Sustained cooling comfort achieved through weft-knit spacer composite fabrics

This research introduces a groundbreaking weft-knitted spacer composite fabric designed for a continuous cool feeling effect. Fabrication involved a double-sided circular weft machine, incorporating ultra-high molecular weight polyethylene (UHMWPE) cool feeling fiber as the surface layer and carbon-coated nylon monofilament as the spacer layer. Quantitative assessments demonstrate a remarkable thermal conductivity of 0.329 W·m⁻ 1 ·K⁻ 1 for the developed fabric, significantly higher than the polyester spacer fabric used for comparison. The UHMWPE cool feeling fiber exhibited exceptional moisture conductivity and wettability, with a wicking height approaching 6 cm within the initial 3 minutes and a water contact angle of 44.47° after 40 seconds. This enables the capillary transport, diffusion, and evaporation of water molecules along the fiber surface. This process efficiently dissipates heat, resulting in a distinct tactile cool sensation. To further enhance the continuous cool feeling effect, the weft-knitted spacer fabric was integrated with needle-punched nonwoven fabrics containing phase change microcapsules (PCM) embedded viscose fiber. The PCM viscose fiber demonstrated a melting phase transition within 25–35°C, with an endothermic enthalpy of 6.48 J/g. This strategic incorporation not only amplifies the fabric’s cooling capabilities but also introduces an advanced dimension of temperature regulation, maintaining a temperature difference of approximately 1.2°C between the upper and lower surfaces of the composite fabric. The findings underscore the fabric’s multifaceted advantages, positioning it as a promising solution for diverse applications. Infrared thermal imaging revealed the composite fabric’s ability to maintain a lower surface temperature over time compared to polyester spacer fabric, while compression recovery tests showed its capacity to provide good mechanical support with a distinctive three-stage compression process. The innovative integration of materials yields a fabric with superior thermal and moisture management properties, making it ideal for applications ranging from advanced apparel to innovative seating materials. The quantitative thermal conductivity result, coupled with the synergistic effects of UHMWPE cool feeling fiber and PCM microcapsules, underscores the fabric’s potential to redefine comfort and functionality in textiles. This research serves as a foundation for future advancements in textile technologies, setting the stage for the creation of fabrics that offer sustained cooling, improved comfort, and enhanced user experiences.