功能性间隔织物的结构与性能研究
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摘要
本文主要对一种三维立体织物——经编间隔织物的结构与性能进行研究。间隔织物拥有两个相对独立的织物表面，间隔纱位于两个面之间，起连接和支撑作用。经编间隔织物在双针床经编机上生产，两个针床之间的距离决定了织物的厚度，目前间隔织物的厚度范围为2—65mm。而我国现有的间隔织物生产与应用主要局限于6mm以下的薄型间隔织物，缺乏6mm以上的间隔织物，因此本课题主要针对中厚型间隔织物的生产和主要使用性能进行了尝试与研究。
首先，由于专门开发用于中厚型间隔织物生产的Highdistance设备价格非常昂贵，我们在原有的中绒型双针床设备上对成圈机构、送经机构、横移机构、牵拉机构都做了适当的改进，以适应间隔织物的生产。其次，在后整理过程中的拉幅定型机上也要针对厚型间隔织物做出相应的改进。此外，根据间隔织物的使用需要，对原料的品种和粗细都进行了选择，并且根据经验对间隔织物在原料粗细和组织结构的选择方面给出了相关参考依据。
对于间隔织物而言，它的压缩性能是非常重要的性能之一，但是针对中厚型间隔织物，缺乏相应的压缩性能测试仪器。我们开发了一个适应厚型间隔织物的压缩仪器，测试了若干种间隔织物的压缩特性曲线，并对影响间隔织物压缩性能的相关因素进行分析和研究。随着压强的增大，间隔织物的压缩曲线分成三个阶段：初始阶段，压缩曲线呈线性，织物具有稳定的压缩刚度；第二阶段为非线性阶段，间隔织物比初始阶段易于被压缩；第三阶段间隔织物难于被压缩，呈现比较高的压缩刚度。间隔织物的压缩性能受到间隔纱粗细、织物厚度、织物密度、间隔纱的倾斜角度的影响。间隔纱线的线圈密度大，间隔纱线粗、织物厚度小以及间隔纱垂直布面程度高都有利于提高织物的抗压缩能力。此外，实验显示单位面积间隔织物受到的压力愈大，材料的弹性回复性能愈差，厚度损失也愈大。所以，工作压强最好在间隔织物压缩曲线的线性阶段，这样对织物的损伤小。相同压强作用下，压缩刚度高的间隔织物，其弹性回复性能也比较好。此外，利用自行开发的织物压缩疲劳仪等还对间隔织物和海绵材料进行了特定压强下的动态和静态压缩疲劳性能测试，结果显示间隔织物的耐压缩疲劳性能与海绵材料接近。
此外，由于间隔织物的压缩过程主要为间隔纱线的弯曲过程，所以把间隔纱线——单丝理想化为弹性弯曲的弹性杆，而且各个单丝之间相互独立，由此可以得到相应的理论压缩曲线。在理论分析过程中，理论分析也证实了前面压缩实验中的影响因素，即间隔纱粗细、织物的厚度、间隔纱的倾斜角度、线圈密度。结果还显示理论曲线与实际压缩曲线在压缩的第一阶段(线性阶段)比较吻合；当压强比较大时，理论曲线与实际压缩曲线偏差增大。这是由于间隔织物在压缩的初期，间隔纱线相互独立、无相互作用，与理想状态比较接近；而随着压缩的进行，间隔纱线弯曲愈加严重，发生明显的相互作用，导致间隔纱容易弯曲、织物容易被压缩，并且随着压缩的加剧，间隔纱线最终弯曲到极点，而被径向压缩。
间隔织物在被压缩时，还能够发挥缓解压力的作用。缓解压力性能的优劣，主要通过压强峰值的大小来进行评价。分别测试了足底以及坐姿情况下臀部的压力分布，结果显示间隔织物比同等厚度的海绵、羊毛毡、絮类能够缓解更多的压强峰值，使用起来更加舒适。此外，对若干种间隔织物进行研究发现，间隔织物缓解压力性能的优劣主要取决于织物的厚度和压缩刚度。厚度确定时，在间隔织物处于压缩第一阶段(弹性压缩阶段)的前提下，织物的压缩刚度愈小，缓解压力效果愈好。而厚度增加则对间隔织物的缓解压力性能也起着积极的作用，在一定范围内成线性关系。因此，选择适当压缩刚度的中等厚度的间隔织物，经过多层叠加完全可以实现厚间隔织物的缓解压力效果。
最后，由于间隔织物在使用时不仅受到压力作用，而且也面临着人体散发的热量和湿气，所以对间隔织物的生理舒适性能也进行了相应的测试。间隔织物的透气性能显著优于海绵等材料，甚至比普通的服用纬编织物还好。因此，间隔织物的透湿性能也优于其它材料，甚至采用特殊纤维材料时，间隔织物还能获得更好的透湿性能。间隔织物的导热性能明显高于海绵材料，能够传递更多的热量，可以有效地避免人体热量的积累，非常适合在温暖环境中使用。
总之，间隔织物压缩性能与海绵等材料相似，而且通过采用不同的原料、组织结构和厚度，还可以设计得到各种不同压缩性能的间隔织物。间隔织物的缓解压力性能优于海绵等其它材料，热湿舒适性能也显著优于常见的褥垫材料，所以间隔织物非常适合在座椅、床垫等场合使用，尤其是在温暖的环境中使用。
This paper shows the research on the structure and properties of thethree-dimensional textile-warp knitted spacer fabrics. Spacer fabric hastwo separated surfaces which are connected and supported by spacer yarns.Warp knitted spacer fabrics are produced on double-needle-bar warpknitting machine, and the thickness of spacer fabric mainly depends on thedistance between two needle beds. Now the range of the thickness ofcommercial spacer fabrics is from 2 to 65mm. But in our country, there areonly the spacer fabrics thinner than 6mm which can be found. So we try toproduce middle-thick spacer fabrics and study the properties of them.
Firstly, it's necessary to make some adjustments on machines includingknitting device, let-off device, shogging device and draft-off device inorder to produce spacer fabrics on traditional machine for pile fabricsinstead of using the expensive machine exclusive for spacer fabrics-Highdistance machine. Some adjustments on heat-setting machine are alsonecessary for the thicker spacer fabrics too. In addition, some suggestionson the materials and structures of spacer fabrics are offered.
