Structural modelling of 100% cotton single jersey fabrics for optimum UV protection

Abstract

Purpose

Lightweight, open construction cotton knitted fabrics generally do not impart good protection from solar ultraviolet radiation (UVR). As lightweight 100% cotton single jersey is highly cherished for summerwear, it is sine qua non to understand the structural parameters that effectively strike a good balance between UV protection and thermophysiological comfort of the wearer. Relatively heavy fabrics protect from UVR, but comfort is compromised because of waning porosity, increase in thickness and thermal insulation. The purpose of this paper is to engineer knits that will bestow maximum UV protection while preserving the thermophysiological comfort of the wearer.

Design/methodology/approach

In total, 27 cotton single jersey fabrics with different areal densities and yarn counts were selected. Ultraviolet protection factor (UPF) was calculated based on the work of Imrith (2022). To précis, the authors constructed a UV box to measure the UPF of fabrics, denoted as UPF_B. UPF_B data were correlated with AATCC 183-2004 and yielded high correlation, R² 0.977. It was concluded that UPF 50 corresponds to UPF_B 94.3. Thermal comfort properties were measured on the Alambeta and water-vapour resistance on the Permetest. Linear programming (LP) was used to optimize UPF_B and comfort. Linear optimization focused on maximizing UPF_B while keeping the thermophysiological comfort and areal density as constraints.

Findings

The resulting linear geometrical and sensitivity analyses generated multiple technically feasible solutions of fabrics thickness and porosity that gave valid UPF_B, thermal absorptivity and water-vapour and thermal resistance. Subsequently, an interactive optimization software was developed to predict the stitch length, tightness factor and yarn count for optimum UPF_B from a given areal density. The predicted values were then used to knit seven 100% cotton single jersey fabrics and were tested for UV protection. All seven fabrics gave UPF_B above the threshold, that is, higher than 94.3. The mathematical model demonstrated good correlations with the optimized parameters and experimental values.

Originality/value

The optimization software predicted the optimum UPF_B reasonably well, starting from the fabric structural and constructional parameters. In addition, the models were developed as interactive user interfaces, which can be used by knitted fabric developers to engineer cotton knits for maximizing UV protection without compromising thermophysiological comfort. It has been demonstrated that LP is an efficient tool for the optimization and prediction of targeted knitted fabrics parameters.

Citation

Imrith, M.K., Rosunee, S. and Unmar, R. (2023), "Structural modelling of 100% cotton single jersey fabrics for optimum UV protection", Research Journal of Textile and Apparel, Vol. 27 No. 3, pp. 343-365. https://doi.org/10.1108/RJTA-02-2022-0016