A comparative study of finer conventional and modified cotton yarns and their resultant woven fabrics

A modified ring spinning technique has been recently developed by incorporating false twisting devices into the conventional ring frame. Its application on the coarser yarn counts (7–32 Ne) showed notable advantages in modified yarn and fabric performance. More recently, it was noted that this technique can also be applied for producing finer cotton yarns. Thus this paper aims to carry out a systematic study of the physical properties of the finer modified yarns (80 Ne) and woven fabrics with respect to the conventional ones. Physical properties of conventional and modified single yarns were evaluated and compared. These two types of single yarn were used for the production of woven fabrics. Moreover, the above two types of single yarn were also plied and used for the production of woven fabrics under a commercial condition. All woven fabrics were assessed in terms of fabric tensile strength, tearing strength, abrasion resistance, fabric weight, and air-permeability as well as other fabric performance measured by the Kawabata Evaluation System (KES). Experimental results showed that finer modified yarns and fabrics exhibit higher strength, lower hairiness, and improved abrasion resistance, slightly better compression property, and smoother surface with relatively larger thickness.     

Improving Application Performance of <Emphasis Type="Italic">in situ</Emphasis> Polymerization and Crosslinking System of Maleic Acid/Itaconic Acid for Cotton Fabric

Maleic acid (MA) and itaconic acid (IA) used as crosslinking agents for cotton fabrics are more cost-effective than the most efficient nonformaldehyde crosslinker 1,2,3,4-butanetetracarboxylic acid (BTCA), but poor stability of finishing bath and fabric yellowing are the main disadvantage of MA/IA in situ polymerization and crosslinking system. In this research, the application performance improvement of MA/IA crosslinking system for cotton fabrics was studied. Replacement of the widely used sodium hypophosphite (SHP) with potassium hypophosphite (PHP) as catalyst allowed for obtaining a stable finishing bath under ambient temperature and led to improved final durable press (DP) performance of the treated fabrics. The influences of PHP concentration, curing temperature, and curing time on the performance of finished fabrics were investigated. Cotton fabrics treated by MA/IA/PHP crosslinking system exhibited comparable DP performance and laundering durability to that finished with BTCA. To address the fabric yellowing problem, the residual MA and IA attached on the treated fabrics by single-ended ester linkage was determined by HPLC. The data indicated that the degree of fabric yellowing was linearly related to the unpolymerized carboxylic acid MA and IA concentration on the treated fabrics. Several approaches were explored to improve the whiteness of MA/IA/PHP crosslinked fabrics. It was found that steam drying with 30-50 % humidity could effectively improve fabric whiteness. The findings of this study have significant implications for better application of unsaturated polycarboxylic acids in crosslinking of cellulose.     

An investigation of continuous finishing and dyeing on the mechanical properties and handle of cotton fabrics

In this paper, the effect of continuous finishing-desizing, scouring, bleaching and dyeing of woven cotton fabrics on the low stress mechanical and surface properties has been studied. The cotton fabric properties were measured by the famous KES-FB system. The handle of the finished fabrics were calculated by the handle evaluation programme. The results showed that the mechanical properties changed significantly by the desizing and gradually by the scouring, bleaching and dyeing processes.     

New insight into compressive shrinkage finishing in a garment company: The effects on physical,mechanical and colorimetric properties of cotton woven fabrics

Compressive shrinkage or compressive shrinkage finishing is one of the most important finishing procedures in the textile industry to improve the dimensional stability of cotton fabrics. Study of the physical and mechanical properties of compressive shrinkage finished fabrics could be useful for optimizing the treatment conditions. This research was carried out in a production line of a recognized garment company on cotton woven fabrics with two different woven patterns (twill and plain). The samples were first dyed with reactive and sulfur dyes in a jigger dyeing machine and finished with a silicone softener. The dried fabrics were then processed in a compressive shrinkage machine. Several physical and mechanical properties of the samples were evaluated including area shrinkage, crimp percentage, thickness, abrasion resistance, drapeability, mechanical and colorimetric properties. The results showed that the thickness of all treated samples increased due to compressive shrinkage. The fabrics were analyzed with a Martindale Abrasion Tester to determine the abrasion resistance. Interestingly, we noted an increase in the abrasion resistance. After the compressive shrinkage process, the strength of the plain woven fabrics decreased in the warp direction, but increased for twill woven cotton fabrics. On the contrary, the strength of all samples increased in the weft direction. Colorimetric evaluation of the samples showed that the effect of compressive shrinkage on the color of all samples was negligible.     

