Study on the preparation and design of chenille/polyester integrated yarns and its acoustic properties | Scientific Reports

Scientific Reports volume 15, Article number: 1729 (2025) Cite this article

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With the rapid development of industrialization and urbanization, the impact of noise on people’s health has become an increasingly serious issue, but it is still a challenge for the reducing the noise due to its complex property. Textiles with many loose porous structures have gained much significant attentions, thus chenille yarns with plush fibers on the surface, and polyester monofilament were chosen to fabricate the integrated knitting yarns, and their fundamental and mechanical properties were fully evaluated. The results showed that the diameter and braiding angle of the blended yarns decreased with the increase of pitch, resulting in a linear correlation of R2 > 0.8. The breaking strength values of the 3 + 1 series were much lower than that of the 4 + 1 series, while the force utilization rates of the 3 + 1 series were much higher than that of the 4 + 1 series, with a force utilization rate of 98%. Moreover, the dynamic friction coefficient of the 3 + 1 series integrated yarns were much lower than that of the 4 + 1 series, and that of the 4 + 1 series integrated yarns exhibited the lowest bending stiffness, indicating that these two kinds of yarns were the most suitable for the potential application of sound absorption.

Noise pollution has been one of the four major factors contributing to environmental pollution, which not only be harmed to the human health and affect the quality of our lives, but also cause seriously negative implications for the stability of social1,2,3. Currently, the two main approaches to protect individuals from noise are controlling the noise source and blocking the propagation path of noise4,5. However, it is still a challenge to reduce noise at the source due to the complex formation6,7,8. Textile materials have garnered significant attention in the field of sound absorption due to their porous and loose structure, high machinability, and soft characteristics9,10. The research on sound-absorbing and noise-reducing materials in the textile industry has become increasingly diverse, with fibers being categorized into organic, inorganic, metal and integrated fibers11,12,13.

From the perspective of fabric, there are concerns regarding research on sound-absorbing materials, specifically non-knitted fabrics, knitted fabrics, knitted fabrics, and integrated materials14,15,16,17. Sakthivel et al.18 developed an environmentally friendly sound-absorbing non-knitted fabric material using recycled cotton and polyester fibers, they created six different forms of recycled non-knitted fabrics, both the white and colored, using thermal bonding technology with these waste materials. The results demonstrated that the sound absorption performance of the recycled PET/cotton waste non-knitted fabric felt exceeded 70%, making it the best performing material. Tang et al.19 investigated the sound absorption of multi-layer lightweight absorbers composed of non-knitted fabrics with kapok fiber and polyethylene (PE) film, the multi-layer integrated materials showed the better sound absorption than that of the single-layer non-knitted fabrics at low frequencies, and the elastic vibration of the polyethylene film contributed to the improvement in sound absorption at low frequencies. Additionally, the gradient thickness structure of non-knitted fabrics effectively improved sound absorption at low frequencies, and the direction of the gradient change also had a significant impact on the sound absorption of multi-layer materials. Khasanah et al.20 studied the absorption coefficient of non-knitted pineapple leaf fiber (PNW), and its layered combination with double weave (PDW) and tricot knitting fabric (PTK). The variation in fabric was tested for sound absorption coefficient using an impedance tube. The results of the absorption coefficient test showed that there was an effect on the absorption coefficient when using layered non-knitted fabrics. Zhou et al.21 prepared a integrated material consisting of a polyvinyl alcohol nanofiber membrane and ribbed air layer fabric. The addition of the polyvinyl alcohol nanofiber membrane significantly improved the sound absorption performance of the fabrics. The sound absorption coefficient of the fabric increased with the density of the fabric. Li min et al.22 used full polymer siro core-spun technology to wrap basalt fibers, improving their quality in spinning. They studied the effects of different materials, thicknesses, and arrangement methods, providing a theoretical reference for thin flexible sound-absorbing knitted materials. However, most studies primarily focus on the fabric layer and rarely cover the sound-absorbing properties of yarn. The inter-mechanism of structure parameters and their properties still remains unclear.

In this study, chenille and polyester yarns were selected and utilized in the creation of integrated yarns through two-dimensional weaving techniques. Six distinct structural parameters of the knitted yarns were designed and evaluated. Based on the comprehensive analysis results, suitable knitted yarn structures for subsequent machine weaving, such as flat needle weave and rib weave were selected. The sound absorption performance of these selected structures was tested and analyzed, taking into consideration the influence of yarn structural parameters on sound absorption performance. This research provides a theoretical reference for future studies on sound-absorbing yarns.