Compressibility is most important character of spacer fabrics. But thereis no proper instrument which can test thicker spacer fabrics'compressibility. We developed one instrument which can test thecompressibility of thick spacer fabrics. We compared the compress-recovercurves of some spacer fabrics and other materials. The factors of effect onspacer fabrics' compressibility were studied and analyzed. The testsconducted on spacer fabrics show that load-compression curve obtained iscomposed of three periods. At the beginning of compression the thicknessof fabric decreased linearly with the increased compressive stress, whichshows stable compressive rigidity. In the second period, the curve isnon-linear and spacer fabric is easier to compress. In the third period, thecurve is linear again but its compressive rigidity increases rapidly whichmeans the spscer fabric is very difficult to compress at last. The thickness of spacer yarn, the thickness of the spacer fabrics, density of fabrics andinclined angles of spacer yarns will affect the compressibility of spacerfabrics. High loop density, thicker spacer yarn, lower thickness and biggerangle between spacer yarn and surface are helpful to improveanti-compression property. Experiments show that excessive pressureimposed on the spacer fabrics will cause less flexible recovery of thethickness of spacer fabrics. It's suggested that the pressure imposed onspacer fabrics is better to work in the linear part of compressive curve,which make little damage on the spacer fabrics. Under the suitable pressure,the spacer fabric with higher compressive rigidity will have high elasticrecovery. In addition, the thickness variation of spacer fabrics and PU foamunder the static and dynamic loadings are compared. The results haveshown that compared with PU foam spacer fabrics have similar stability ofthe thickness under the loadings during the usage.
Because the process of compression of spacer fabrics is the process ofbending of spacer yarn, the spacer yarn(monofilament) is supposed to beelastic rod in condition of limited strain, and the elastic rod areindependent without jamming each other. Then the theoretical compressioncurve of spacer fabric can be obtained by using the mechanics of elastic rod.By the theoretical analysis on the spacer fabrics, the factors which affectthe compressibility are also discussed too. The theoretical compressioncurve is quite agreed with to the experimental curve in the first linearperiod of compression. When the pressure is much higher so that theexperimental compression curve is not linear, in this period bigger gapbetween theoretical and experimental curves will occur. At the beginning ofcompression, the spacer yarns are independent and do not jam each other, innormal work condition. But when the pressure on spacer fabric is highenough the spacer yarns bend too much, then the spacer yarns will touchand jam each other, so that the spacer yarn will be easier to bend whichmake the spacer fabric easier to be compressed. At last, the spacer yarnswill be crushed by the excessive pressure and difficult to be compressedmore.