Mechanical characterization of flocked fabric for automobile seat cover

In this study, the tensile and tearing properties of substrate, substrate with adhesive and flocked fabric were studied with developed regression model which explains the relationships between fabric forms and tensile and tearing strength of the flocked fabrics. Warp and weft tensile strengths of wet flocked fabric are generally higher than the warp and weft tensile strengths of dry flocked fabric due to the high wet properties of cotton yarn. Weft tensile elongation of the flocked fabric is generally higher than warp tensile elongation due to the higher crimp ratio of the flocked fabric in the weft direction. Warp and weft tearing strengths of wet form substrate with adhesive and flocked fabric are higher than those of dry forms of substrate with adhesive and flocked fabric. One of the reasons could be the decrease of inter-yarn frictional forces due to the lubrication effect of the wet form of acrylic adhesive in substrate with adhesive fabric. Generally, tearing strength of flocked fabric is low compared with substrate. It was concluded that the regression model used in this study could be viable and reliable tools and flocked fabric could be considered as an alternative seat cover material to use in automotive industry.     

Predicting the tensile strength of polyester/cotton blended woven fabrics using feed forward back propagation artificial neural networks

Tensile strength plays a vital role in determining the mechanical behavior of woven fabrics. In this study, two artificial neural networks have been designed to predict the warp and weft wise tensile strength of polyester cotton blended fabrics. Various process and material related parameters have been considered for selection of vital few input parameters that significantly affect fabric tensile strength. A total of 270 fabric samples are woven with varying constructions. Application of nonlinear modeling technique and appreciable volume of data sets for training, testing and validating both prediction models resulted in best fitting of data and minimization of prediction error. Sensitivity analysis has been carried out for both models to determine the contribution percentage of input parameters and evaluating the most impacting variable on fabric strength.     

Selection of yarn for the predefined tensile strength of cotton woven fabrics

In order to meet the required strength of a fabric, selection of yarn is difficult because tensile strength of woven fabric depends upon a number of factors. Still, the manufacturers have to use hit and trial method in order to select the yarn for the required tensile strength of fabric. This study was carried out to develop regression equations for the prediction of yarn tensile strength suitable for the predefined strength of cotton woven fabrics. These equations were developed by using empirical data obtained from two hundred and thirty four fabric samples prepared under a systematic plan with different constructions. Prediction proficiency and precision of these regression equations were evaluated by correlation analysis of the predicted and actual warp and weft yarn strength values of another set of thirty six fabric samples. The results show a very strong prediction precision of the equations.     

Evaluation of the structural properties of plain fabrics woven from various fibers using Peirce’s model

Peirce’s fabric model has been widely used to predict the structural behavior of various plain woven fabrics. The structure of plain woven fabric can be defined in terms of the warp yarn number, weft yarn number, warp fabric density, weft fabric density, warp crimp, and weft crimp. The warp and weft yarn diameters are calculated from the warp and weft yarn numbers, and the effective coefficient of the yarn diameter is defined by using this model. We have investigated structural properties, such as the effective coefficient of the yarn diameter, yarn crimp, and fabric thickness for two different fabrics in which the constituent yarns are assumed to be either incompressible or compressible. This model is also applied to various plain fabrics woven from cotton, rayon, wool, linen, nylon, acetate, polyester, and silk yarns.     

