Cut Protective Textiles

Cut Protective Textiles

Daniel (Xuedong) Li

Table of Contents

Cover image

Title page

Copyright

Foreword

Foreword

Preface

1. Cut and slash hazards

Abstract

2. Evaluate cut resistance

Abstract

2.1 ISO13997

2.2 EN388:2016 and ISO23388:2018

2.3 ASTM F2992/F2992M-15

2.4 ISO13998

2.5 ISO13999

2.6 Cut resistance for protection against chainsaw

3. Fundamental of fibers

Abstract

3.1 Basic forms of fibers

3.2 Basic properties of fibers

4. Convert fiber to textile

Abstract

4.1 Knitting

4.2 Weaving

4.3 Nonwoven

5. Choice of materials for cut protective textile

Abstract

5.1 Spinning

5.2 Materials

5.3 Dipping or coating materials for cut protective textile

6. Mechanism of cut and cut resistance, factors affecting cut resistance, and development trend of cut resistant products

Abstract

6.1 Mechanism of cut

6.2 Factors affecting cut resistance

6.3 Development trend and measures to improve cut resistance

Appendix A. Conversions between different units of tenacity and strength

Appendix B. Data in patents²⁴²–²⁵⁸²⁴²²⁴³²⁴⁴²⁴⁵²⁴⁶²⁴⁷²⁴⁸²⁴⁹²⁵⁰²⁵¹²⁵²²⁵³²⁵⁴²⁵⁵²⁵⁶²⁵⁷²⁵⁸

Appendix C. Statistical analysis for data in patents

Appendix D. Physical properties of materials

Appendix E. Constructions of knit fabric with different fibers

References

Index

Copyright

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Notices

Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary.

Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.

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Foreword

Alan E. Learned Dr. , Retired Global Technology Manager, DuPont de Nemours, Inc.

Over 1 million workers in North America will be taken to the emergency room this year for the treatment of hand injuries. Seventy percent of those injuries occurred, while the workers were not wearing any protective gloves, and the remaining 30% were wearing the wrong type of gloves for the level of hazard they were experiencing.

So YES!!!, cut protective gloves is an important topic from both a business cost perspective, with the average medical treatment cost ranging from $6000 to $10,000 for each injury, and from a personal pain and suffering perspective, where the impact is not only in the workplace, but also at home among families when a mother/father/wife/husband/brother/sister/son/daughter returns from work injured. According to the Occupational Health and Safety Administration (OSHA is a federal agency in the United States responsible for assuring a safe and healthful environment for workers), more than 70% of those injuries could have been avoided with the appropriate training, design, and personal protective equipment, such as cut protective gloves.

It was over a decade ago at a technology leadership conference that I first met Dr. Xuedong Li. My career in textiles and technology development has spanned over 40 years, and in that first meeting, I was impressed by Dr. Li’s passion for safety and protection. During the following years while Dr. Li worked in my global technology team, I learned to appreciate even more his strong intellectual curiosity that drove him to relentlessly pursue the fundamentals of his development projects, searching for better ways to provide higher performance and better protection.

Dr. Li’s book on Cut Protective Gloves will provide you both a broad and deep look at this fascinating and complex topic, cut protection. He will introduce the basic building blocks of the protective materials, polymers, and fibers, how the fibers and fabrics are measured to understand their ability to protect the workers, and how the materials are constructed into their final protective form, gloves. Dr. Li will explore with you the fundamental mechanisms of cut protection and will even unpack for you several of the current mysteries that still exist in this field.

Whether you are just beginning your journey to understand cut protection, or if you are an experienced professional in this area, I believe you will find new insights that will act as a catalyst to ultimately help workers return home safe and uninjured.

Foreword

Vlodek Gabara Dr. , Retired DuPont Fellow, DuPont de Nemours, Inc.

I have enjoyed writing this foreword for two reasons: I have spent most of my professional life doing research in the field of advanced fibers and I have known, the author, Dr. Daniel Li, for most of his professional life.

R&D in advanced fiber field shares many elements with research on other fibers. In both cases, one needs to develop understanding of polymer chemistry and technology of polymer formation, in both one needs to develop understanding of engineering of fiber formation and many other technologies. What distinguishes the advanced fiber field is the necessity to understand how these fibers perform in final applications. This is as sophisticated and as fundamental science as science of polymerization chemistry or spinning solution rheology. This understanding is necessary to design final objects while maximizing the utilization of the unusual physical properties of these fibers. The unique anisotropy of properties of these fibers has to be considered in almost all applications.

