Preparation and characterization of 3D flexible high-distance spacer fabric/foam composite

Abstract In order to solve the problem of poor damage resistance of foam, limited thickness of ordinary spacer fabric and complex preparation process of composite, a high-distance spacer fabric/foam composite (HFFC) was designed via a simple and rapid method without molds. The HFFC was composed of two polyvinyl chloride (PVC) faces and a foam-filled high-distance spacer fabric core. Nine kinds of high-distance spacer fabric/foam composites (HFFCs) were prepared by changing the density of the core layer and spacer yarns. The microstructure, compression, bending, thermal insulation, sound absorption and low-velocity impact resistance properties of HFFCs were characterized. Remarkably, the HFFCs with lower foam density have better thermal insulation, sound absorption and low-velocity impact resistance properties while reducing weight. The HFFCs with higher density of spacer yarns exhibit more outstanding compression and thermal insulation properties. In addition, the thermal conductivities of the nine kinds of HFFCs are lower than 0.05 w/(m*K), belonging to high-efficiency thermal insulation material. The developed HFFCs show great potential in many practical applications in packaging, construction and other fields.