Newsletter May 2013 

Introduction  The objective of SAFEPROTEX is to  develop  highly  effective  protec‐ tive clothing for people who oper‐ ate  under  complex  emergency  situations.  The  garments  shall  (1)  provide  protection  against  multi‐ ple hazards, (2) present extended  useful lifetime and (3) ensure the  physiological  comfort  of  the  wearer.  For  the  implementation  of  the  innovative  features,  the  project  has taken a bottom‐up approach,  starting  at  the  nano‐scale  and  encompassing  the  entire  value  chain  of  the  textile  industry  (spinning, weaving, surface  treat‐

ment technologies and design) up to  the prototyping of the actual protec‐ tive uniforms. This approach covers a  multi‐step  development  scheme,  with contributions from several part‐ ners in each case.     During the third  year and till the end  of the project  the ergonomic design  for the three  cases  of    rescue  teams  risky operations has been developed.    Prototypes  are  being  developed  for  each  case  following  ergonomic  de‐ sign  recommendations  and  using  yarns,  fabrics  and  treatments  that  have resulted from research in previ‐ ous stages of the project.

Three representative risky operation cases  CASE  1:  protective  garments  for  operations in extreme weather  conditions.  Main  functionalities/ properties  required  are:  water  impermeability  and  wind  resis‐ tance,  water  repellency,  protec‐ tion  against  cold,  antimicrobial  properties,  self‐cleaning  proper‐ ties, comfort and high visibility.     CASE  2:  protective  garments  for  operations  under  the  risk  of  wild  land  fires.  Main  functionalities/ properties  required  are:  FR  and  heat  protection,  UV  protection,  comfort properties and self clean‐ ing properties.  

CASE  3:  protective  garments  for  operation  by  first  aid  personnel,  potentially  exposed  to  any  type  of  hazard.  Main  functionalities/ properties  required  are  a  combina‐ tion of CASE 1 and CASE 2, plus anti‐ static properties.      GENERAL PROPERTIES  that apply in  all  three  cases:  self  cleaning,  en‐ hanced  mechanical  parameters,  thermal  comfort,  mechanical  com‐ fort, between others.

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CASE 1: Extreme weather situation  The main targeted properties are water impermeability and water repellency, thermal insulation, high visibility and antibacterial protection. It was decided to produce a three-layer structure. The proposed garment structure and materials to be used for this prototype include: (a) a knitted undergarment made of PET-based bicomponent thermoregulating yarns incorporating PCMs that melt at 32°C and (b) an overall made of a 3-layer structure: a thin spacer fabric as inner layer for protection against cold, an imperme-

able membrane in the middle for impermeability and wind resistance and a high visibility outer fabric surface treated with alkoxysilane nanosol (potentially incorporating chitosan microspheres) for water repellent and antimicrobial properties. Since the alkoxysilane treatment will reduce the adhesion of the fabric to the membrane, the treatment will be performed after membrane lamination. Reflective bands will be used for “high visibility” purposes.

PROTOTYPE 1 DESIGN  It is proposed to use an overall configuration. In those particular situations hazards are constantly appearing so avoiding getting trapped through the protection equipment is very important. Wearing an overall provides the user with a major tightness and reduces the parts with openings and access to the inner layers that can be the cause of getting trapped or hooked. The uniform is shaped to four season climate fit,

with the intermediate and inner layers while provides streamlined performance with minimal bulk. Strategic seams are provisioned to minimize wear & tear in high abrasion zones. The design ensures high mobility. The seams will be waterproof sealed & watertight laminated zippers will be used; water tight inner pockets and neoprene inner cuff ensure the best performance.

PROTOTYPE 1 NEW DEVELOPMENTS  (PCM, 3D, Alkoxysilane)  Bi-component fibers and yarns incorporating non-encapsulated phase-change materials (PCMs) are chosen for thermoregulating purposes. Fabric manufactured with bi-component fibers will be used in contact with the skin to maximize thermal comfort for the user. Fabrics combining super-hydrophobicity and antimicrobial properties have been developed by the application of sol-gel treatments on membrane laminated fabric. The composition of the nanosol was optimized in order to achieve the highest soil stability as well as efficiency and durability. Spacer fabrics have been chosen to reduce heat built up and allow air circulation, as well as cushioning and shock absorbing. Spacer fabrics will be used as inner layers to protect against cold, and in form of patches for shock absorbing.

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CASE 2: Personnel exposed to the Risk of Wild Land  The main properties targeted in this case are FR and heat protection, UV protection, comfort properties and self cleaning properties. The proposed garment structure and materials to be used for this prototype include: (a) a knitted undergarment made of PET-based bicomponent thermoregulating yarns incorporating PCMs that melt at 32°C (optional) and jacket/ (b) a 2 piece garment trousers) made of fabric with PA yarns incorporating FR modified clays or SiO2 (yarns still under optimisation) and surface treated with HMW benzophenone compounds for self-cleaning. Alternative to fabric from modified FR PA yarns, is a CO/PES fabric specially treated. The garment will in-

clude a knitted liner made of 100 % PA based bi-component thermoregulating yarns incorporating PCMs that melt at 45°C ensuring heat protection. Thermochromic patches will act as high temperature alert systems. Due to the poor ageing and UV stability, the patches will be used as an extra part of the uniform, on the helmet and/or on the wrists only to be used when the user goes on an operation and needs the alert system.

PROTOTYPE 2 DESIGN  A two pieces garment configuration (jacket and trousers) is proposed here. In these particular situations being able to relieve the temperature in a fast way is very important. Using two pieces of garment simplifies the action of putting off the upper or lower part, depending on the occasion. Intermediate and inner layers are designed in order to allow a four season climate fit. UV

protection is considered also important since guards in forests should very often stay under the sun for many hours, especially in southern countries. Other characteristics of the garment are the streamlined performance with minimal bulk, the strategic seams location to minimize wear & tear in high abrasion zones and the articulated patterning for unrestricted mobility.

