Design for Multi-Layer Thermal Protective Clothing Based on Numerical Simulation of Heat Transfer

It is well-known that high-performance thermal protective clothing is crucial for personnel working in high-temperature environments, such as firefighters. Thermal protective clothing design usually integrates textile material‌s’ type, thickness, physical and chemical properties (such as thermal conductivity), ergonomics, and environmental adaptability. In this study, the heat transfer process and the optimal thickness are mainly discussed for providing some references on the design of this clothing. The thickness design of thermal protective clothing fabrics is carried out via numerical heat transfer simulations based on experimental data obtained from manikin tests. Firstly, one heat transfer model for thermal protective clothing, including three textile materials’ layers and one air layer, is constructed according to Fourier’s law of heat conduction, Newton’s law of cooling, and the Stefan–Boltzmann law, with appropriate boundary conditions assigned. Secondly, the finite volume element method, which has the important advantage of preserving conservation properties for physical quantities, is employed to discretize the heat transfer model. Thirdly, the convective heat transfer coefficient, which characterizes heat exchange between fluid and solid surfaces, is determined approximately by the least-squares method based on the given data, while the heat transfer process is simultaneously simulated. Fourthly, the thicknesses of the second and fourth layers are critical to the performance of thermal protective clothing. Two optimization algorithms are proposed to determine the optimal thickness configuration that effectively balances thermal insulation and wearing comfort. From the above results, it is recommended to use multilayer textile composite materials incorporating aerogel insulation layers and phase-change material interlayers.