High-breathability polyester fabric and preparation method thereof

Abstract

The invention belongs to the field of fabrics, and discloses a high-breathability polyester fabric and a preparation method thereof.The high-breathability polyester fabric comprises a base cloth layer, the base cloth layer is of a double-layer structure, the inner layer is a hydrophilic fiber woven layer, and the outer layer is a modified polyester fiber woven layer; the hydrophilic fiber woven layer is formed by weaving hydrophilic fiber yarns, and the modified polyester fiber woven layer is formed by weaving modified polyester fiber yarns; the section of the modified polyester fiber yarn is of a hollow structure, a micropore structure is arranged on the surface of the modified polyester fiber yarn, the micropore diameter of the micropore structure ranges from 0.1 micrometer to 10 micrometers, and the porosity ranges from 20% to 40%. The fabric is of a double-layer woven structure, the hydrophilic fibers on the inner layer quickly absorb sweat and conduct the sweat to the outer layer, sweat accumulation is avoided, the microporous structure of the modified polyester on the outer layer accelerates moisture evaporation, meanwhile, the hollow structure reduces moisture absorption expansion of the fibers, the dry and comfortable form of the fabric is kept, the micro protrusions on the surface form air turbulence, moisture discharge is accelerated, and stuffiness is avoided when the fabric is attached to the skin.

Description

Technical Field

[0001] The present invention relates to the field of fabrics, and more particularly to a highly breathable polyester fabric and a preparation method thereof. Background Art

[0002] In recent years, polyester (polyester fiber) fabrics have been widely used in clothing, home textiles and industrial fields due to their high strength, wear resistance and easy care. However, traditional polyester fibers have the problem of poor hygroscopicity. Their hydrophobic properties make it difficult for sweat to be quickly absorbed and diffused, and sweat easily accumulates on the skin surface, which can easily cause a stuffy feeling, affecting wearing comfort, especially during exercise or in high-temperature environments. Although the market has improved hygroscopicity through hydrophilic finishing agent modification or composite fiber design, such solutions often sacrifice the inherent lightweight and quick-drying advantages of polyester, and the single-layer structure cannot take into account the synergistic needs of efficient moisture absorption and rapid evaporation, limiting its application in outdoor clothing, sports equipment, medical protection and other fields. Summary of the Invention

[0003] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a highly breathable polyester fabric and a preparation method thereof.

[0004] In order to solve the above problems, the present invention adopts the following technical solutions:

[0005] Highly breathable polyester fabric, comprising a base fabric layer, wherein the base fabric layer has a double-layer structure, an inner layer being a hydrophilic fiber woven layer, and an outer layer being a modified polyester fiber woven layer;

[0006] The hydrophilic fiber braided layer is woven from hydrophilic fiber yarns, and the modified polyester fiber braided layer is woven from modified polyester fiber yarns;

[0007] The modified polyester fiber yarn has a hollow cross-section, a microporous structure is provided on the surface of the modified polyester fiber yarn, the microporous structure has a pore size of 0.1-10 μm, a porosity of 20%-40%, and a micro-convex structure is provided on the surface of the base fabric layer;

[0008] The fabric has a unit area weight of 80-150g / m 2 , air permeability ≥5000L / (m 2 ·s).

[0009] As a further description of the above technical solution: the hydrophilic fiber woven layer has a plain needle structure, and the modified polyester fiber woven layer has a rib structure. The hydrophilic fiber woven layer and the modified polyester fiber woven layer are connected through interweaving points, and the interweaving point density is one every 3-5 longitudinal rows. Modified polyester fiber yarn is used as a connecting line at the interweaving points.

[0010] As a further description of the above technical solution: the hydrophilic fiber yarn is composed of at least one of cotton fiber, viscose fiber or polyethylene glycol-modified polyester fiber.

[0011] As a further description of the above technical solution: the hydrophilic fiber yarn accounts for 10%-50%, and the modified polyester fiber yarn accounts for 50%-90%.

[0012] As a further description of the above technical solution: the micro-protrusion structure is formed by a hot embossing process, the hot pressing temperature is 120-180° C., and the pressure is 5-15 MPa.

