Development of protective fabric systems with spacer fabric and performance evaluation upon hot pressurized steam.

Developing new fabric systems with excellent thermal protective performance is essential to protecting workers from hot pressurized steam hazards. In this study, a laminated fabric was selected and a weft-knitted spacer fabric was developed for steam protective fabric systems. Effects of the configuration of the fabric systems and heat setting of spacer fabric on performances were investigated. The results demonstrate that the developed spacer fabric significantly prolonged skin burn times compared with controls. However, heat setting of spacer fabric had a negligible effect on improving thermal protective performance. Spacer fabric provided superior thermal protection while ensuring thermal comfort and enhancing air permeability, especially for spacer fabric after heat setting. Generally, a fabric system composed of a laminated outer shell and a spacer fabric is the best choice for steam protective clothing. The findings help develop a novel thermal liner to decrease energy transfer and provide better protection from pressurized steam.

Highly Thermal-Wet Comfortable and Conformal Silk-Based Electrodes for On-Skin Sensors with Sweat Tolerance.

Noninvasive and seamless interfacing between the sensors and human skin is highly desired for wearable healthcare. Thin-film-based soft and stretchable sensors can to some extent form conformal contact with skin even under dynamic movements for high-fidelity signals acquisition. However, sweat accumulation underneath these sensors for long-term monitoring would compromise the thermal-wet comfort, electrode adherence to the skin, and signal fidelity. Here, we report the fabrication of a highly thermal-wet comfortable and conformal silk-based electrode, which can be used for on-skin electrophysiological measurement under sweaty conditions. It is realized through incorporating conducting polymers poly(3,4-ethylenedioxythiophene): polystyrenesulfonate (PEDOT:PSS) into glycerol-plasticized silk fiber mats. Glycerol plays the role of tuning the mechanical properties of silk fiber mats and enhancing the conductivity of PEDOT:PSS. Our silk-based electrodes show high stretchability (>250%), low thermal insulation (∼0.13 °C·m2·W-1), low evaporative resistance (∼23 Pa·m2·W-1, 10 times lower than ∼1.3 mm thick commercial gel electrodes), and high water-vapor transmission rate (∼117 g·m-2·h-1 under sweaty conditions, 2 times higher than skin water loss). These features enable a better electrocardiography signal quality than that of commercial gel electrodes without disturbing the heat dissipation during sweat evaporation and provide possibilities for textile integration to monitor the muscle activities under large deformation. Our glycerol-plasticized silk-based electrodes possessing superior physiological comfortability may further engage progress in on-skin electronics with sweat tolerance.

Interaction effects of washing and abrasion on thermal protective performance of flame-retardant fabrics.

In this study, common flame-retardant fabrics were treated with single washing or abrasion and their interactions to simulate wearing away during use. The changes in thickness, mass/m2 and protective performance of the fabrics under both flame and radiation environments were evaluated. Results demonstrated that the protective performance was firstly increased after washing or abrasion, and then decreased with further increasing washing or abrasion cycles. After certain treatment cycles, the combined effect of washing and abrasion was significantly greater than the single effect of washing or abrasion alone. The interaction modes of washing and abrasion also showed significant differences in protective performance under a flame test. Under radiation exposure, the effect of combined washing and abrasion was more obvious. There was a positive correlation between the fabric weight and its protective performance with different treatments. The findings provide useful guidance for the actual use and maintenance of protective clothing.

Development and performance assessment of electrically heated gloves with smart temperature control function.

A pair of lightweight electrically heated gloves (EHG) with smart temperature control function was developed. To evaluate the thermoregulation properties of the EHG, human trials were conducted in a climate chamber (2.5 °C, 60% RH). The changes in skin temperature at all fingers and the opisthenar, and the subjective thermal sensation were recorded over 60 min. The effects of two air velocities (i.e., 0.17 and 0.50 m/s) on the cold protective performance of the EHG in scenarios of heating and control were also investigated. For heating scenarios, skin temperature and thermal sensation at all fingers and the opisthenar were found significantly higher than those in control conditions. Moreover, the air velocity at 0.50 m/s greatly reduced the cold protective performance of the gloves. The research findings can be applied to improve thermal comfort and extend working times for persons in cold environments.

On the Improvement of Thermal Protection for Temperature-Responsive Protective Clothing Incorporated with Shape Memory Alloy.

This study explored the application of shape memory alloy (SMA) springs in a multilayer protective fabric assembly for intelligent insulation that responded to thermal environment changes. Once the SMA spring was actuated, clothing layers were separated, creating an adjustable air gap between the adjacent fabric layers. The impacts of six different SMA arrangement modes and two different spring sizes on thermal protection against either a radiant heat exposure (12 kW/m²) or a hot surface exposure (400 °C) were investigated. The findings showed that the incorporation of SMA springs into the fabric assembly improved the thermal protection, but the extent to which the springs provided thermal protection was dependent on the arrangement mode and spring size. The effectiveness of reinforcing the protective performance using SMA springs depended on the ability of clothing layers to expand an air layer. The regression models were established to quantitatively assess the relationship between the air gap formed by SMA spring and the thermal protective performance of clothing. This study demonstrated the potential of SMA spring as a suitable material for the development of intelligent garments to provide additional thermal protection and thus reduce the number of clothing layers for transitional thermal protective clothing.

