New Technology Protective Clothing Meets Emergency Rescue Protection Needs

Recently, the project titled “Multifunctional Design R&D and Performance Evaluation of Protective Clothing,” jointly developed by Donghua University and Shenzhen Utopai Apparel Technology Co., Ltd., was awarded the 2013 "Textile Light" Science and Technology Second Prize. This groundbreaking initiative focused on the design, research, and evaluation of multi-functional protective garments, which offer a range of critical features such as fire resistance, heat insulation, waterproofing, breathability, and antibacterial properties. These innovations make the clothing ideal for use in emergency rescue scenarios, where individuals require reliable and versatile protection.

Traditional protective clothing typically relies on flame-retardant fibers, such as meta-aramid, which are inherently flame-resistant due to their unique chemical structure. These materials do not easily catch fire, self-extinguish when the flame source is removed, and form a carbonized layer that acts as an insulator, preventing melting or dripping. However, these garments often lack versatility and comfort, limiting their effectiveness in complex environments where multiple hazards may be present.

According to Li Jun, the project leader and director of the Department of Fashion Design and Engineering at Donghua University, the initiative introduced a new theoretical model for functional design in protective clothing. It established concepts such as “layered insulation,” “multiple protections,” and “function build-up” to ensure comprehensive protection against various threats. The project also integrated thermal protection performance (TPP) with total heat loss (THL) to optimize fabric systems. A two-step optimization technique was used to develop a composite fabric system, including an outer waterproof breathable layer, a heat-insulating layer, and a comfort layer. Additionally, arylsulfone fibers were employed to create flame-retardant outer layers and heat-insulating components. A “triple-play” technology was developed to produce a fabric with a “sandwich” structure, offering waterproof, breathable, anti-viral, and antibacterial properties. A four-dimensional dynamic body structure design method was also proposed to enhance the adaptability of protective clothing during work activities.

The project also made significant progress in evaluating the overall protective performance of fabrics and garments. It developed a characterization technique that comprehensively assessed physical, chemical, and ergonomic comfort properties of protective fabric systems. This led to the establishment of a scientific framework for evaluating garment performance from fabric properties to finished products. The team created a thermal protection performance tester capable of simulating the tensile deformation of micro-space fabrics under simulated clothing conditions. They also developed a device to evaluate scald protection performance when exposed to high-temperature liquids, contributing to theoretical research on liquid permeation protection. Furthermore, the “Donghua Fireman” system—a burning dummy designed to replace biological human bodies—was used to quantitatively predict skin burn sites and severity in simulated fire environments. This allowed for objective evaluations of the thermal protection performance of protective clothing, fire-fighting gear, and other similar garments.

“Donghua Fireman” is China’s first burning dummy, designed to simulate real fire scenes. In high-risk environments, effective protective equipment can significantly reduce harm to firefighters and evacuees. Previously, fabric combustion tests were commonly used, but they failed to accurately reflect the impact on the human body. Using the dummy allows researchers to better understand how protective clothing performs in actual conditions. The laboratory, the world's first fire body human protection combustion lab, fully replicates the Chinese body structure. It can sense high-temperature heat flow in different postures and accurately report skin burns. Its joints can be adjusted to simulate the movements of firefighters, helping researchers improve the ease of movement and reduce gaps in fabric design based on the physical characteristics of Chinese users. After each test, the research team analyzes the data collected from the dummy to refine future designs.

Hu Zuming, director of the Chemical Fiber Research Institute at Donghua University, emphasized that fabric development and combustion testing are like a process of continuous improvement. By refining combustion tests, researchers can design more scientifically sound and rational thermal protection equipment, effectively reducing thermal damage caused by dangerous environments such as fires, battlefields, and heat radiation.

Li Jun explained that the project adopted a structured approach, with clear responsibilities assigned to all participants. This ensured that the mission was well-defined and efficiently executed. Donghua University, working alongside Shenzhen Utopai, leveraged the theoretical advantages of the “Donghua Fireman” Laboratory, combining expertise from both academic and industry sectors. The company provided years of experience in the research, development, and production of specialized protective clothing, allowing the latest research findings to quickly reach the production line.

Both parties in the product development process made full use of existing resources for integration between production, research, and application. The Chemical Fiber Research Institute of Donghua University and Utopai Corporation were involved throughout the project, enabling rapid application of the developed technologies to large-scale production. This significantly shortened the time required for technology and product development. Most of the production relied on the existing facilities of the project unit. Regular meetings were held with experts, scholars, and engineers from various industries, universities, and research institutes to discuss challenges and priorities in the project. Through a platform for production, research, and innovation, the research results were promptly transformed into practical applications, creating a supportive environment for the commercialization of technological achievements.

The outcomes of the “Multifunctional Design and Development of Protective Clothing and Performance Evaluation” project have been widely applied in the production of flame-retardant clothing, protective gear, and chemical protective equipment. These innovations represent a major step forward in the field of protective clothing, enhancing safety and functionality in high-risk environments.

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