Modifying 3D composite textiles as functional panels

Honeycomb fabric-reinforced composites have been widely used recently, due to their prominent properties, when compared to other materials. This is because they are lighter in weight and stronger than other materials. Thus, they can absorb different types of energies, such as mechanical and thermal energies. A multi-layer fabric is developed by creating a unique fabric structure, to enable the presence of air voids within the panels produced, which diminishes the heat transfer rate through the material. The structure applied in samples used in this manuscript is novel, as it consists of a 3D fabric produced using a traditional loom with a special technique, by dividing the warp yarns into four layers. A skin of textile, produced from textile wastes, is applied, along with the technique of hardening the 3D fabrics to keep the open areas in the structure with the aid of pre-designed pins and a resin. The composite panel was produced with the pins used to open the fabric’s structure, and the resin was applied as a matrix holding the structure and keeping its dimensions. Panels of the 3D fabric-reinforced composite obtained from cotton and polyester yarns were produced, to achieve thermal insulation and good mechanical properties, which enable the use of the fabric in various applications. The fabric has two panels of each material, one with skin and the other without skin. This skin consists of low-quality fabric, mainly made from textile wastes. The physical and mechanical characteristics of the developed panels were measured. Functional performance, such as thermal and sound properties, were also measured. Testing thermal conductivity, it was found that panels made of cotton had higher conductivity than panels made of polyester. In addition, the presence of the skin improved the thermal insulation and mechanical strength of the panels compared to those without skin. In mechanical testing, polyester-based panels showed better mechanical properties than panels based on cotton. In sound absorption testing, all samples reached the limits for sound absorption. The number of layers affected the sound absorption coefficient (SAC) and the noise reduction coefficient (NRC). Also, the presence of the skin improved NRC. Finally, all samples had an aesthetic appearance, due to the presence of surface waves, but the sample containing the polyester material, with double layers, and the laminated skin made of waste fabric had the highest functional panel performance, in terms of radar chart areas. This means that it can be used in the field of architecture as a façade panel or as an indoor wall used for isolation, which do not require paint.