As shown in Table 1, the chenille yarn (total fineness 59.1 tex, breaking strength 13.4 cN/tex, Shaoxing Yingshi Textile Co., Ltd) is composed of knitting wool (fineness 11.1 tex, Zhuji Datang Chenyu Chemical Fiber Factory) and core yarn (fineness 18.5tex, Shaoxing Yingshi Textile Co., Ltd). The final integrated yarn are composed of chenille yarn and polyester monofilament (fineness 15.6 tex, breaking strength 55.8 cN/tex, Nantong Xindike Monofilament Technology Co., Ltd).

A high-speed braiding machine (C12, Dongguan Guanbo Precision Electromechanical Co., Ltd.) is used for 2D blended yarns, and a hand-rolled flat machine (SK280, stitch length 5.6G, Suzhou Yinseiko Co., Ltd.) is adopted to knit the fabrics.

In this study, six types of samples were prepared by combining chenille yarn with polyester yarn. The samples consisting of 3 Chenille yarns and 1 PET yarn are denoted as 1-x which includes 1–1, 1–2 and 1–3. The samples consisting of 4 Chenille yarns and 1 PET yarn are denoted as 2-x which includes 2 − 1, 2–2 and 2–3. It is important to note that the pitch of the above six samples is different, and the details of the integrated yarn are shown in Table 2.

The 2D spindle braiding machine is consisted of rotating angle wheel system and 8-shaped track, which will carry the spindle move regularly to form ropes and knitting fabrics, and the two parts of the spindle cross each other evenly and move at equal speeds in opposite directions, repeatedly driving the spindle to interweave yarn or metal wire and other braiding materials, thus forming a braiding layer on the surface of the target object. The prepared blended yarns presented 1 × 1 + 2 × 2 mixed knitting structure, and the structure principle of this braiding machine and the diagram of blended yarns are shown in Fig. 1.

(a) The structure of braiding machine; (b) The principle of integrated yarn weaving; (c) The integrated yarn diagram.

From the six types of integrated yarns knitted, two yarns with the best weaving ability were selected to weave knitted fabrics. To fully reflect the impact of yarn structure on the sound absorption performance of the fabric, 3 different structures such as flat needle, ribbed, double-sided are fabricated using the flat knitting machine, and their coil diagram and knitting diagram are shown in the Fig. 2.

(a) Coil diagram of fabrics; (b) Knitting diagram of fabrics.

The diameter of the integrated yarn was measured using the YG141N electronic thickness gauge in accordance with the standard YY0167-2005. Each sample was measured 10 times, and the average value was recorded. An image of the integrated yarn was captured using a NIKON SMZ745T stereo microscope and processed using Adobe Photoshop 2020 software to obtain the weaving angle of the integrated yarn. To examine the distribution and surface morphology of the yarns in the integrated yarn, the micromorphology was collected using a scanning electron microscope (SEM).

The mechanical performance of integrated yarns was tested using the YG061F electronic single yarn strength tester, in accordance with the GB/T 14,344 − 2008 standard titled “Experimental Method for Tensile Properties of Chemical Fiber Filaments”. Prior to testing, the integrated yarns were subjected to pre-conditioning treatment under standard atmospheric conditions for a duration of 4 h. The stretching experimental parameters included a pre-tension of 0.2 cN/tex, a clamping distance of 250 mm, stretching speed of 250 mm/min, and 10 times repeated measurements for each type of integrated yarn.

The friction coefficient of integrated yarns was tested using the LFY 110 yarn dynamic friction coefficient tester, in accordance with the ASTM D3108-2001 “Standard Test Method for Friction Coefficient between Yarns and Solid Materials”. The samples were pre conditioned under standard atmospheric conditions for 16 h. During the experiment, the yarns were wrapped around the friction roller of the dynamic friction coefficient tester as instructed, and the instrument was connected to a computer for data recording. Prior to officially recording data, the instrument switch was turned on and the weaving yarn was allowed to move smoothly before data recording. The experimental speed was set at 10 m/min, the testing angle was 180°, and the experimental time was 10 s. Each type of sample was repeated three times for testing.

The KES-FB2S semi-automatic bending tester was used to assess the bending performance of the samples. During testing, the samples were subjected to a forward and reverse composition rate, causing them to move back and forth in a specific direction. The machine connected display provided data indicators such as torque, curvature, bending stiffness and bending hysteresis. Bending performance can be characterized by two indicators: bending stiffness (B) measured in cN cm2/cm and bending hysteresis (2HB) measured in cN cm/cm.

