Design and Development of Denim Fabrics with Improved Strength and Impact Abrasion Resistance for Motorcyclist Clothing
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Onur Kurtulmuş, Semin Güner, Design and Development of Denim Fabrics M. Şahin Akkaya, Burçak Karagüzel Kayaoğlu* with Improved Strength and Impact Abrasion Resistance for Motorcyclist Clothing DOI: 10.5604/01.3001.0010.7797 Istanbul Technical University, Abstract Faculty of Textile Technologies and Design, This study aims to design and develop denim fabrics with enhanced mechanical and impact Department of Textile Engineering, abrasion resistance performance using different materials, yarn types and fabric construc- Istanbul, Turkey tions. It was aimed to reach the standard impact abrasion resistance requirements of motor- * E-mail: [email protected] cycle protective clothing for Level 1 in high impact areas of the body (zones 1 and 2), such as hip and knee areas. The existence of cotton/Cordura® yarn in warp and T400 polyester yarn in the weft and the use of higher yarn densities increased the performance in tensile strength and impact abrasion resistance, compared to a classical cotton denim fabric. The use of coarser yarns and fabrics with a double weave construction increased impact abrasion resistance compared to single layer cloths. The double and backed cloth samples developed with cotton/Cordura® and Kevlar®/polyester yarns in their construction showed impact abrasion resistance times over 4 s and reached the “EN 13595-2:2002 Level 1 abrasion resistance” standard requirement. Key words: denim fabric, Kevlar®, Cordura®, impact abrasion, strength, motorcyclist. ® Introduction The series of standards of EN 13595 as- and Lycra , a polyurethane elastomer, sess the requirements, such as abrasion have been utilised in fabrics used for Motorcycle clothing is designed to pro- resistance or cut resistance, for motorcy- protective motorcyclist clothing [1, 9]. tect the motorcyclist against injuries clists’ protective clothing [2]. According For instance, tear and abrasion resistant during rides. In case a rider or pillion to EN 13595-2:2002 [5], for motorcycle Keprotec® fabric from Shoeller Textiles passenger falls from the motorcycle and protective clothing, the minimum abra- AG, Switzerland [10], have been wide- slides along a tarmac surface, the mo- sion resistance requirements (in seconds) ly used in premium brand motorcycling torcyclist clothing would be exposed to of the material for use over high impact garments. Laminate and layered fabric a high level of abrasion and impact [1- areas of the body (zones 1 and 2, repre- constructions have also been employed 3]. Therefore the protective clothing has senting hip and knee areas) are: 4.0 s for in motorcycle apparel to enhance abra- a main function of providing appropriate level 1 (low weight clothing and minor sion resistance [1]. protection of the user by acting as an ef- ergonomic limitations) and 7.0 s for lev- fective barrier between the user’s skin el 2 (increased weight clothing and ergo- Traditionally denim has a warp-faced and the road surface [4]. In this respect, nomic constraints). The same standard twill fabric construction made from in- attention should be paid to the fabric de- also assesses abrasion resistance require- digo dyed cotton warp yarns and undyed signs regarding the construction of fab- ments for level 1, as 1.8 s in zone 3, and weft yarns made from cotton, polyester, rics and selection of materials to provide 1.0 s in zone 4, and for level 2, as 2.5 s and elastane yarns [11]. Durable denim better abrasion and impact resistance. in zone 3 and 1.5 s in zone 4 [1, 6, 7]. motorcycle riding jeans have been re- Figure 1 shows zone positions on a suit ferred to as protective denim [9]. Their according to the standard [5]. manufacturers use different construc- tions in the garments such as plain and Motorcycle clothing is made mainly of twill woven protective liners and single leather or textile materials. Leather pro- jersey, double jersey, rib and loop knitted vides mechanical strength but its breath- protective liners. Protective lined denim ability was reported to be insufficient garments comprise woven and knitted [2]. Also coatings such as paraffin-wax, internal reinforcements or protective PU and PVC are applied onto heavy- linings in the seat, hip and knee areas weight cotton fabric to increase durabil- made nylon, polyester, para-aramid, ul- 1 Front ity and reduce the coefficient of friction, tra-high molecular weight polyethylene 2 Back thereby providing enhanced resistance and Vectran®. Cordura® denim as outer to abrasion. However these coatings fabric along with a polycotton lining and make the fabric heavy and stiff, thus ob- polyamide protective layer has also been Zone 1 structing wearer comfort [1, 8]. There- used [12-14]. Another