Eco-friendly and Durable Antibacterial Cotton Fabrics Prepared with Polysulfopropylbetaine

A novel antibacterial agent polysulfopropylbetaine (PSPB) bearing carboxyl groups was synthesized and its application on cotton fabric to provide durable antibacterial property was also presented. The successful synthesis of PSPB and its immobilization onto the cotton fabric surface were verified by a series of tests including FTIR, ¹H NMR, XPS and SEM. Viable cell counting method was employed to investigate antibacterial properties of the finished cotton fabrics. It was found that the cotton fabrics treated with PSPB were endowed with desirable antibacterial activity against both gram-negative bacteria Esherichia coli (E.coli, AATCC 6538) and gram-positive bacteria Staphylococcus aureus (S.aureus, AATCC 25922), with the bacterisotatic rates of 99.69 % and 99.95 %, respectively. Notably, the bacterial reduction rates still maintained over 90 % against both bacteria even after 50 consecutive laundering cycles. Moreover, tests concerning the hydrophilicity, air permeability, water vapor transmission, mechanical properties as well as thermal properties were carried out systematically. The experimental results indicated the hydrophilic performance, air permeability and moisture penetrability of the cotton fabrics finished with PSPB were improved greatly in spite of a slight reduction in thermal performance and little obvious influence on mechanical performance. The antibacterial cotton fabric has the potential to be applied in sportswear, underwear, household textiles, medical fields and much more.     

A new approach for numerical identification of bending behavior of plain woven fabric

There is a variety of approaches for investigating bending behavior of woven fabrics. Some of them are based on fabric deformation with one edge fixed; the others are based on measurement of force, moment or energy producing bending deformation. In all methods, bending properties is acquired after testing prepared fabric samples. Therefore, in this work an attempt is made by a mechanical model and a novel calculation technique to determine bending characteristics of the plain woven fabrics before sample production. Theoretical data including bending length, bending rigidity and bending modulus were directly determined for supposed fabric samples with a given yarn count and yarn density using Peirce’s structural model for plain woven fabric and a especial code written in Maple12. Besides, fabric samples with the defined characteristics were woven on a Sulzer-Ruti weaving machine. Then, these fabrics were tested for bending behavior using Shirley bending tester. Comparison showed good agreement between predicted and measured bending characteristics of the fabrics. However, theoretical bending rigidities of the samples were more than experimental values.     

Empirical modelling of tensile strength of woven fabrics

Aesthetic properties of fabrics have been considered as the most important fabric attribute for years. However, recently there has been a paradigm shift in the domain of textile material applications and consequently more emphasis is now being given on the mechanical and functional properties of fabrics rather than its aesthetic appeal. Moreover, in certain woven fabrics used for technical applications, strength is a decisive quality parameter. In this work, tensile strength of plain woven fabrics has been predicted by using two empirical modelling methods namely artificial neural network (ANN) and linear regression. Warp yarn strength, warp yarn elongation, ends per inch (EPI), picks per inch (PPI) and weft count (Ne) were used as input parameters. Both the models were able to predict the fabric strength with reasonably good precision although ANN model demonstrated higher prediction accuracy and generalization ability than the regression model. The warp yarn strength and EPI were found to be the two most significant factors influencing fabric strength in warp direction.     

Development of antimicrobial medical cotton fabrics using synthesized nanoemulsion of reactive cyclodextrin hosted coconut oil inclusion complex