[0013] This solution also provides a method for preparing a highly breathable polyester fabric, comprising the following steps:

[0014] Step S1: blending polyester chips and a porogen into a melt, and spinning through a porous spinneret to obtain porous hollow modified polyester fibers;

[0015] Step S2: performing an alkali weight reduction treatment on the modified polyester fiber to remove the porogen to form a microporous structure;

[0016] Step S3: selecting hydrophilic fibers, whose fineness matches that of the modified polyester, and performing pre-softening finishing on the hydrophilic fibers;

[0017] Step S4: Blending the modified polyester fiber with the hydrophilic fiber in proportion, using a double-sided circular knitting machine or a double-needle bed warp knitting machine, equipped with two sets of yarn guide needles to feed the inner and outer layer yarns respectively, adjusting the needle selection mechanism to set an interweaving point every 3-5 wales, and using the modified polyester fiber yarn as a connecting thread at the interweaving point to weave a base fabric layer;

[0018] Step S5: embossing the base fabric layer by using a hot pressing roller with micro grooves at 120-180° C. to form a micro-convex structure on the surface;

[0019] Step S6: performing hydrophilic finishing on the base fabric layer, padding the finishing liquid, and then drying and shaping to obtain a highly breathable polyester fabric.

[0020] As a further description of the above technical solution: the porogen is calcium carbonate or silicon dioxide nanoparticles, and the addition amount is 5-10wt%;

[0021] As a further description of the above technical solution: the process conditions of the alkali weight reduction treatment are: NaOH solution concentration 5%-10%, temperature 80-100°C, and time 30-60 minutes.

[0022] As a further description of the above technical solution: the micro grooves of the hot pressing roller have a depth of 20-60 μm and a width of 80-150 μm.

[0023] As a further description of the above technical solution: the finishing liquid contains 3%-5% polyether modified silicone oil and 1%-2% acrylate crosslinking agent.

[0024] Compared with the prior art, the advantages of the present invention are:

[0025] The fabric of this scheme is a double-layer woven structure. The hydrophilic fiber of the inner layer quickly absorbs sweat and conducts it to the outer layer to prevent sweat accumulation. The microporous structure of the modified polyester on the outer layer accelerates water evaporation. At the same time, the hollow structure reduces the moisture absorption and expansion of the fiber, keeping the fabric dry. The micro-protrusions on the surface create air turbulence, accelerating moisture discharge and avoiding stuffiness next to the skin. Through the coordinated design of microporous and micro-protrusion composite structure and double-layer fiber, the air permeability can reach 5000L / (m 2 ·s) and above, suitable for sportswear, medical protection and other fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a structural schematic diagram of the present invention;

[0027] Figure 2 Schematic diagram of the structure of the hydrophilic fiber braided layer and the modified polyester fiber braided layer connected at the interweaving points of the present invention;

[0028] Figure 3 Schematic diagram of the structure of the modified polyester fiber yarn of the present invention.

[0029] Description of the numbers in the figure:

[0030] 1. Base fabric layer; 11. Hydrophilic fiber woven layer; 101. Hydrophilic fiber yarn; 12. Modified polyester fiber woven layer; 102. Modified polyester fiber yarn; 2. Microporous structure; 3. Micro-convex structure. DETAILED DESCRIPTION

[0031] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0032] Example 1

[0033] See also Figure 1-3 , highly breathable polyester fabric, the fabric weight per unit area is 80-150g / m 2 , air permeability ≥5000L / (m 2s). The fabric comprises a double-layer base fabric layer 1, with an inner hydrophilic fiber woven layer 11 and an outer modified polyester fiber woven layer 12. The hydrophilic fiber woven layer 11 is woven from hydrophilic fiber yarn 101, while the modified polyester fiber woven layer 12 is woven from modified polyester fiber yarn 102. The hydrophilic fiber yarn 101 is composed of at least one of cotton, viscose, or polyethylene glycol-modified polyester fiber. The inner hydrophilic fiber layer rapidly absorbs sweat through a capillary effect, allowing it to diffuse outward. The outer modified polyester layer, through its hydrophobic surface, creates a humidity gradient, accelerating water evaporation.

[0034] The hydrophilic fiber yarn 101 accounts for 10%-50%, while the modified polyester fiber yarn 102 accounts for 50%-90%. The differential composition of the inner and outer layers creates a directional moisture-wicking path, preventing both excessive water accumulation inside and excessive water absorption in the outer layer, which could reduce breathability. The modified polyester fiber, comprising 50%-90% of the outer layer, provides primary mechanical support, resisting external friction and tearing. The differential modulus of the inner and outer layers creates an energy-buffering structure during impact, reducing the risk of single-layer damage. This design embodies the functional layering concept of "external protection, internal drainage," and has high application value in outdoor apparel, sports equipment, medical protection, and other fields.