end-use of protec- Zone 2 Zone 3 fore, as opposed to leather goods, re- tive denim trousers for chainsaw opera- Zone 4 cently, alternative high performance ma- tors was also reported, where a denim terials such as DuPont’s Kevlar®, a high outer fabric with inner layers made from 1 2 ® modulus para-aramid fiber, Invista’s Kevlar , ultra-high molecular weight Figure 1. Zone positions on a motorcyclist’s suit according to EN® 13595[15]. Figure 1. Zone positions on a Figuremotorcyclist 1. Zone positions’s suit on according a motorcyclist’s to ENCordura 13595[15]., a high-tensile polyamide, ul- polyethylene and ballistic nylon was em- suit according to EN 13595[15]. tra-high molecular weight polyethylene ployed [6]. Kurtulmuş O, Güner S, Akkaya MŞ, Kayaoğlu BK. Design and Development of Denim Fabrics with Improved Strength and Impact Abrasion Resistance for Motorcyclist Clothing. 53 FIBRES & TEXTILES in Eastern Europe 2018; 26, 1(127): 53-58. DOI: 10.5604/01.3001.0010.7797 Figure 2. Mean of maximum tensile strength in warp and weft directions. 1 Figure 2. Mean of maximum tensile strength in warp and weft directions. 1 Table 1. Fabric parameters of the reference and designed samples. Fabric Warp density, Weft density, Reed Reeded Weight, Fabric type Warp count & yarn type Weft count & yarn type samples Ends/cm Picks/cm no. width, cm g/m2 1 Single cloth Ne 10/1 Cotton/ Cordura® 330 dtex T400 Polyester 35 22 75/4 168 331 2 Single cloth Ne 10/1 Cotton/ Cordura® 9/1 Ne Cotton 30 19 75/4 168 334 3 Single cloth Ne 10/1 Cotton/ Cordura® Ne 10/1 Cotton / Cordura® 34 20 75/4 168 337 4 Single cloth Ne 10/1 Cotton/ Cordura® Ne 16/1 Cotton / 78dtex Elastane 32 22 75/4 168 309 5 Single cloth Ne 6.4/1 Cotton/ Cordura® 9/1 Ne Cotton 26 20 56/4 168 415 6 Single cloth Ne 6.4/1 Cotton/ Cordura® 450 dtex T400 Polyester 22 30 56/4 168 445 7 Double cloth Ne 10/1 Cotton/ Cordura® Ne 10/1 Cotton/ Cordura® 42 32 80/5 45 578 8 Double cloth Ne 6.4/1 Cotton/ Cordura® Ne 6.4/1 Cotton / Cordura® 39 16 80/5 45 771 9 Double cloth Ne 6.4/1 Cotton/ Cordura® Ne 5.2 (4 plied) Kevlar®/Polyester 40 23 80/5 45 745 10 Backing fabric Ne 5.4 (3 plied) Kevlar® Ne 2.5 (4 plied) Kevlar® 12 18 110/1 32 704 Reference Single cloth Ne 10/1 Cotton 10/1 Cotton / 78 dtex Elastane 34 20 75/4 175 420 (control) Considering the very limited studies strength tester (England). These meas- Results and discussions available, and the growing industrial in- urements were performed to determine terest, this study will contribute to the the performance of different yarn types Production of fabric samples current literature in the field of designing used to produce the samples. A test speed 75/25 cotton/Cordura® (T420 Nylon 6.6) of denim fabrics for protective motor- of 100 mm/min was used. Five different blended warp yarns in two different lin- cyclists’ clothing. Commercial protec- measurements were taken in both the ear densities of 59 tex and 92 tex were tive denim garments mostly comprise warp and weft directions and the average used. Invista’s Cordura® was selected due protective linings in single layer denim values calculated. Tear strength values to its high abrasion resistance [1, 9] Ta- garments to provide sufficient impact are reported as the tear strength of warp ble 1 shows fabric parameters of the sin- abrasion resistance. However, in this and weft yarns in the results section. gle and double layered samples designed study, double cloth denim constructions and produced. Approximately 2 meters were also studied to improve the impact Impact abrasion resistance test of each sample was produced. For the production of fabric samples 1-6, warp abrasion resistance time. Nevertheless Both single and double cloth samples yarns were rope dyed and sized prior to this study aims to design and develop were tested for impact abrasion resist- weaving. Fabric samples were woven denim fabrics with enhanced mechani- ance by SATRA Technologies (UK) ac- with a 3/1 twill design on a Picanol Op- cal and impact abrasion resistance using cording to EN 13595-2:2002 [5]. This timax industrial rapier weaving machine different materials, yarn types and single test is practically applied to double cloths (Pinacol, Belgium) at a running speed of and double layered fabric constructions. and backed fabrics. However, in order to The fabric samples produced are then 550 rpm. After weaving, the fabric sam- compare their performance, both single ples were exposed to a basic finishing evaluated to determine which design and double cloth samples were tested in constitutes better protection with respect process where the sizing on the fabric this study. was partially removed. These fabrics were to the mechanical strength and impact then tested for the impact abrasion resist- abrasion resistance. It was aimed to reach A test sample mounted on a holder was ance time.