Reactive cyclodextrin (RCD) based nanoemulsion and loaded with coconut oil in presence of Tween 80 emulsifying agent for development of antimicrobial medical cotton fabrics is the subject of current research. RCD based nanoemulsion was prepared at different stirring duration, viz, 2, 4, 6 and 24 h in presence of Tween 80. This was done in order to induce varieties in size and morphology of the nanoemulsion. The coconut oil encapsulated RCD based nanocomposite was precipitated as powder using centrifugation technique for 60 min at 4500 rpm and the resulted powder was investigated using TEM and SEM techniques. The images that provided by these techniques confirmed the nano-sized scale of the coconut oil loaded RCD nanocomposite. In addition, the entrapment efficiency of coconut oil loaded RCD based nanoemulsion after centrifugation was calculated and was found to more than 93 %; this is a proof for the successful inclusion of the coconut oil inside the cavity of RCD molecules. Moreover, the obtained RCD based nanoemulsions were applied to bleached cotton fabrics as per the pad-dry-cure method. The as treated cotton fabrics were monitored for nitrogen content, add-on, mechanical properties and morphology vis-a-vis those similarly treated fabrics but using the as prepared microemulsion of RCD loaded with coconut oil in absence of Tween 80. The morphological structure of cotton fabrics treated with the nanoemulsion in question was also examined using SEM technique. Moreover, the biological activity of the nanoemulsion finished fabrics before and after being submitted to 20 washing cycles was investigated against different types of bacteria and fungi as per the inhibition zone method. Results obtained signify: (i) deposition on the fabric of coconut oil loaded RCD nanoemulsion; (ii) the add-on of the nanoemulsion on the surface of cotton fabric is a manifestation of the stirring duration, proofing the formation of ultrafine oil nanoemulsion which penetrates the fabric surface; (iii) the finished fabrics display antimicrobial activity with clear excellent inhibition zone even after 20 washing cycles, indicating the protection of these fabrics for human beings from harmful microbes. In conclusion, the cotton fabrics treated with nanoemulsion of RCD loaded coconut oil is considered as an effective super antimicrobial medical textile against pathogenic microorganisms of both bacteria and fungus species.     

Facile Fabrication of Durable Antibacterial Cotton Fabric Realized by Thioglycolic Acid and Silver Nanoparticles

In this study, durable antibacterial cotton fabrics were prepared by a simple two-step impregnation method. Firstly, thioglycolic acid (TGA) was grafted onto cotton fabric via esterification with the hydroxyl groups of cellulose, then silver nanoparticles (Ag NPs) were immobilized on the cotton fabric surface via coordination bonds with the TGA thiol groups. As a result, the mean size of Ag NPs coating on the cotton fabric is around 74 nm, and these functionalized cotton fabrics show superior antibacterial properties and excellent laundering durability. After withstand 50 laundering cycles, the obtained cotton fabrics still showed outstanding bacterial reduction rates (BR) against both S. aureus and E. coli, and the rates are all higher than 97 %. Therefore, this method to prepare antibacterial cotton fabric shows great potential applications in socks, cosmetic, and medical textiles.     

Analysis and tensile characterization of air-entangled textured polyester woven fabrics depending on interlacement and yarn sets

The aim of this study was to understand the failure mechanism of two dimensional dry fabric structure considering yarn sets and interlacements. For this purpose, data generated on air-entangled textured polyester woven fabric under the simple tensile load and analyzed by developed regression model. The regression model showed that warp and weft directional tensile strengths of satin fabric were higher than those of plain and rib fabrics in unravel sample. This might be related to the number of interlacements of the fabrics. There was not a considerable difference between warp directional tensile strength of ravel and unravel satin fabrics, whereas weft directional tensile strength of ravel satin fabric decreased rapidly with respect to its unravel form. The satin fabric showed the highest warp directional tensile strength among the others. The lowest weft directional tensile strength was received from ribs fabric. In semi-ravel sample, all fabrics showed low warp and weft directional tensile strength values except in plain fabric. Warp directional tensile elongation of plain fabric was the highest in unravel sample. Satin fabric showed the highest warp directional tensile elongation in the ravel sample. Warp directional tensile elongations of all the fabrics in the semi-ravel sample became low. Weft directional tensile elongation of satin fabric was the highest in unravel sample. In addition, satin and plain fabrics showed the highest weft directional tensile elongations in the ravel sample. Weft directional tensile elongations of all the fabrics in the semi-ravel sample became low except in ribs fabric.     