Dr. Li monograph covers cut protection, one the important applications of these fibers. The monograph covers a complete range of topics required to understand the problem. It includes basic science of fibers, yarns, composite yarn, and finally fabrics and their production. A very useful, brief description of fibers used in this application gives readers the necessary background information. Mechanism of cut protection and treatment of fabrics used in this application completes the monograph.

In addition to its completeness, it is well written and I am convinced it will be useful for scientists and engineers with different levels of familiarity with the field. I do hope that Dr. Li will consider expanding his work into other applications of advanced fibers.

January 2019

Preface

The awareness of and demand for safety protection have been constantly increasing along with the ongoing development of our global economies. Worldwide, the developed countries are leading in the legislation and execution for labor protection as well as the development and use of personal protective equipment, which set examples for and can be used by the developing countries.

I used to work in DuPont for many years on the applications of aramid fibers. In the manufacturing sector, the safety system and practices of DuPont have been well known across the world and have been viewed by many as setting the highest bar of safety performance in industry. DuPont has also participated in establishing many safety standards in the United States. I have experienced and learned tremendously both safety theory and practice during working in the laboratories in DuPont. In the DuPont manufacturing groups, safety contacts, auditing, and training were expected on each shift of every day…7 days per week…365 days per year. In nonmanufacturing group, safety is also a daily topic. In the R&D labs I worked, besides all the safety measures and information exchange done on a daily basis, a formal monthly safety training was mandatory for every employee. The training covered different contents each month, such as electric safety, hand safety, machinery safety, chemical safety, household safety, sports safety, motorcycle and bicycle safety, pedestrian safety, children safety, sometimes latest changes in laws and regulations such as new traffic laws. I always left my cell phones in office and sat in front of the training class in order for me to focus on the training. More than 10 years, such experience in training also benefits me tremendously.

I had the opportunity to get hands-on and participate in upgrading many types of equipment and processes to improve the safety. As I handled lots of equipment, in DuPont’s machinery safety management standard and practice have tremendously benefited me at my job.

The safety practices of DuPont not only cover on-the-job areas, but also extend to off-the-job, especially to the employees’ families, for instance, household safety, appliance safety, children safety. The strict policy of safety belt use and the penalty for not using also help to save lives of my colleagues who became involved in traffic accidents. I always remember a surprising moment in Shanghai, China that a taxi driver told me that I must be from DuPont when I got into his taxi and insisted on getting the seat belt to fasten. Influenced by the safety culture of DuPont, many employees equip fire extinguishers at home, which is not common in China. This did save one of my colleagues’ family in a home fire incident.

In addition, aramid fibers are widely used in protective products. As my technical field was in aramid fibers, I did extensive research and development in cut protective products. A large portion of workplace injuries are hand injuries, with mechanical hazards, including cuts, being the most common. However, a search of the literature reveals that no definitive books have been written on this very important topic. Likewise there is also very limited academic research published on this subject. After having conducted extensive research and development in cut protective products during my career, I felt compelled to summarize the critical knowledge on this topic. I hope that readers of this book will be able to better understand the complexities of cut protection and continue to advance the technology in a way that helps to protect more people in their daily work for the decades to come.

Originally, I intended to write a book on all major applications of aramid fiber, in which cut protection was supposed to be only one chapter. But during the writing of this chapter, the contents were gradually expanded and eventually became a stand-alone book. Some basic knowledge of textile and fiber materials is added, and thus this book can be used for all practitioners in this industry along the entire value chain.

No confidential information from DuPont was used in writing this book.

As I have a full-time busy job and also demanding family needs, I can only use part of the weekends and holidays to write this book to make sure this writing work does not conflict with the full-time job and family needs. It has been a difficult journey. I got up at 5:30 a.m. on every weekend day and holiday during the 2 years of writing, including in the coldest winter, and write until 8:30 or 9 a.m. when my daughters started to be active. Though this book is not long, it still took me more than 2 years to complete. I hereby would like to appreciate my family for their tolerance, especially my two daughters Esther and Joy. Though they really wanted to play with me, they knew I was rushing to complete this book and therefore behaved very well not to disturb my writing. Thank you Esther and Joy, you are my sunshine. And to my lovely wife, none of this would be possible without your love and support. You are my rock and my inspiration.