PROTOTYPE 2 NEW DEVELOPMENTS  (PCM, Thermocromic, FR, 3D)  Bi-component fibers and yarns incorporating non-encapsulated phasechange materials (PCMs) will be used for protection from heat. Knitted fabrics from these yarns will be used as an intermediate layer for short time heat radiation protection. PP-based masterbatches incorporating microencapsulated thermochromic dyes were produced. Films of this materials will be incorporated as patches in specific parts of the garments to act as a high temperature alert system. Spacer fabrics are used to reduce heat built up and allow air circulation, as well as cushioning and shock absorbing. Could be used as an inner layer to protect against the cold, and in the form of patches for shock absorbing.

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CASE 3: First Aid Medical Personnel  The main targeted properties are water impermeability and water repellency, thermal insulation, high visibility and antibacterial protection, FR and heat protection, UV protection, comfort properties and self cleaning properties, as well as antistatic properties.

For the antistatic properties, conductive filaments will be incorporated in the structure of the fabric during weaving so as to form a conductive network.

The proposed garment structure and materials to be used for this prototype include: (a) a knitted undergarment made of PET-based bicomponent thermoregulating yarns incorporating PCMs that melt at 32° C (optional) and (b) a 2 piece garment jacket/trousers) made of FR fabric with antistatic properties, surface treated with HMW benzophenone compounds for self-

Thermochromic patches will be adjusted on the outer fabric to act as high temperature alert systems.

cleaning.

The garment could also include a knitted liner made of 100 % PA based bi-component thermoregulating yarns incorporating PCMs that melt at 45°C for heat protection.

Reflective bands will be used for “high visibility” purposes.

PROTOTYPE 3 DESIGN  It is proposed to use two pieces of garment configuration (jacket and trousers). In these particular situations full protection from infective agents could mean avoiding openings and access to inner layers as well as providing extra mobility.

Extra care should be given in cuff size and design to guarantee blood circulation over the brachial artery. Moreover since first aid personnel has to do operations of high sensitivity the design should minimize movement hindrance.

PROTOTYPE 3 NEW DEVELOPMENTS  (PCM, Alkoxysilane, 3D)  Bi-component fibers and yarns incorporating non-encapsulated phase-change materials (PCMs) for thermoregulating purposes. Will be used in contact with the skin to provide thermal comfort. Fabrics combining super-hydrophobicity and antimicrobial properties developed by application of sol-gel treatments and membrane lamination. The composition of the nanosol was optimized in order to achieve the highest sol stability as well as efficiency and durability of the fabric. Solgel treatment will be used as a finishing process of the outer fabric after membrane lamination. Spacer fabrics to reduce heat built up and allow air circulation, as well as cushioning and shock absorbing can be used depending on the situation. Could be used as patches for shock absorbing.

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Life Cycle Analysis  The objective is to study environmental impacts of high protective clothing applying LCA method according the principles of ISO 14 040 & 14 044 Standards. According to ergonomic design, for example, Prototype 1 includes 16 different materials, most of them accessories like cords, zippers and other fasteners. Main load though is considered to be from the fabrics that contribute to the garment. Therefore, LCA analysis in this case is based on the environmental load of: 1. Flame retardant outer fabrics 2.

Hydrophilic PU-membrane (non porous, 20 g/m2)

3. 3D spacer fabric (100 % PES) 4. Alkoxysilane treatment (antimicrobial, stain resitant, super-hydrophobicity)

Next figure (by NTT) was resulted as a combination of Ergonomic Design report and data and protocol sheets collected from project partners. Environmental impact has been estimated through Simapro 7.3 software. Climate Change (CO2-eqv.), Human Toxicity (1,4-DB eq.) and Fossil Depletion (oil eq.) were chosen as indicators.

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Development &  Validation of prototypes  The three prototypes are being constructed in the last phase of the project by responsible partners, in base of the design specifications and the selected composition of fabrics and finishing processes.

       CASE 1  

  CASE 2     CASE 3 

Coordinator:

Phone: +30-210-9234932 Fax: +30-210-9235603 Web: www.ebetam.gr

Contact persons: Silvia Pavlidou ([email protected]) Fani Kotzia ([email protected])

The SAFEPROTEX Project is funded by European Commission, under 7th Framework Programme

www.safeprotex.org

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Two samples of each prototype CASE will be developed, one to be tested under lab conditions, functionalities, and another to be testes on end users, usability.

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The prototypes will be evaluated/ validated in the last phase of the project for their thermal comfort and wear comfort in laboratory tests in controlled conditions with sweating thermal manikin and in the field by a limited number of endusers.

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The results of the prototype testing, as well as the outcome of the previous research in fibres, finishing treatments and 3D fabrics, will be disseminated in a conference that will be organized together with the last Project meeting.

Beneficiaries: INOTEX spol,s.r.o. (CZ) RESCOLL Technical Centre of Materials (FR) TDV Industries (FR) De Montfort University (UK) Tampere University of Technology (FI) GAIKER Technological Centre (ES) Swerea IVF AB (SE) Next Technology Tecnotessile Societá Nazionale di Ricerca r.l.; (IT) LEITAT Technological Center (ES) Lenzi Egisto S.p.A (IT) Vyskumny ustav chemických vlakien, a.s; (SK) CALSTA Work Wear S.A. (GR) NANOTHINX S.A. (GR) Suministros Iruñako S.V. (ES) Fundació Privada CETEMMSA (ES) SAR-ESPAÑA (ES)