Development of Breathable Waterproof Polyurethane-Coated Cotton Fabric Using Surfactant

The use of polyurethane (PU) coatings to produce water-resistant textiles has grown in popularity over the past few decades. However, they lack breathability, which is crucial for comfort in textile clothing. This research presents the development of a breathable and waterproof polyurethane-based protective fabric tailored for outdoor apparel. A key innovation involves the incorporation of a surfactant into the PU coating formulation, which enables the creation of micropores within the coating. These micropores allow for efficient heat and moisture exchange while maintaining excellent water resistance. The resulting fabric exhibits superior performance, characterized by a high contact angle of 110°, excellent resistance to water penetration of 6.4 cm H₂O, exceptional air permeability of 210 L/m²/s, and water vapor permeability of 480 g/m²/day, making it highly suitable for demanding outdoor activities such as sports. The fabric also demonstrates robust mechanical properties, including high water repellency, strong abrasion resistance, and good tear strength. This innovative technique addresses the challenge of balancing breathability and water resistance in waterproof textiles, leading to more comfortable and functional outdoor apparel. Future investigations may explore its broader applications in other textile sectors, where waterproofness and breathability are critical factors. This study additionally endorses the Sustainable Development Goal (SDG 9, Industry, Innovation, and Infrastructure), through its focus on process innovation.