Wear trial assessment of layer structure effects on vapor permeability and condensation in a cold weather clothing ensemble

A human physiological study was performed to verify the claim that the structure of a layer, without a change in the component materials, can reduce condensation in a multilayered cold weather clothing ensemble. Two five-layered clothing ensembles were constructed using different array types: an all-separated type and a combined type in which the final insulating layer was mechanically attached to a jacket without an air gap. The materials in the two arrays were identical and 100% polyester. The results showed that the combined type produced significantly less sweat (33.8%), displayed 31.3% improved vapor permeability, and had 25.0% lower sweat accumulation compared to the separated type (p < 0.05). Following exercise, the all-separated type displayed up to a 74% greater cooling rate of skin temperature compared to the combined-type ensemble. There was a tendency to note a warmer, drier, and less clammy condition in the combined clothing ensemble by participants. The results were in good agreement with the simulator results, and suggest that an appropriate layer arrangement, in addition to material selection, should be considered for the design of novel functional clothing for cold conditions.