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This paper aims to deal with the thermal resistance of multilayer nonwovens. The effect of fibre denier, cross-sectional shape and positioning within the layers were analysed with respect to the thermal resistance. Moreover, effect of compression on thermal resistance of the multilayer nonwoven structure have also be studied.

The study involves multiple layering of thermal bonded nonwoven webs and the effect of fibre denier and positioning of different nonwovens from the hot plate. To avoid the increase in thermal resistance because of the air gaps between layers, the nonwovens were enclosed within an acrylic frame to compress them to a thickness of 12 mm. Compressional behaviour of the nonwovens were tested at a rate of 5 mm/min with peak compressive load of 50 N. Multilayer nonwoven assemblies were tested for thermal resistance with compressive pressure of 3.5 gf/cm² and compared with that tested at zero pressure.

In the study, three-layered nonwoven structure, provided better thermal resistance than their single component counterparts. The structural characteristic of the multilayer nonwovens affected the conductive, convective and the radiative heat transfer. In a multi-layer nonwoven, the top most layer should have the finest fibre as possible. Second preference may be given to the middle and followed by bottom layers in terms of fibre fineness. However, fine solid fibres performed poorly in terms of compression and recovery resulting in poor thermal resistance under compressive load.

The experimental approach of controlling thickness while evaluating the thermal resistance will help in nullify the effect of air gaps between the layer interface, thus focussing on the effect of fibre denier and the positioning of nonwovens. This paper also discusses the unique properties of fine solid fibre and hollow fibres and their role in providing better thermal insulation for extreme cold weather applications.

Woven fabrics have been popularised in use owing to their superior properties and functionality. Today, weavers strive to add value to their product to be competitive and to secure profit in performance fabrics such as technical fabrics, smart fabrics and sportswear fabrics. Over the years, fabrics with special properties such as moisture management have gained higher demand. In this context, multi-layer fabrics provide a reasonable solution to the demand.

An attempt was made to develop two-layer fabrics with different compositions and properties. A two-layer woven fabric was produced using handloom weaving, with a hydrophobic inner layer and hydrophilic outer layer, the two layers being attached together using different stitching methods. Different fabric structures and yarn counts were used to achieve the objectives.

Experiments carried out verified the suitability of the developed fabric for effective moisture management. It was found that a fabric with a 100% cotton outer layer and 100% polyester inner layer, both layers of 2 × 2 matt weave, showed the best properties.

In the present COVID-19 pandemic situation, the use of masks in public has become mandatory in many countries. This research will help handloom manufacturers meet the need using simple methods.

This research uses handloom fabric. As such it provides an opportunity for small and medium enterprises to use available low-cost technology to develop fabric with superior properties.