Predicting the air permeability of polyester/cotton blended woven fabrics

The aim of this study was to model the air permeability of polyester cotton blended woven fabrics. Fabrics of varying construction parameters i.e. yarn linear densities and thread densities were selected and tested for air permeability, fabric areal density and fabric thickness. A total of 135 different fabric constructions were tested among which 117 were allocated for development of prediction model while the remaining were utilized for its validation. Four variables were selected as input parameters on basis of statistical analysis i.e. warp yarn linear density, weft yarn linear density, ends per 25 mm and picks per 25 mm. Response surface regression was applied on the collected data set in order to develop the prediction model of the selected variables. The model showed satisfactory predictability when applied on unseen data and yielded an absolute average error of 5.1 %. The developed model can be effectively used for prediction of air permeability of the woven fabrics.     

Effect of glycols and catalysts on cotton fabrics treated with glyoxal

The optimum conditions for durable press treatment of cotton fabrics using glyoxal as a nonformaldehyde crosslinking agent were investigated. Crosslinking reaction was conducted in the presence of different catalysts such as aluminum sulfate, magnesium chloride, or magnesium chloride-citric acid mixture at various mole ratios of catalyst to glyoxal. Aluminum sulfate was proven the most effective one among those used. Glycol addition into a glyoxal padding bath increased the wrinkle recovery angle(WRA) and whiteness of treated fabrics. The optimum mole ratio of glycol to glyoxal was 1:1. Diethylene glycol addition produced better overall performance to the glyoxal-crosslinked fabric compared to ethylene glycol addition.     

Assessment of the surface roughness of cotton fabrics through different yarn and fabric structural properties

The effects of some yarn properties (i.e. type, count, twist level, ply number, unevenness and crimp) and fabric constructional properties (i.e. cover, thickness and balance) on surface roughness values of cotton woven fabrics were investigated. A general overview of the results showed that surface roughness values of fabrics were affected from yarn and fabric properties and the effects were related to fabric balance, fabric cover (not cover factor), fabric thickness and crimp values of yarns in fabric structures. Surface roughness values of fabrics decreased as yarn fineness and yarn twist levels increased but as yarn ply number decreased. Also, surface roughness values gradually decreased from open-end yarn constituting fabrics to combed yarn constituting fabrics. Results showed that different properties of yarns caused changes in yarn crimps in fabric structure and also governed the changes in fabric balance, as well as changes in roughness of fabric surfaces. The changing properties of yarns and impact of these properties on fabric construction affected the formation of cotton fabric surfaces from smooth to coarse.     

Predicting bending rigidity of woven fabrics using artificial neural networks

This paper reports an investigation on the predictability of bending property of woven fabrics from their constructional parameters using artificial neural network (ANN) approach. Number of cotton grey fabrics made of plain and satin weave designs were desized, scoured, and relaxed. The fabrics were then conditioned and tested for bending properties. Thread density in fabric, yarn linear density, twist in yarn, and weave design were accounted as input parameters for the model whereas bending rigidity in warp and weft directions of fabric formed the outputs. Gradient descent with momentum and an adaptive learning rate back-propagation was employed as learning algorithm to train the network. A sensitivity analysis was carried out to study the robustness of the model.     

Analysis and off-axis tensile characterization of air-entangled textured polyester woven fabrics depending on unit cell interlacing frequency

The aim of this study is to analyze and determine the off-axis tensile properties of air-entangled textured polyester fabrics based on unit cell interlacing frequency. For this purpose, continuous filament polyester air-entangled textured yarn was used to produce plain, ribs and satin woven fabrics. The fabrics were cut from the warp direction (0°) to weft direction (90°) at every 15° increment, and tensile tests were applied to those of the off-axis samples. The strength and elongation results were introduced to the statistical model developed, and regression analyses were carried out. Hence, the effects of off-axis loading and interlacement on the directional tensile properties of the fabric were investigated. The regression model showed that off-axis loading influences fabric tensile strength. On the other hand, interlacement frequency is the most important factor for fabric tensile elongation. The results from the regression model were compared with the measured values. This study confirmed that the method used in this study as can be a viable and reliable tool. Future research will concentrate on multiaxially directional fabric and the probability that it will result in homogeneous in-plane fabric properties.