Lab Shares a Stake in Better Military Tents Published March 4, 2010 By Peggy Allen Materials and Manufacutring WRIGHT-PATTERSON AIR FORCE BASE, Ohio -- In an effort geared towards protecting military lives and property, Air Force Research Laboratory materials experts at Tyndall Air Force Base, Florida, teamed with researchers from North Carolina State University and Armacell, LLC, to develop a highly cost-effective, materials integration approach for manufacturing improved military tents. The new method will result in well-insulated, fire-resistant tents that are lighter-weight, less expensive, and more durable than tents made with conventional fabrics. The team's finished product--a "demonstrator" model intended for display, examination, and evaluation purposes--incorporates a compacted, closed-cell foam guarded by a tough outer fabric. These special inner and outer layers are bonded with a fire-retardant adhesive and laminated to provide impermeability and thereby further enhance fire resistance. In addition to providing a viable demonstration product, this collaborative effort generated an array of materials samples that will be put to use in follow-on analysis of the technology. The joint endeavor began when members of the Tyndall AFB Fire Research Group embarked on a shelter textile replacement project. Their primary goal was to develop a fire-resistant, insulated shelter capable of providing suitable living conditions for personnel deployed in a variety of weather conditions. Of paramount importance was that the shelter material be capable of withstanding storage temperatures of 160°F, as well as maintaining its fire-retardant properties. The team ultimately created a product meeting these qualifications and more. Armacell, a global leader in engineered foams, manufactured the durable, waterproof, compacted foam, which resembles vinyl (but with the texture of fine sandpaper) and is commonly used in yoga mats. NCSU, a recognized leader in nonwoven materials education and research, developed the supertough, lightweight, fibrous, and nonwoven outer textile sheet. AFRL's involvement in integrating these materials yielded a novel product about 20% lighter than--and half the cost of--conventional military tent-making materials. In formulating their final product, the researchers evaluated the technology's three major components (fabric, foam, and coating) according to American Society for Testing and Materials International standards. They examined tensile strength and other critical performance characteristics for the nonwoven fabric and focused on key areas such as vertical flame resistance, flammability, limited oxygen index, density, compression deflection, low-temperature flexibility, tensile strength, elongation, and thermal conductivity for the foam. For the specialized coating that seals the adhesively bonded inner and outer layers, they tested for enhanced tensile strength, tear strength, hydrostatic resistance, weathering (ultraviolet xenon arc), and vertical flame resistance. This successful joint venture between AFRL, academia, and industry marks a significant step forward in providing warfighters a much improved, safer living environment during times of deployment. The results extend beyond personnel safety to include property protection as well, since the approach is equally applicable to manufacturing the aircraft shelters and maintenance/storage tents used to house equipment in remote expeditionary locations. The technology is likewise transferable to the commercial world for a variety of applications.