[0035] Furthermore, the modified polyester fiber yarn 102 has a hollow cross-section and a microporous structure 2 on its surface. The micropores in this structure range from 0.1 to 10 μm in diameter and have a porosity of 20% to 40%. The hollow channels within the fibers create airflow pathways, reducing fiber density and increasing ventilation space, allowing moisture and heat to quickly escape through the fibers. The microporous structure further expands the fiber surface area, enhancing the capillary effect and accelerating the transfer and evaporation of sweat from the inner layer to the outer layer.

[0036] Furthermore, the surface of the base fabric layer 1 is provided with a micro-protrusion structure 3, formed through a hot embossing process at a temperature of 120-180°C and a pressure of 5-15 MPa. The micro-protrusion structure 3 creates an uneven texture on the fabric surface, creating tiny air channels between the fabric and the skin or the external environment, promoting air flow and improving overall breathability. The gaps between adjacent micro-protrusions serve as additional ventilation holes, reducing the fit between the fabric and the contact surface and preventing the stuffiness caused by close contact.

[0037] It should be noted that the hydrophilic fiber woven layer 11 has a flat stitch structure. This tight and smooth stitch provides excellent moisture absorption and skin-friendliness, making it suitable for direct contact with the skin, quickly absorbing sweat and dispersing it to the outer layer. The modified polyester fiber woven layer 12 has a ribbed structure. The ribbed structure of the modified polyester imparts elasticity and breathability, while its hydrophobic properties accelerate moisture evaporation and prevent moisture accumulation. These two layers work together to achieve "inner absorption and outer expulsion" moisture management.

[0038] The hydrophilic fiber woven layer 11 and the modified polyester fiber woven layer 12 are connected by interlacing points, with one interlacing point every 3-5 wales. Modified polyester fiber yarn 102 serves as the connecting thread at these interlacing points. This moderate interlacing frequency ensures a secure bond between the two layers while avoiding excessively restricting the elasticity of the rib layer. The high strength of polyester ensures durability at the interlacing points, preventing delamination after repeated stretching. Chemical modification also enhances the bond with the hydrophilic fibers.

[0039] Example 2

[0040] Based on the above embodiments, the present invention provides a method for preparing a highly breathable polyester fabric, comprising the following steps:

[0041] Step S1: blending polyester chips and a porogen into a melt, and spinning through a porous spinneret to obtain porous hollow modified polyester fibers; wherein the porogen is calcium carbonate or silicon dioxide nanoparticles, and the addition amount is 5-10wt%.

[0042] Step S2: performing alkali weight reduction treatment on the modified polyester fiber to remove the porogen and form a microporous structure 2. The process conditions of the alkali weight reduction treatment are: NaOH solution concentration 5%-10%, temperature 80-100° C., and time 30-60 minutes.

[0043] Step S3: Selecting hydrophilic fibers with a fineness matching that of the modified polyester, and pre-softening the hydrophilic fibers to avoid breakage due to fiber brittleness during subsequent processing;

[0044] Step S4: The modified polyester fiber and the hydrophilic fiber are blended in proportion, and two sets of yarn guide needles are configured to feed the inner and outer layer yarns respectively through a double-sided circular knitting machine or a double-needle bed warp knitting machine. The needle selection mechanism is adjusted to set an interweaving point every 3-5 longitudinal rows, and the modified polyester fiber yarn 102 is used as a connecting thread at the interweaving point to weave the base fabric layer 1.

[0045] Step S5: The base fabric layer 1 is embossed using a hot pressing roller with micro-grooves at 120-180°C to form a surface micro-protrusion structure 3. The micro-grooves of the hot pressing roller have a depth of 20-60 μm and a width of 80-150 μm. The micro-protrusion structure 3 formed by the hot pressing roller has a controllable morphology and distribution, and the process parameters can be standardized to ensure consistency in mass production.

[0046] Step S6: The base fabric layer 1 is subjected to a hydrophilic finishing step, impregnated with a finishing solution, and then dried and shaped to produce a highly breathable polyester fabric. The finishing solution contains 3%-5% polyether-modified silicone oil and 1%-2% acrylate crosslinker. The polyether-modified silicone oil significantly improves the fabric's feel while maintaining breathability. The acrylate crosslinker forms a network structure, enhancing washability. Through molecular-level hydrophilic-crosslinking synergistic design, a durable and breathable functional nanofilm is constructed on the fabric surface, preventing micropore clogging and achieving a balance between breathability and hydrophilicity.