Investigation of the thermal hazardous effect of protective clothing caused by stored energy discharge.

In addition to direct thermal energy from a heating source, a large amount of thermal energy stored in clothing will continuously discharge to skin after exposure. Investigating the thermal hazardous effect of clothing caused by stored energy discharge is crucial for the reliability of thermal protective clothing. In this study several indices were proposed and applied to evaluate the impact of thermal energy discharge on human skin. The heat discharge from different layers of fabric systems was investigated, and the influences of air gaps and applied compression were examined. Heat fluxes at the boundaries of fabric layers and the distribution of heat discharge were determined. Additionally, the correlation between heat storage during exposure and heat discharge after exposure was identified. The results demonstrated that heat discharge to the skin could be correlated with heat storage within the fabric, however, it highly depended on the air gap under clothing, the applied compression, and the insulation provided by the fabric layers. Results from this study could contribute to thoroughly understanding the thermal hazardous effect of clothing and enhance the technical basis for developing new fabric combinations to minimize energy discharge after exposure.

Effect of two sweating simulation methods on clothing evaporative resistance in a so-called isothermal condition.

The effect of sweating simulation methods on clothing evaporative resistance was investigated in a so-called isothermal condition (T manikin = T a = T r ). Two sweating simulation methods, namely, the pre-wetted fabric "skin" (PW) and the water supplied sweating (WS), were applied to determine clothing evaporative resistance on a "Newton" thermal manikin. Results indicated that the clothing evaporative resistance determined by the WS method was significantly lower than that measured by the PW method. In addition, the evaporative resistances measured by the two methods were correlated and exhibited a linear relationship. Validation experiments demonstrated that the empirical regression equation showed highly acceptable estimations. The study contributes to improving the accuracy of measurements of clothing evaporative resistance by means of a sweating manikin.

Effect of sweating set rate on clothing real evaporative resistance determined on a sweating thermal manikin in a so-called isothermal condition (T manikin = T a = T r).

The ASTM F2370 (2010) is the only standard with regard to measurement of clothing real evaporative resistance by means of a sweating manikin. However, the sweating set-point is not recommended in the standard. In this study, the effect of sweating rate on clothing real evaporative resistance was investigated on a 34-zone "Newton" sweating thermal manikin in a so-called isothermal condition (T manikin = T a = T r). Four different sweating set rates (i.e., all segments had a sweating rate of 400, 800, 1200 ml/hr ∙ m(2), respectively, and different sweating rates were assigned to different segments) were applied to determine the clothing real evaporative resistance of five clothing ensembles and the boundary air layer. The results indicated that the sweating rate did not affect the real evaporative resistance of clothing ensembles with the absence of strong moisture absorbent layers. For the clothing ensemble with tight cotton underwear, a sweating rate of lower than 400 ml/hr ∙ m(2) is not recommended. This is mainly because the wet fabric "skin" might not be fully saturated and thus led to a lower evaporative heat loss and thereby a higher real evaporative resistance. For vapor permeable clothing, the real evaporative resistance determined in the so-called isothermal condition should be corrected before being used in thermal comfort or heat strain models. However, the reduction of wet thermal insulation due to moisture absorption in different test scenarios had a limited contribution to the effect of sweating rate on the real evaporative resistance.

Correction of the heat loss method for calculating clothing real evaporative resistance.

In the so-called isothermal condition (i.e., Tair [air temperature]=Tmanikin [manikin temperature]=Tr [radiant temperature]), the actual energy used for moisture evaporation detected by most sweating manikins was underestimated due to the uncontrolled fabric 'skin' temperature Tsk,f (i.e., Tsk,f

A novel personal cooling system (PCS) incorporated with phase change materials (PCMs) and ventilation fans: An investigation on its cooling efficiency.

Personal cooling systems (PCS) have been developed to mitigate the impact of severe heat stress for humans working in hot environments. It is still a great challenge to develop PCSs that are portable, inexpensive, and effective. We studied the performance of a new hybrid PCS incorporating both ventilation fans and phase change materials (PCMs). The cooling efficiency of the newly developed PCS was investigated on a sweating manikin in two hot conditions: hot humid (HH, 34°C, 75% RH) and hot dry (HD, 34°C, 28% RH). Four test scenarios were selected: fans off with no PCMs (i.e., Fan-off, the CONTROL), fans on with no PCMs (i.e., Fan-on), fans off with fully solidified PCMs (i.e., PCM+Fan-off), and fans on with fully solidified PCMs (i.e., PCM+Fan-on). It was found that the addition of PCMs provided a 54∼78min cooling in HH condition. In contrast, the PCMs only offered a 19-39min cooling in HD condition. In both conditions, the ventilation fans greatly enhanced the evaporative heat loss compared with Fan-off. The hybrid PCS (i.e., PCM+Fan-on) provided a continuous cooling effect during the three-hour test and the average cooling rate for the whole body was around 111 and 315W in HH and HD conditions, respectively. Overall, the new hybrid PCS may be an effective means of ameliorating symptoms of heat stress in both hot-humid and hot-dry environments.

