMPLES

[0062] NFPA 1971, 2007 Edition Section 7.3 Additional Performance Requirements for Proximity Fire Fighting Protective Garment Elements Only lists the performance requirements required in addition to meeting the requirements in Section 7.1 Protective Garment Elements Performance Requirements for Both Ensembles. These include Section 8.52 Radiant Protective Performance Test with a value of not less than 20 seconds, Section 8.54 Wet Flex Test showing no signs of cracking or delamination, Section 8.55 Adhesion After Wet Flex--Tape Method showing no evidence of separation, Section 8.56 Flex at Low Temperature showing no evidence of breaking, shattering, or cracking, and Section 8.57 Resistance to High-Temperature Blocking showing no blocking

Test 1

[0063] One embodiment of a coat comprising a thermally reflective liner as described elsewhere herein is tested and found to comply with the test requirements of NFPA 1971, 2007 Edition Section 7.3; Section 7.1; Section 8.52; Section 8.54; Section 8.55; Section 8.56; and Section 8.57.

[0064] The performance of the coat during the section tests is better than expected as it was believed that the reflective liner had to be on the outer surface of the clothing to meet the requirements of NFPA 1971. Outer layers, such as the outer shell of a coat or pants, are generally considered to be opaque and therefore were expected to interfere with the ability of the reflective surface to reflect back infrared radiation. But the data from the tests suggests otherwise. Specifically, the thermally reflective liner reflects away from the coat a sufficient amount of the radiant heat received by the coat to allow the coat to pass the tests. The internal reflective liner allows the coat to pass the tests. A similar coat without the thermally reflective liner, but with an additional thermal liner of greater thickness instead, fails the tests. Therefore, the use of an internally positioned thermally reflective liner improves the conductive heat resistance of the coat so it is able to meet the requirement.

Test 2

[0065] One embodiment of pair of pants comprising a thermally reflective liner as described elsewhere herein is tested and found to comply with the test requirements of NFPA 1971, 2007 Edition Section 7.3; Section 7.1; Section 8.52; Section 8.54; Section 8.55; Section 8.56; and Section 8.57.

[0066] The performance of the pair of pants during the section tests is better than expected as it was believed that the reflective liner had to be on the outer surface of the clothing to meet the requirements of NFPA 1971. Outer layers, such as the outer shell of a coat or pants, are generally considered to be opaque and therefore were expected to interfere with the ability of the reflective surface to reflect back infrared radiation. But the data from the tests suggests otherwise. Specifically, the thermally reflective liner reflects away from the pair of pants a sufficient amount of the radiant heat received by the pair of pants to allow the pair of pants to pass the tests. The internal reflective liner allows the pair of pants to pass the tests described above. A similar pair of pants without the thermally reflective liner, but with an additional thermal liner of greater thickness instead, fails the tests. Therefore, the use of an internally positioned thermally reflective liner improves the conductive heat resistance of the pair of pants so it is able to meet the requirement.

[0067] While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto; the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, system, article, material, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, and/or methods, if such features, systems, articles, materials, and/or methods are not mutually inconsistent, is included within the scope of the present invention.

[0068] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0069] The indefinite articles "a" and "an," as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean "at least one."

[0070] The phrase "and/or," as used herein in the specification and in the claims, should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the "and/or" clause, whether related or unrelated to those elements specifically identified, unless clearly indicated to the contrary.

[0071] "Opaque" refers to a material that transmits less than 50 percent of incident visible light.

[0072] "Fastener" refers to fasteners such as hook and loop (VELCRO.RTM.), zipper, buttons, adhesive, snaps, slides, or other mechanical fastener suitable for clothing use.

[0073] "Thermally reflective liner" refers to a layer of material having a radiant energy reflectivity. The thermally reflective liner may satisfy the NFPA 1971 2007 requirements. Some of these materials may reflect (throw/cast back) more than 50%, more than 70% or more than 90% of incident radiant heat (infrared).

[0074] "Shell" used in reference to an article of clothing refers to the "outer layer" of the article of clothing and the terms may be used interchangeably herein. An outer shell of a coat may be made of a material that is fire and abrasion resistant and may be substantially non-reflective.

