Development and characterization of warp knitted spacer fabrics for helmet comfort liner application

The inner padding layer of the motorcycle helmet is one of the important components that control the factors of comfort during wearing the helmet and provides a perfect fit and stability of the helmet on the head. The inner padding consists of a low-density flexible polyurethane layer attached to a soft fabric layer that is in direct contact with the head. The present study aims to replace foam in the comfort liner of a helmet with spacer fabrics to avoid the risk of heat stress during the use of the helmet. In this work, 9 warp-knitted spacer fabrics were produced by varying the course/cm (10, 12 & 14) and thickness (3, 3.5, and 4 mm). Air permeability, thermal, and water vapour resistance of the developed spacer fabrics were characterized along with compression properties and compared with commercially available standard liner. The results showed that warp-knitted spacer fabrics had better energy absorption compared to the standard liner. Also, the developed spacer fabrics had better breathability and evaporative heat transfer compared to the standard liner.