I would like to extend my appreciation to Dr. Alan E. Learned and Dr. Vlodek Gabara. Dr. Learned used to lead the DuPont global personal protection technology team in aramid business and now has already retired. Dr. Learned helped me review the entire book and gave invaluable suggestions and also helped me on the language in this book. Dr. Gabara used to be a DuPont Fellow and had spent most of his career on aramid technology. He is a worldwide recognized high performance fiber expert and has played a critical role in commercial success of Kevlar and Nomex aramid fibers. He therefore earned a name of Godfather of Kevlar Fiber. He has retired from DuPont. Dr. Gabara has been a role model for me in my technical career and encouraged me to write something from application aspect. He helped me review the book.

I would also like to extend my appreciation to Larry J. Prickett, a productive researcher in DuPont. Larry has worked on Kevlar aramid fiber for more than 40 years and developed many cut protective products containing Kevlar aramid fiber. He is a very kind coach and taught me a lot in cut protection and cut protective products.

Daniel Li (Xuedong), Shanghai, China

July 2019

1

Cut and slash hazards

Abstract

This chapter gives an overview of the injury caused by cutting in different working environments. Representative injury statistics and associated costs are briefly introduced. Occupations and workplaces which pose cut hazards are discussed.

Keywords

Cut; slash; laceration; injury; PPE

According to the data released by the US Bureau of Labor Statistics, there were approximately 2.8 million nonfatal workplace injuries and illnesses reported by private industry in 2017, among which 882,730 occupational injuries and illnesses resulted in days away from work.¹ Besides, there was a total of 89,180 injuries caused by cut, laceration or punctures (not only on hands), accounting for some 10% of the total injuries. While the top two categories are sprains, strains, tears, and soreness and pain, which are usually caused by overexertion of body, overstretch, and awkward body position, not by tools, as a contrast, the cut, lacerations, and punctures are usually caused by tools. Among these 882,730 injuries and illnesses, 201,910 (22.9%) occurred to hands, arms, and wrists. Hence, cut protection, especially for hand protection, is critically important to workplace safety. Table 1.1 shows the incident rate of different categories of injuries in the private industry of the United States in 2017.

Table 1.1

Source: From Bureau of Labor Statistics, USA. <bls.gov/iif/oshsum.htm#17Summary_News_Release>.

Cut hazards are everywhere. Cuts and lacerations occur at a rate of 8.1 incidents for every 10,000 workers. Some common workplaces with high cut hazards include the following:

1. Sheet metal handling such as metal forging and stamping, and sheet metal manual carrying. For instance, in stamping workshops of car manufacturing facilities, the workers need to transport thin steel sheets. It is often unavoidable to do manual handling of sheet metal on many occasions. Very thin sheet metal poses significant cut injury threats to the workers. The sharp edge can easily cut through flesh and even bones especially when the sheet metal slips from hands if the workers do not grip it well. The author witnessed an injury when a worker in a stamping workshop of an automotive manufacturing factory carried a stainless steel sheet and it slipped from his hand and caused a thumb cut, even though he wore a pair of cut-resistant gloves. Handling sheet metal is shown in Fig. 1.1.

2. Metal-processing factories where workers need to handle processed parts and offcuts. The workplaces are different from those in the metal forging and stamping process but the hazards are similar (Fig. 1.2).

3. Glass manufacturing factories where workers need to handle glass sheets (see Fig. 1.3). The edges of finished glass-sheet products are usually not a problem as they are usually ground and, therefore, are smooth. The threat is posed by those semifinished sheets and broken sheets. Many workers suffer cut on hands and arms when they carry and move glass sheets. The author also witnessed many injuries caused by glass in glass-sheet factories. Some of those injuries are very serious and some workers lose some functions permanently.

4. Slaughtering. Butchery is a very old occupation. The cutting hazard is very obvious to everyone. Slaughtering usually requires a high force for cutting; therefore the threat level is high (see Fig. 1.4). Steel chainmail gloves are commonly used in slaughtering houses to respond to this kind of high level of risk.