When the spacer fabrics used for mattress and cushions the property ofpressure reduction is considered. The degree of pressure reduction mainlydepends on the value of peak pressure. The pressure imposed on the feetand buttocks are measured respectively. The results show it clearly that the spacer fabrics can reduce more peak pressure than PU foam, wool felt andwadding with same thickness.
In addition, more spacer fabrics are studied for the factors of pressurereduction. The pressure reduction mainly depends on the thickness andcompression rigidity of the spacer fabrics. When the thickness is definiteand the spacer fabrics are compressed in the linear period, the spacer fabricwith lower compressive rigidity will have better pressure reduction. Andalso high thickness can help spacer fabrics reduce more pressure. By usingone layer of thick spacer fabrics or several layers of middle-thick spacerfabrics with proper compressive rigidity the better pressure reduction canbe achieved.
For the usage of mattress not only the pressure reduction has to beconsidered, the thermal property and moisture permeability are veryimportant too. We also tested the physiological comfort of spacer fabrics.Spacer fabrics have better air permeability comparing with PU foam andnormal weft-knitted fabric for garments. So the spacer fabrics should alsohave better vapor permeability than other materials. Using properfunctional fiber such as hygroscopic fibre and moisture-transmitting fibrein the spacer fabrics can improve its vapor permeability too. Spacer fabricshave lower heat resistance than other materials, which means it can transfermore heat from human body, so that the heat accumulation on human bodyin the warm environment can be avoided by using spacer fabric.
Though spacer fabrics have similar compressibility to PU foam, thespacer fabrics with different compressibility can be achieved by usingdifferent materials, structures and thickness to meet the demand of user.Spacer fabrics have better properties of pressure reduction andthermo-hydro comfort than other traditional materials for mattresses andcushions. Spacer fabrics are very suitable for the wadding of mattresses andcushions, especially in the warm environment.
Ye Xiaohua(Textile Engineering)
Supervised by Prof. Hu Hong and Prof. Feng Xunwei
首先，由于专门开发用于中厚型间隔织物生产的Highdistance设备价格非常昂贵，我们在原有的中绒型双针床设备上对成圈机构、送经机构、横移机构、牵拉机构都做了适当的改进，以适应间隔织物的生产。其次，在后整理过程中的拉幅定型机上也要针对厚型间隔织物做出相应的改进。此外，根据间隔织物的使用需要，对原料的品种和粗细都进行了选择，并且根据经验对间隔织物在原料粗细和组织结构的选择方面给出了相关参考依据。