The arrangement and composition of yarns within the fabric were observed using SEM. The sound absorption coefficient of the fabric was measured in accordance with the ASTM E1050-2012 standard using a standing wave tube in the frequency range of 800–3150 Hz. The test conditions were as follows: atmospheric temperature of 25.0 °C, relative humidity of 50.0%, atmospheric pressure of 101.30 Pa, air density of 1.2 kg/m3, sound speed of 344.457 m/s, and air characteristic impedance of 409.094 Pa s/m. The diagram of the impedance tube sound absorption test system is shown in Fig. 3.

The diagram of the impedance tube sound absorption test system.

Prior to study the properties of the prepared integrated yarn, the composition structure of the integrated yarn was characterized and shown in Fig. 4.

(a) Surface of Chenille single yarn; (b) Cross-section of Chenille yarn; (c) Surface of Chenille/polyester integrated yarn; (d) Cross-section of Chenille/polyester integrated yarn.

As shown in Fig. 4a,b, Chenille yarn is fabricated as the core yarn for the composed of two parts, which retains its good mechanical properties, and the knitting wool, which has provided the novel texture and the other desirable qualities. As shown in Fig. 4c,d demonstrate that the knitting wool on the surface of the integrated yarn, produced by using chenille yarn and polyester integrated weaving has experienced a significant increase, and the arrangement of each yarn during weaving can be observed from the cross-section.

The fundamental properties of the prepared integrated yarn were tested, and the results are shown in Fig. 5.

The test data of integrated yarn diameter and weaving angle.

As shown in Fig. 5, the diameter of the 4 + 1 integrated yarn is larger than that of the 3 + 1 integrated yarn. Additionally, as the pitch increased, the diameter of the yarn is slightly decreased. The variation in the weaving angle follows a similar pattern, with the weaving angle of the 4 + 1 integrated yarn, which has been greater than that of the 3 + 1 integrated yarn. Furthermore, as the pitch increased, the weaving angle of the yarn will decrease obviously.

To study of braiding pitch on basic performance of yarn, regression equation was used to establish a correlation between the weaving angle and pitch of the integrated yarn, as shown in Fig. 6.

(a) Fitting curve of the relationship between diameter and pitch of 3 + 1 integrated yarn; (b) Fitting curve of the relationship between diameter and pitch of 4 + 1 integrated yarn; (c) Fitting curve of the relationship between braid angle and pitch of 3 + 1 integrated yarn; (dd Fitting curve of the relationship between braid angle and pitch of 4 + 1 integrated yarn.

As shown in Fig. 6a,b, the relationship between the diameter and pitch for samples the 3 + 1 series and 4 + 1 series yarn are relatively consistent. As the pitch increased, the weaving angle of the integrated yarn decreased sharply, along with a decrease in the inclination of the single yarn for the integrated yarn. Furthermore, the cross-sectional area contributed by each single yarn to the integrated yarn decreases, resulting in a reduction in the diameter of the Chenille/polyester integrated yarn.

As shown in Fig. 6c,d, the weaving angle of the Chenille/polyester integrated yarn decreased with the increase of the pitch. As the increase of pitch, the number of interweaving times for a single yarn within the same length decreases, leading to a decrease in the structural compactness of the integrated yarn, and subsequently reducing the weaving angle. Whether it is the 3 + 1 series or the 4 + 1 series, there is a linear relationship between the weaving angle and pitch of the knitted yarn, with a correlation coefficient (R2) close to 1. The measured data closely aligns with the fitted curve.

To further investigated the properties of the prepared integrated yarn, the effect of braiding pitch on mechanical performance of yarn was examined, as shown in Fig. 7.

As shown in Fig. 7a, the breaking force and elongation for the 4 + 1 integrated yarn are greater than those of the 3 + 1 integrated yarn. The breaking force and elongation at break of the yarn remain are relatively constant as the pitch increased. Notably, the performance of the 2 − 1 integrated yarn is superior, while the breaking strength of the 4 + 1 series integrated yarn is significantly higher than that of the 3 + 1 series. As shown in Fig. 7c, the impact of pitch on the breaking strength of the Chenille/polyester integrated yarn is not clearly evident, and the overall elongation at break of the 4 + 1 series integrated knitted yarn is higher than that of the 3 + 1 series. The elongation at break of both the 3 + 1 series and 4 + 1 series integrated yarns gradually decreased as the increase of integrated yarn pitch.