5. Forestry (Fig. 1.5). In the forestry industry, logging usually requires full-body protection due to the use of chainsaw, and hand protection is the minimum requirement.

6. Recycling and waste handling (Fig. 1.6). According to a study, garbage collection is ranked as one of the most dangerous jobs in the United States.² There are many kinds of stuff that may cut the workers, such as broken glasses, knives, cans, porcelain, and so on and so forth. Fig. 1.5 shows the hazards of handling waste.

7. Electronics assembling and handling exhibit cutting hazards too. For instance, the sharp edge of printed circuit board and the soldering point can easily cut hands when the hands slide on top of them. Fig. 1.7 shows such working environment. Certainly, the sharp soldering points also pose puncturing hazard which is different from cut hazard. The puncturing is not a subject of this book.

8. Food processing (Fig. 1.8). In food-processing factories and even in busy kitchens the workers do very frequent cutting with sharp tools; therefore the cutting hazard is very high.

9. Construction (Fig. 1.9). In construction work the workers need to handle construction materials with rough surfaces, such as cement blocks and bricks, and sharp-edged materials and tools, such as cut pipe ends and structure metal.

10. Pressurized glass bottle handling such as in beer brewery (Fig. 1.10). The pressurized glass bottles sometimes break or explode under pressure due to defects in the glass. The workers need to wear cut-resistant gloves when handling these bottles.

11. Pulp and paper industry. Pulp and paper manufacturing poses heavy hazards to the workers due to the massive weights and rolling and sliding pulpwood loads and fast-moving sharp paper. Many people have experience of being cut by copy paper in the office when a piece of paper slides on top of a finger. The moving speed of paper is much faster than that in the office and, therefore, is much more hazardous in terms of cut injury potential. Fig. 1.11 shows the personal protection from cutting by paper.

12. Leather and textile mills. Leather and textile industries exercise numerous cutting in their manufacturing, including cutting leather to desired shape, cutting yarn threads and fabrics to metered length or desired dimension, and so on. In textile mills the moving threads in spinning are also a type of cutting hazard to the operators. Fig. 1.12 shows the cutting hazard in fabric mill.

13. Sports. In hockey sports (Fig. 1.13) the skate blades are fairy sharp. Many players have full protection over the body but some skip the throat protection due to discomfort. However, throat cut accident did happen from time to time.³,⁴

Figure 1.1 Sheet metal handling. Source: Courtesy MCR Safety.

Figure 1.2 Metal processing. Source: From Chevanon Photography on Pexels.com.

Figure 1.3 Glass-sheet handling. Source: Courtesy Kezzled Pakistan.

Figure 1.4 Slaughtering house. Source: Courtesy Birk Staal Denmark.

Figure 1.5 Use chainsaw. Source: Courtesy Irish Farmers Journal.

Figure 1.6 Waste handling. Source: From <https://www.epa.gov/sites/production/files/2017-10/recycling_from_above_0.jpg>.

Figure 1.7 Handling electronics. Source: From <denvergov.org>.

Figure 1.8 Food processing. Source: From chuttersnap on Unsplash.

Figure 1.9 Construction work. Source: Courtesy MCR Safety.

Figure 1.10 Handling pressurized glass bottles. Source: Courtesy Myanmar Times.

Figure 1.11 Handling paper.

Figure 1.12 Cut fabrics. Source: Courtesy Ordnur Textile and Finance.

Figure 1.13 Risk of skate blade slash injury. Source: Photo by Markus Spiske on Unsplash.

Last but not least, many office and household works are also hazardous, such as cutting with knives and scissors, cleaning glass fragments, scrap metals, and doing plumbing work.

The top 30 nature of work which has the highest incident rates of cut and laceration in the United States are listed in Table 1.2.¹

Table 1.2

Source: From Bureau of Labor Statistics, USA. <bls.gov/iif/oshsum.htm#17Summary_News_Release>.

The entire personal protection equipment (PPE) market was valued at some US$48 billion in 2018, and expected to grow to some 70 billion by 2025 at an estimated compounded annual growth rate of 6.6%.⁵ There is no market size information available for the cut protection alone. Usually the protective products’ market is categorized as hand protection, fall protection, head protection, respiratory protection, etc. However, most cut injuries occur to hands. Though hand protection also includes the chemical and other protections the majority is for cut protection or multifunction