Clothing resultant thermal insulation determined on a movable thermal manikin. Part II: effects of wind and body movement on local insulation.

Part II of this two-part series study was focused on examining the effects of wind and body movement on local clothing thermal insulation. Seventeen clothing ensembles with different layers (i.e., 1, 2, or 3 layers) were selected for this study. Local thermal insulation with different air velocities (0.15, 1.55, and 4.0 m/s) and walking speeds (0, 0.75, and 1.17 m/s) were investigated on a thermal manikin. Empirical equations for estimating local resultant clothing insulation as a function of local insulation, air velocity, and walking speed were developed. The results showed that the effects of wind and body movement on local resultant thermal resistance are complex and differ distinctively among different body parts. In general, the reductions of local insulation with wind at the chest, abdomen, and pelvis were greater than those at the lower leg and back, and the changes at the body extremity such as the forearm, thigh, and lower leg were higher than such immobile body parts as the chest and back. In addition, the wind effect interacted with the walking effect. This study may have important applications in human local thermal comfort modeling and functional clothing design.

Clothing resultant thermal insulation determined on a movable thermal manikin. Part I: effects of wind and body movement on total insulation.

In this serial study, 486 thermal manikin tests were carried out to examine the effects of air velocity and walking speed on both total and local clothing thermal insulations. Seventeen clothing ensembles with different layers (i.e., one, two, or three layers) were selected for the study. Three different wind speeds (0.15, 1.55, 4.0 m/s) and three levels of walking speed (0, 0.75, 1.2 m/s) were chosen. Thus, there are totally nine different testing conditions. The clothing total insulation and local clothing insulation at different body parts under those nine conditions were determined. In part I, empirical equations for estimating total resultant clothing insulation as a function of the static thermal insulation, relative air velocity, and walking speed were developed. In part II, the local thermal insulation of various garments was analyzed and correction equations on local resultant insulation for each body part were developed. This study provides critical database for potential applications in thermal comfort study, modeling of human thermal strain, and functional clothing design and engineering.

Performance study of protective clothing against hot water splashes: from bench scale test to instrumented manikin test.

Hot liquid hazards existing in work environments are shown to be a considerable risk for industrial workers. In this study, the predicted protection from fabric was assessed by a modified hot liquid splash tester. In these tests, conditions with and without an air spacer were applied. The protective performance of a garment exposed to hot water spray was investigated by a spray manikin evaluation system. Three-dimensional body scanning technique was used to characterize the air gap size between the protective clothing and the manikin skin. The relationship between bench scale test and manikin test was discussed and the regression model was established to predict the overall percentage of skin burn while wearing protective clothing. The results demonstrated strong correlations between bench scale test and manikin test. Based on these studies, the overall performance of protective clothing against hot water spray can be estimated on the basis of the results of the bench scale hot water splashes test and the information of air gap size entrapped in clothing. The findings provide effective guides for the design and material selection while developing high performance protective clothing.

A novel approach for fit analysis of thermal protective clothing using three-dimensional body scanning.

The garment fit played an important role in protective performance, comfort and mobility. The purpose of this study is to quantify the air gap to quantitatively characterize a three-dimensional (3-D) garment fit using a 3-D body scanning technique. A method for processing of scanned data was developed to investigate the air gap size and distribution between the clothing and human body. The mesh model formed from nude and clothed body was aligned, superimposed and sectioned using Rapidform software. The air gap size and distribution over the body surface were analyzed. The total air volume was also calculated. The effects of fabric properties and garment size on air gap distribution were explored. The results indicated that average air gap of the fit clothing was around 25-30 mm and the overall air gap distribution was similar. The air gap was unevenly distributed over the body and it was strongly associated with the body parts, fabric properties and garment size. The research will help understand the overall clothing fit and its association with protection, thermal and movement comfort, and provide guidelines for clothing engineers to improve thermal performance and reduce physiological burden.

Analysing performance of protective clothing upon hot liquid exposure using instrumented spray manikin.

Hot liquid hazards existing in work environments present a common risk in workplace safety in numerous industries. In this study, a newly developed instrumented manikin system was used to assess the protective performance provided by protective clothing against hot liquid splash. The skin burn injury and its distribution for the selected clothing system were predicted and the effects of clothing design features (fabric properties and garment size) on protective performance were investigated. The air gap size and distribution existing between protective clothing and human skin were characterized using 3D body scanning, and their relation to skin burn injury was identified. The mechanism associated with heat and mass transfer under exposure to hot liquid splashes was discussed. The findings provided technical bases to improve the performance of protective clothing. For protective clothing design, minimizing mass transfer through clothing system is very important to provide high performance. Keeping the air gap between the garment and the human body is an essential approach to improve thermal performance. This can be achieved by proper design in size and fit, or applying functional textile materials.