[0075] All references, patents and patent applications and publications that are cited or referred to in this application are incorporated in their entirety herein by reference.

Claims

1. A thermally resistant coat for protecting a responder against thermal hazards, the coat comprising: a) a flame and abrasion resistant outer shell, the resistant outer shell comprising a torso portion and two sleeve portions; and b) a thermally reflective liner positioned in the thermally resistant coat internal to the outer shell and comprising a thermally reflective surface facing the resistant outer shell.

2. The thermally resistant coat of claim 1, wherein the thermally reflective liner further comprises two sleeve portions.

3. The thermally resistant coat of claim 1, further comprising a means for connecting the thermally reflective liner to the coat.

4. The thermally resistant coat of claim 3, wherein the means for connecting the thermally reflective liner to the coat comprises a means for connecting the thermally reflective liner to the outer shell.

5. (canceled)

6. The thermally resistant coat of claim 4, wherein the thermally reflective liner is connected to the resistant outer shell at a sleeve region of each.

7. The thermally resistant coat of claim 1, wherein the thermally reflective surface comprises a metalized surface.

8-12. (canceled)

13. The thermally resistant coat of claim 1, wherein the thermally reflective liner comprises at least one vent.

14. The thermally resistant coat of claim 1, wherein the thermally reflective surface is positioned throughout the torso of the thermally reflective liner.

15. The thermally resistant coat of claim 1, wherein the thermally reflective surface is positioned throughout the torso and sleeves of the thermally reflective liner.

16. The thermally resistant coat of claim 1, wherein the thermally reflective liner is removably connected to the resistant outer shell.

17. (canceled)

18. The thermally resistant coat of claim 1, further comprising an insulating liner.

19-20. (canceled)

21. The thermally resistant coat of claim 1, further comprising a moisture barrier liner.

22. The thermally resistant coat of claim 21, wherein the moisture barrier liner is positioned in the thermally resistant coat internal to the thermally reflective liner.

23. (canceled)

24. The thermally resistant coat of claim 4, wherein the means for connecting the thermally reflective liner to the resistant outer shell is a means for removably connecting the reflective liner to the outer shell.

25. (canceled)

26. The thermally resistant coat of claim 4, wherein the means for connecting is hook and loop, zipper, buttons, adhesive, stitching, bonding, or snaps.

27. An emergency responder's ensemble that complies with at least one of NFPA Standards Meeting Section 7.1 Protective Garment Elements Performance Requirements for Both Ensembles, Section 7.3 Additional Performance Requirements for Proximity Fire Fighting Protective Garment Elements Only, the ensemble comprising the thermally resistant coat of claim 1.

28. A thermally resistant pair of pants for protecting a responder against thermal hazards, the pair of pants comprising a pair of full length pants legs each having a long dimension extending from the top to the bottom of the leg, each pair of pants comprising: a) a flame and abrasion resistant outer shell, and b) a thermally reflective liner, wherein the thermally reflective liner is positioned in the pair of pants internal to the outer shell and comprises a thermally reflective surface facing the resistant outer shell.

29-51. (canceled)

52. A thermally reflective liner for use as part of an emergency responder's clothing article, the liner comprising a metalized thermally reflective surface; wherein the liner is constructed in a manner to be positioned in the clothing article internal to a flame and abrasion resistant outer shell with the thermally reflective surface facing the outer shell, and wherein the liner comprises a fastener for removably connecting the liner to the outer shell.

53-55. (canceled)

56. The thermally reflective liner of claim 52, wherein the clothing article is a coat and the thermally reflective liner comprises a thermally reflective surface comprising a torso portion and two sleeve portions; and the liner is constructed in a manner to be positioned in the coat internal to a flame and abrasion resistant outer shell with the thermally reflective surface facing the resistant outer shell.

57-77. (canceled)

78. An emergency responder's ensemble that complies with at least one of NFPA Standards Meeting Section 7.1 Protective Garment Elements Performance Requirements for Both Ensembles, Section 7.3 Additional Performance Requirements for Proximity Fire Fighting Protective Garment Elements Only, the ensemble comprising the thermally reflective liner of claim 52.

79-109. (canceled)