对于间隔织物而言，它的压缩性能是非常重要的性能之一，但是针对中厚型间隔织物，缺乏相应的压缩性能测试仪器。我们开发了一个适应厚型间隔织物的压缩仪器，测试了若干种间隔织物的压缩特性曲线，并对影响间隔织物压缩性能的相关因素进行分析和研究。随着压强的增大，间隔织物的压缩曲线分成三个阶段：初始阶段，压缩曲线呈线性，织物具有稳定的压缩刚度；第二阶段为非线性阶段，间隔织物比初始阶段易于被压缩；第三阶段间隔织物难于被压缩，呈现比较高的压缩刚度。间隔织物的压缩性能受到间隔纱粗细、织物厚度、织物密度、间隔纱的倾斜角度的影响。间隔纱线的线圈密度大，间隔纱线粗、织物厚度小以及间隔纱垂直布面程度高都有利于提高织物的抗压缩能力。此外，实验显示单位面积间隔织物受到的压力愈大，材料的弹性回复性能愈差，厚度损失也愈大。所以，工作压强最好在间隔织物压缩曲线的线性阶段，这样对织物的损伤小。相同压强作用下，压缩刚度高的间隔织物，其弹性回复性能也比较好。此外，利用自行开发的织物压缩疲劳仪等还对间隔织物和海绵材料进行了特定压强下的动态和静态压缩疲劳性能测试，结果显示间隔织物的耐压缩疲劳性能与海绵材料接近。
此外，由于间隔织物的压缩过程主要为间隔纱线的弯曲过程，所以把间隔纱线——单丝理想化为弹性弯曲的弹性杆，而且各个单丝之间相互独立，由此可以得到相应的理论压缩曲线。在理论分析过程中，理论分析也证实了前面压缩实验中的影响因素，即间隔纱粗细、织物的厚度、间隔纱的倾斜角度、线圈密度。结果还显示理论曲线与实际压缩曲线在压缩的第一阶段(线性阶段)比较吻合；当压强比较大时，理论曲线与实际压缩曲线偏差增大。这是由于间隔织物在压缩的初期，间隔纱线相互独立、无相互作用，与理想状态比较接近；而随着压缩的进行，间隔纱线弯曲愈加严重，发生明显的相互作用，导致间隔纱容易弯曲、织物容易被压缩，并且随着压缩的加剧，间隔纱线最终弯曲到极点，而被径向压缩。
间隔织物在被压缩时，还能够发挥缓解压力的作用。缓解压力性能的优劣，主要通过压强峰值的大小来进行评价。分别测试了足底以及坐姿情况下臀部的压力分布，结果显示间隔织物比同等厚度的海绵、羊毛毡、絮类能够缓解更多的压强峰值，使用起来更加舒适。此外，对若干种间隔织物进行研究发现，间隔织物缓解压力性能的优劣主要取决于织物的厚度和压缩刚度。厚度确定时，在间隔织物处于压缩第一阶段(弹性压缩阶段)的前提下，织物的压缩刚度愈小，缓解压力效果愈好。而厚度增加则对间隔织物的缓解压力性能也起着积极的作用，在一定范围内成线性关系。因此，选择适当压缩刚度的中等厚度的间隔织物，经过多层叠加完全可以实现厚间隔织物的缓解压力效果。
最后，由于间隔织物在使用时不仅受到压力作用，而且也面临着人体散发的热量和湿气，所以对间隔织物的生理舒适性能也进行了相应的测试。间隔织物的透气性能显著优于海绵等材料，甚至比普通的服用纬编织物还好。因此，间隔织物的透湿性能也优于其它材料，甚至采用特殊纤维材料时，间隔织物还能获得更好的透湿性能。间隔织物的导热性能明显高于海绵材料，能够传递更多的热量，可以有效地避免人体热量的积累，非常适合在温暖环境中使用。
总之，间隔织物压缩性能与海绵等材料相似，而且通过采用不同的原料、组织结构和厚度，还可以设计得到各种不同压缩性能的间隔织物。间隔织物的缓解压力性能优于海绵等其它材料，热湿舒适性能也显著优于常见的褥垫材料，所以间隔织物非常适合在座椅、床垫等场合使用，尤其是在温暖的环境中使用。
This paper shows the research on the structure and properties of thethree-dimensional textile-warp knitted spacer fabrics. Spacer fabric hastwo separated surfaces which are connected and supported by spacer yarns.Warp knitted spacer fabrics are produced on double-needle-bar warpknitting machine, and the thickness of spacer fabric mainly depends on thedistance between two needle beds. Now the range of the thickness ofcommercial spacer fabrics is from 2 to 65mm. But in our country, there areonly the spacer fabrics thinner than 6mm which can be found. So we try toproduce middle-thick spacer fabrics and study the properties of them.
Firstly, it's necessary to make some adjustments on machines includingknitting device, let-off device, shogging device and draft-off device inorder to produce spacer fabrics on traditional machine for pile fabricsinstead of using the expensive machine exclusive for spacer fabrics-Highdistance machine. Some adjustments on heat-setting machine are alsonecessary for the thicker spacer fabrics too. In addition, some suggestionson the materials and structures of spacer fabrics are offered.
