Stretchable flame resistant materials

A laminate comprising:

• a textile layer that is elastic and includes a meltable material;
• a barrier layer having less than 5% elasticity and defining a corrugated structure within the laminate;
• and
• an intermediate layer including a heat reactive material between the textile layer and the barrier layer;
• wherein the heat reactive material comprises a polymer resin-expandable graphite mixture of a polymer resin and an expandable graphite, the expandable graphite having an expansion of at least 900 μm at 280° C., as measured according to the TMA expansion test.

A process for producing a laminate comprising:

• imparting a stretching force on an elastic textile having an initial relaxed width in a machine direction so as to stretch the elastic textile and reduce a width of the elastic textile to 90 percent or less of the initial relaxed width;
• providing a barrier layer;
• applying a layer of a heat reactive material to the stretched elastic textile or the barrier layer or both;
• wherein the heat reactive material comprises a polymer resin-expandable graphite mixture of a polymer resin and an expandable graphite, and the expandable graphite is configured to expand by at least 900 μm at 280° C.;
• adhering the barrier layer to the stretched elastic textile so that the heat reactive material is between the elastic textile and the barrier layer;
• curing the heat reactive material while the elastic textile remains stretched;
• and
• reducing the stretching force on the elastic textile to produce the laminate;
• wherein the barrier layer has a corrugated structure after the stretching force is reduced.