(a) The test data for the strength of integrated yarn; (b) The relationship between force utilization ratio and pitch of integrated yarn; (c) The relationship between breaking force, elongation at break and pitch of integrated yarn; (d) The test data of average friction coefficient and bending stiffness of integrated yarn; (e) The relationship between friction coefficient and pitch of integrated yarn; (f) The relationship between bending rigidity and curving lag of integrated yarn.

The reason for the above phenomenon is attributed to the variation in the number of Chenille single yarns involved in the weaving process. Consequently, the 4 + 1 series integrated yarn exhibits a significantly higher breaking strength compared to the 3 + 1 series. Additionally, the overall diameter of the 4 + 1 series integrated yarn surpasses that of the 3 + 1 series. When the pitch remains constant, the weaving angle of the 4 + 1 series is also higher than that of the 3 + 1 series. The single yarn whin the integrated yarn possesses a higher degree of inclination. Consequently, when subjected to tensile force, the inclined and twisted single yarn must first be straightened before it can be stretched to the point of fracture. As a result, the breaking elongation of the 4 + 1 series integrated knitted yarn exceeds that of the 3 + 1 series. Furthermore, as the pitch increases the structure of the integrated yarn becomes looser, the weaving angle decreases, and the degree of inclination and torsion of the single yarn diminishes, leading to a lower elongation at break.

The overall strength utilization rate of the 3 + 1 series integrated yarn is higher compared to that of the 4 + 1 series, as shown in Fig. 7b. This can be attributed to the fact that the 4 + 1 series integrated yarn has a greater number of single yarns than the 3 + 1 series, leading to increased variability in fiber breakage whin the integrated yarn and a decrease in strength utilization rate. Based on thefindings presented in Fig. 7b, the structures that exhibit higher utilization rates of integrated yarn strength are the 3 + 1–6 mm and 3 + 1–7 mm integrated knitted yarns.

The average friction coefficient of the 3 + 1 integrated yarn is lower than that of the 4 + 1integrated yarn, as shown in Fig. 7d. With an increase in pitch, the average friction coefficient of the yarn initially decreases and then increase. The lowest average friction coefficient is observed at a pitch of 6 mm. As shown in Fig. 7e, the friction coefficient of the 3 + 1 series and 4 + 1 series of Chenille/polyester integrated yarns exhibits a pattern of initially decreasing and then increasing at pitches of 5 mm, 6 mm, and 7 mm. Specifically, the friction coefficient of the 3 + 1 series integrated yarn is lower than that of the 4 + 1 series. This discrepancy can be attributed to the existence of a critical value for the impact of pitch on the friction coefficient of integrated yarns, which is determined to be 6 mm in this study. When the pitch is less than 6 mm, the larger the pitch, the smaller the diameter of the integrated yarn, resulting in a reduction in the frictional force area and consequently a decrease in the friction coefficient. Conversely, when the pitch exceeds 6 mm, the larger the pitch, the looser the structure of the integrated yarn, leading to increased gaps between the individual yarns of the integrated knitted yarn. This, in turn, causes the individual yarns to separate from each other, resulting in an increase in the friction coefficient of the integrated yarn. Furthermore, the 4 + 1 series involves an additional Chenille yarn in the weaving process compared to the 3 + 1 series, leading to an expansion in the friction area and consequently an increase in the friction coefficient. In conclusion, in order to minimize the friction coefficient of Chenille/polyester integrated yarn, it is recommended to select a critical value of 6 mm for the pitch.

The bending stiffness of yarns has little relation with yarn composition and pitch, as shown in Fig. 7d. Among them, the bending stiffness of the 2 − 1 series is the largest. As shown in Fig. 7f, the 4 + 1 series integrated yarn with the lowest bending rigidity is the one with a pitch of 7 mm, followed by the 3 + 1 series integrated yarn with a pitch of 6 mm. This indicates that these two types of yarns are the softest and most suitable for weaving on machines. Among them, the curving lag of the 3 + 1 series integrated yarn continues to increase with the increase of pitch, indicating that the viscosity of this series of integrated yarn continues to increase.

The sound absorption coefficient of flat needle and ribbed fabrics knitted with six yarns using flat knitting machines was obtained by impedance tube testing. The frequency-absorption coefficient curves were plotted at 800 Hz, 1000 Hz, 1250 Hz, 1600 Hz, 2000 Hz, 2500 Hz, and 3150 Hz based on the 1/3 octave data. Additionally, the average sound absorption coefficient of the two fabric samples whin the range of 800 Hz to 3150 Hz was calculated at 6 Hz intervals. The results presented in Fig. 8.