[0047] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto. Any person skilled in the art who, within the technical scope disclosed by the present invention, makes equivalent substitutions or modifications based on the technical solutions and improved concepts of the present invention shall be covered by the scope of protection of the present invention.

Claims

1. Highly breathable polyester fabric, characterized by: The invention comprises a base fabric layer (1), wherein the base fabric layer (1) is a double-layer structure, wherein the inner layer is a hydrophilic fiber braided layer (11), and the outer layer is a modified polyester fiber braided layer (12); The hydrophilic fiber braided layer (11) is braided from hydrophilic fiber yarns (101), and the modified polyester fiber braided layer (12) is braided from modified polyester fiber yarns (102); The cross section of the modified polyester fiber yarn (102) is a hollow structure, the surface of the modified polyester fiber yarn (102) is provided with a microporous structure (2), the microporous structure (2) has a micropore diameter of 0.1-10 μm and a porosity of 20%-40%, and the surface of the base fabric layer (1) is provided with a micro-protrusion structure (3); The fabric has a unit area weight of 80-150g / m 2 , air permeability ≥5000L / (m 2 ·s).

2. The highly breathable polyester fabric according to claim 1, characterized in that: The hydrophilic fiber braided layer (11) has a plain needle structure, and the modified polyester fiber braided layer (12) has a rib structure. The hydrophilic fiber braided layer (11) and the modified polyester fiber braided layer (12) are connected through interweaving points, and the density of the interweaving points is one per 3-5 longitudinal rows. Modified polyester fiber yarns (102) are used as connecting lines at the interweaving points.

3. The highly breathable polyester fabric according to claim 1, characterized in that: The hydrophilic fiber yarn (101) is composed of at least one of cotton fiber, viscose fiber or polyethylene glycol-modified polyester fiber.

4. The highly breathable polyester fabric according to claim 1, characterized in that: The hydrophilic fiber yarn (101) accounts for 10%-50%, and the modified polyester fiber yarn (102) accounts for 50%-90%.

5. The highly breathable polyester fabric according to claim 1, characterized in that: The micro-protrusion structure (3) is formed by a hot embossing process, with a hot embossing temperature of 120-180° C. and a pressure of 5-15 MPa.

6. The method for preparing a highly breathable polyester fabric according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step S1: blending polyester chips and a porogen into a melt, and spinning through a porous spinneret to obtain porous hollow modified polyester fibers; Step S2: performing an alkali weight reduction treatment on the modified polyester fiber to remove the porogen and form a microporous structure (2); Step S3: selecting hydrophilic fibers, whose fineness matches that of the modified polyester, and performing pre-softening finishing on the hydrophilic fibers; Step S4: blending the modified polyester fiber and the hydrophilic fiber in proportion, using a double-sided circular knitting machine or a double-needle bed warp knitting machine, configuring two sets of yarn guide needles to feed the inner and outer layer yarns respectively, adjusting the needle selection mechanism to set an interweaving point every 3-5 longitudinal rows, using the modified polyester fiber yarn (102) as a connecting thread at the interweaving point, and weaving a base fabric layer (1); Step S5: performing embossing treatment on the base fabric layer (1) by using a hot pressing roller with micro grooves to perform hot pressing at 120-180°C to form a surface micro-convex structure (3); Step S6: performing hydrophilic finishing on the base fabric layer (1), dipping it in the finishing liquid and then drying and shaping it to obtain a highly breathable polyester fabric.

7. The method for preparing a highly breathable polyester fabric according to claim 6, wherein: The porogen is calcium carbonate or silicon dioxide nanoparticles, and the addition amount is 5-10 wt%.

8. The method for preparing a highly breathable polyester fabric according to claim 6, wherein: The process conditions of the alkali weight reduction treatment are: NaOH solution concentration 5%-10%, temperature 80-100° C., and time 30-60 minutes.

9. The method for preparing a highly breathable polyester fabric according to claim 6, wherein: The micro grooves of the hot pressing roller have a depth of 20-60 μm and a width of 80-150 μm.

10. The method for preparing a highly breathable polyester fabric according to claim 6, wherein: The finishing liquid contains 3%-5% polyether modified silicone oil and 1%-2% acrylate crosslinking agent.

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