This paper investigates the development of fabric materials using several blends of inherently fire-resistant (FR) fibers and various knitted structures. The samples are evaluated with respect to their performance and comfort-related properties. Inherently fire-resistant fibers, e.g., Nomex, Protex, carbon and FR viscose, were used to develop different structures of knitted fabrics. Cross-miss, cross-relief, and vertical tubular structures were knitted by using optimum fiber blend proportions and combinations of stitches. Several important aspects of the fabric samples were investigated, e.g., their physical, mechanical and serviceability performance. Thermo-physiological and tactile/touch-related comfort properties were evaluated in addition to flame resistance performance. An analysis of mechanical performance indicated that the knitted structure has a significant influence on the tensile strength, bursting strength and pilling resistance. The cross-relief structure proved to be the strongest followed by the cross-miss and vertical tubular structures. The FR station suits made from 70:30 Protex/Nomex exhibited the best combination of tensile and bursting strength; therefore, this material is recommended for making a stable and durable station suit. Interestingly, it was also concluded from the experimental study that knitted samples with a cross-relief structure exhibit the best fire-resistance performance. Fiber blends of 70:30 Protex/Nomex and 70:30 Nomex/carbon were found to be optimum in terms of overall performance. The best flame resistance was achieved with Nomex:carbon fiber blends. These results were confirmed with vertical flammability tests, TGA, DTGA and cone calorimetry analysis. The optimization of blend composition as well as knitting structure/architecture is a crucial finding toward designing the best FR station suit in terms of mechanical, dimensional, thermal, thermo-physiological and flame resistance performance.
Keywords: comfort properties; fire-resistant (FR) material; inherently fire-retardant fiber; knitted structure; mechanical performance; station suits.