World population is increasing rapidly and the resources which are available are very limited. Human life is very important part in this world as it has the power to change reality and create future. To preserve once life from cold weather there exists technologies which cannot be afforded by most. In addition most of the apparels made for cold weather climates limits human behavior. To answer these existing silent needs new material has to be developed. Creation of more flexible thin material which uses less raw material that can be recyclable was created through testing and learning. This new material was tested using industry standard devices to see how it performs against other thermal insulation material that made for the same purpose.
This thesis contains the steps for developing an innovative IR reflective spacer material.
Table of Contents
1. Introduction
1.2 Problem recognition
1.3 Goal
2. Cold weather effect and technologies
2.1. Cold weather effect on the human body
2.2. Standards for cold weather apparels.
2.2.1. Commercial sector
2.2.2. Daily consumer
2.3. Thermal insulation methods.
2.3.1. Passive insulation
2.3.1.1. Insulation layer
2.3.2. Active insulation
3. Market analysis
3.1. Market needs
3.1.2. Cold weather textiles
3.1.3. Cold weather sports
3.1.4. Special care for older people
3.1.5. Work related
4. Theories and law’s
4.1. Thermal dynamics
4.1.2. Thermal Conduction principles.
4.1.2.1. Thermal conductivity value.
4.1.3. Infra-Red
4.2. Human skin
4.3. Ohm’s law
5. Concept development
5.1. Spacer fabric
5.1.1. Reflective layer
5.2. Material
5.2.1. Heat reflection and metals.
5.2.1.2. Yarns
5.3. Knitting Technology
5.3.1. Needle notations
5.4. Machines equipment’s
5.4.1. CMS 302 TC knitting machine
5.4.2. Stoll M1 Plus® version 5.4.0.62
6. Material Production
6.1. Material name classification
6.2. Production flow chart
6.3. Production
A-x -1HH
A-x-3HH
C-y-3HH
D-y-3HH
E-z-2HH
F-z-2HH
G-z-2II
G-z-2JI
6.4. Reflective surface comparison
7. Material testing
7.1. Testing of average rate of heat loss
7.1.1. Development map
7.1.2. Setup
7.1.3. Testing method
7.1.4. Evaluation of data
7.2. Testing of thermal resistance value
7.2.1. Development map
7.2.2. Setup
7.2.3. Testing method
7.2.4. Evaluation of data
7.3. Permetest
7.3.1. Testing method
7.4 Sweating guarded hotplate
7.4.1. Testing method
7.5. Other tests
7.5.1. Testing of knitted material
7.5.2. Digital microscope
7.5.3. M-IR spectroscopy
8. Benchmarking process
8.1. Benchmarking material
8.1.1. Duck down material
8.1.2. Omni heat material
8.1.3. Felted wool
8.1.4. Jacket inner lining
8.1.5. Temptrol reflective material
8.1.6. ReF.110x
8.1.7. Non reflective spacer material
8.1.8. Reflective spacer material – G-z-2JI
8.2. Performance comparison
9. Conclusion
Research Objectives and Key Topics
The thesis aims to explore the effects of cold weather conditions on human body performance and to develop a new, high-performance thermal insulating material using spacer fabric technology that incorporates reflective properties to improve thermal retention.
- Analysis of physiological impacts of cold weather and current insulation standards.
- Evaluation of thermal dynamics, radiation, and conduction principles in textiles.
- Market analysis of existing thermal insulation solutions and identified performance limitations.
- Development and iterative testing of a reflective 3D spacer fabric prototype.
- Benchmarking the developed material against market-standard insulation solutions.
Excerpt from the Book
5.1. Spacer fabric
Spacer fabrics are also known as three dimensional material because of its unique structure. Spacer fabrics possess unique properties that cannot be achieved easily by any other material. They are such as – Low area density, wide range of thickness (from 2 to 65mm), high thermal insulation properties. Although still increasing in trend it is believed that spacer fabrics will be used more and more in the future due to its unique structural properties.