Compressibility is most important character of spacer fabrics. But thereis no proper instrument which can test thicker spacer fabrics'compressibility. We developed one instrument which can test thecompressibility of thick spacer fabrics. We compared the compress-recovercurves of some spacer fabrics and other materials. The factors of effect onspacer fabrics' compressibility were studied and analyzed. The testsconducted on spacer fabrics show that load-compression curve obtained iscomposed of three periods. At the beginning of compression the thicknessof fabric decreased linearly with the increased compressive stress, whichshows stable compressive rigidity. In the second period, the curve isnon-linear and spacer fabric is easier to compress. In the third period, thecurve is linear again but its compressive rigidity increases rapidly whichmeans the spscer fabric is very difficult to compress at last. The thickness of spacer yarn, the thickness of the spacer fabrics, density of fabrics andinclined angles of spacer yarns will affect the compressibility of spacerfabrics. High loop density, thicker spacer yarn, lower thickness and biggerangle between spacer yarn and surface are helpful to improveanti-compression property. Experiments show that excessive pressureimposed on the spacer fabrics will cause less flexible recovery of thethickness of spacer fabrics. It's suggested that the pressure imposed onspacer fabrics is better to work in the linear part of compressive curve,which make little damage on the spacer fabrics. Under the suitable pressure,the spacer fabric with higher compressive rigidity will have high elasticrecovery. In addition, the thickness variation of spacer fabrics and PU foamunder the static and dynamic loadings are compared. The results haveshown that compared with PU foam spacer fabrics have similar stability ofthe thickness under the loadings during the usage.
Because the process of compression of spacer fabrics is the process ofbending of spacer yarn, the spacer yarn(monofilament) is supposed to beelastic rod in condition of limited strain, and the elastic rod areindependent without jamming each other. Then the theoretical compressioncurve of spacer fabric can be obtained by using the mechanics of elastic rod.By the theoretical analysis on the spacer fabrics, the factors which affectthe compressibility are also discussed too. The theoretical compressioncurve is quite agreed with to the experimental curve in the first linearperiod of compression. When the pressure is much higher so that theexperimental compression curve is not linear, in this period bigger gapbetween theoretical and experimental curves will occur. At the beginning ofcompression, the spacer yarns are independent and do not jam each other, innormal work condition. But when the pressure on spacer fabric is highenough the spacer yarns bend too much, then the spacer yarns will touchand jam each other, so that the spacer yarn will be easier to bend whichmake the spacer fabric easier to be compressed. At last, the spacer yarnswill be crushed by the excessive pressure and difficult to be compressedmore.
When the spacer fabrics used for mattress and cushions the property ofpressure reduction is considered. The degree of pressure reduction mainlydepends on the value of peak pressure. The pressure imposed on the feetand buttocks are measured respectively. The results show it clearly that the spacer fabrics can reduce more peak pressure than PU foam, wool felt andwadding with same thickness.
In addition, more spacer fabrics are studied for the factors of pressurereduction. The pressure reduction mainly depends on the thickness andcompression rigidity of the spacer fabrics. When the thickness is definiteand the spacer fabrics are compressed in the linear period, the spacer fabricwith lower compressive rigidity will have better pressure reduction. Andalso high thickness can help spacer fabrics reduce more pressure. By usingone layer of thick spacer fabrics or several layers of middle-thick spacerfabrics with proper compressive rigidity the better pressure reduction canbe achieved.
For the usage of mattress not only the pressure reduction has to beconsidered, the thermal property and moisture permeability are veryimportant too. We also tested the physiological comfort of spacer fabrics.Spacer fabrics have better air permeability comparing with PU foam andnormal weft-knitted fabric for garments. So the spacer fabrics should alsohave better vapor permeability than other materials. Using properfunctional fiber such as hygroscopic fibre and moisture-transmitting fibrein the spacer fabrics can improve its vapor permeability too. Spacer fabricshave lower heat resistance than other materials, which means it can transfermore heat from human body, so that the heat accumulation on human bodyin the warm environment can be avoided by using spacer fabric.
Though spacer fabrics have similar compressibility to PU foam, thespacer fabrics with different compressibility can be achieved by usingdifferent materials, structures and thickness to meet the demand of user.Spacer fabrics have better properties of pressure reduction andthermo-hydro comfort than other traditional materials for mattresses andcushions. Spacer fabrics are very suitable for the wadding of mattresses andcushions, especially in the warm environment.
Ye Xiaohua(Textile Engineering)
Supervised by Prof. Hu Hong and Prof. Feng Xunwei
引文
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