As shown in Fig. 8a, the sound absorption coefficient of jersey fabric exhibits a rapid increase with the frequency, particularly for fabrics with a yarn composition of 4 + 1–5 and 4 + 1–6. The slope of the rising curve for their sound absorption performance is greater compared to other fabrics. Figure 8b illustrates that the sound absorption performance curves of each fabric with a 1 + 1 rib structure follow the same pattern. Under identical test conditions, the maximum sound absorption coefficient of ribbed fabrics surpasses that of jersey fabrics. By analyzing the thickness and air permeability of the two fabric structures, it is evident that the 1 + 1 ribbed fabric has a larger thickness and lower air permeability. Consequently, it exhibits greater resistance to sound waves, leading to higher sound energy consumption within the fabric and better sound absorption performance.

(a) Frequency-absorption coefficient curve of jersey fabrics; (b) Frequency-absorption coefficient curve of 1 + 1 ribbed fabrics; (c) The average sound absorption coefficient of jersey fabrics; (d) The average sound absorption coefficient of 1 + 1 ribbed fabrics.

As showed in Fig. 8c,d, the composition of the integrated yarn also influences the sound-absorbing properties of the final knitted sound-absorbing fabric. Obviously, the fabric containing a higher proportion of chenille yarn in the integrated yarn exhibits superior sound absorption performance. It is due to the increased exposure of fluff on the surface of the integrated yarn with a higher chenille yarn content, resulting in a larger diameter and a more pronounced blocking effect on sound waves, thereby enhancing the sound absorption performance.

Chenille yarn with plush fibers and polyester monofilament were chosen as the raw materials for this study. The 2D spindle weaving technology was selected to design and prepare six distinct types of integrated knitted yarns with varying structures. Subsequently, the basic properties, tensile fracture, friction, and bending properties of these yarns were tested. The specific conclusions were as follows:

The diameter and weaving angle of the Chenille/polyester integrated yarn decreased as the pitch increased, showing a linear correlation. The correlation coefficient R2 of integrated yarn diameter, weaving angle and pitch was above 0.8, indicating a high degree of fitting.

Despite the fact that the breaking strength of the 3 + 1 series was lower than that of the 4 + 1 series, its utilization rate for single yarn strength was significantly higher than that of the 4 + 1 series, especially for 6 mm and 7 mm, with a strength utilization rate exceeding 98%.

The sample 4 + 1–7 mm integrated knitted yarn exhibited the lowest bending stiffness, followed by the sample of 3 + 1–6 mm integrated knitted yarn. This suggests that these two types of yarns are the most pliable and well-suited for machine weaving.

The sound absorption coefficient of jersey and 1 + 1 ribbed fabrics exhibited a rapid increase with frequency. Under the same test conditions, the maximum sound absorption coefficient of ribbed fabrics was found to be higher than that of jersey fabrics. Furthermore, fabrics with a higher proportion of chenille yarns in the integrated yarns demonstrated superior sound absorption performance.

The data that support the findings of this study are available from the corresponding author upon reasonable request.

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This work is sponsored by “Chenguang Program” supported by Shanghai Education Development Foundation and Shanghai Municipal Education Commission (No. 21CGA76). The Center for Civil Aviation Composites, Donghua University and Shanghai High Performance Fibers and Composites Center (Province-Ministry Joint), Donghua University. The Fundamental Research Funds for the Central Universities (2232024D-08). Donghua University 2024 Cultivation Project of Discipline Innovation(xkcx-202401). Research Projects of Zhejiang Provincial Department of Education (Y202454555).

College of Mechanical and Electrical Engineering, Jiaxing Nanhu University, Jiaxing, 314001, China

Xin He & Gonghai Wang

Shanghai Frontiers Science Research Center of Advanced Textiles, College of Textiles, Donghua University, Shanghai, 201620, China

Mengfan Hu & Shaoju Fu

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Xin He: Conceptualization, Methodology, Funding acquisition, Writing Original Draft, Writing Review & Editing. Gonghai Wang: Conceptualization, Writing Review & Editing. Mengfan Wu: Data Curation, Writing Original Draft. Shaoju Fu: Writing Review & Editing, Validation, Data Curation, Supervision.

Correspondence to Shaoju Fu.

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He, X., Hu, M., Wang, G. et al. Study on the preparation and design of chenille/polyester integrated yarns and its acoustic properties. Sci Rep 15, 1729 (2025). https://doi.org/10.1038/s41598-025-86128-2

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Received: 07 November 2024

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Published: 11 January 2025

DOI: https://doi.org/10.1038/s41598-025-86128-2

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