The spacer fabric has two external layers which is internally connected to one another by third structure or an internal layer. This internal layer is a yarn system that makes loops on both of the outer layers and keeps passing from one layer to the other. Thus separately two layers are joined together by this third layer. It looks much like a sandwich. The gap or the space can be adjusted depending on the machine that is used for production from 2mm up to 65mm. Different material can be used for each layer. Although still gaining its popularity as material it was developed and patented in 1868 by Mr. Matthew Townsend.
Summary of Chapters
1. Introduction: This chapter outlines the growing complexity of human needs and the dependency on reliable technical solutions, specifically focusing on the apparel industry's role and the urgent need for better thermal protection in cold climates.
2. Cold weather effect and technologies: This chapter details the physiological effects of cold on the human body, such as blood flow reduction and the risks of hypothermia, while reviewing existing ISO standards and insulation methods like passive and active systems.
3. Market analysis: This section identifies unfulfilled market needs for thinner, more flexible, and affordable thermal insulation, particularly for sports, elderly care, and work-related environments.
4. Theories and law’s: This chapter provides the theoretical foundation for the thesis by explaining thermal dynamics, heat loss mechanisms (radiation, convection, conduction), and the principles of infrared absorption and reflection.
5. Concept development: This chapter details the design process of the new material, focusing on 3D spacer fabric construction and the integration of reflective layers to effectively bounce back body heat.
6. Material Production: This section describes the material classification system and the iterative production steps taken to create and optimize various prototypes to achieve the desired thermal performance.
7. Material testing: This chapter explains the development of custom testing apparatus and standard methodologies used to measure thermal insulation, including heat loss rates and thermal resistance.
8. Benchmarking process: This chapter compares the developed prototypes against commercially available materials like duck down, Omni heat, and felted wool to validate the performance improvements.
9. Conclusion: The final chapter summarizes the findings, confirming the superior performance of the developed reflective spacer material and suggesting its potential for future industrial application.
Key Keywords
Thermal insulation, Spacer fabric, Infrared reflection, Thermal conductivity, Cold weather apparel, Reflective layer, Material testing, Knitting technology, Heat loss, Human thermal comfort, Material development, Performance benchmarking, Polyester, Emissivity, Thermal resistance.
Frequently Asked Questions
What is the core focus of this research?
The research focuses on the development of a novel thermal insulating textile that integrates a reflective layer within a 3D spacer fabric to improve warmth retention while maintaining flexibility.
Which market sectors are primarily addressed?
The work addresses needs in high-performance sportswear, personal protective equipment for work environments, and apparel for elderly populations susceptible to cold-related health risks.
What is the primary research goal?
The goal is to move beyond conventional bulky insulation by developing a thin, highly efficient material that reflects body heat, thereby offering a lightweight alternative to traditional down-filled garments.
What scientific methods are applied?
The study utilizes thermal physics, infrared spectroscopy for reflectivity analysis, and specialized textile testing equipment, including both self-developed devices and standardized hotplate testing systems.
What does the main body of the work cover?
It covers the theoretical physics of heat transfer, the analysis of existing market technologies, the detailed mechanical production steps of 3D knitting, and rigorous material testing and benchmarking.
Which keywords define this thesis?
Thermal insulation, Spacer fabric, Infrared reflection, Cold weather apparel, Material testing, and Thermal conductivity are the central concepts characterizing the work.
How is the material's reflective capability tested?
The reflectivity is evaluated using M-IR spectroscopy to measure how effectively the material reflects infrared wavelengths corresponding to human skin temperature.
What role does the spacer fabric structure play?
The 3D spacer structure allows for a specific distance between layers, enabling the trapping of air to reduce conductive heat loss while providing a foundation to incorporate reflective yarns.
Why was aluminium chosen as the reflective material?
Aluminium was selected due to its very low emissivity coefficient and excellent IR reflective properties, making it highly effective for bouncing thermal radiation back toward the body.
What were the findings regarding the final prototype?
The final prototype, based on the G-z-2JI construction, demonstrated the highest average thermal resistance, outperforming both traditional down materials and existing market solutions.
- Quote paper
- Tharaka de Silva Hikkaduwa Liyanage (Author), 2013, Development of Thermal Insulating Textiles. An Innovative IR Reflective Spacer Material, Munich, GRIN Verlag, https://www.grin.com/document/283424
