Three-layer structure fabric with continuous microporous pu resin film attached to heating fabric and cooling fabric and method thereof

Abstract

The present application is a three-layer structure fabric with continuous microporous PU resin film attached heating fabric and cooling fabric and its method. The method is to coat a layer of PU resin coating on PET film or release paper, form PU resin foam shape by foaming machine, dry to form PU polyester film, then use PU polyester film to heat the surface PU resin to form a horn-shaped microporous hole, and produce a sticking reaction with the upper and lower layers of fabric, then after aging, the PET film or release paper is peeled off, and the three-layer structure fabric is formed by attaching and transferring processing, wherein the upper layer is a heating fabric, which means that the back of the fabric woven by polyester or nylon with elastic fiber is coated with a layer of volcanic agent layer, the middle layer is a continuous microporous PU resin film, which means a polyurethane resin film, and the bottom layer is a cooling fabric, which means that the back of the fabric woven by polyester or nylon yarn is coated with a layer of xyloglucan layer, and the upper layer of heating fabric has the effects of releasing far infrared heating, heat preservation and anti-UV, the middle layer of continuous microporous PU resin layer has the characteristics of high air permeability, high elasticity, high stretch and high recovery, and the bottom layer of polyester or nylon cooling fabric has the cooling effect of containing xyloglucan, so the product of the present application is widely used on textile functional cloth.

Description

Technical Field

[0001] This invention relates to a three-layer structure fabric consisting of a continuous multi-porous PU resin film bonded to a heating fabric and a cooling fabric, and its manufacturing method. The method involves coating a PU resin layer onto a PET film or release paper, forming a PU resin film on the release paper. This film is then bonded to an upper heating fabric and a lower cooling fabric to form a three-layer structure fabric. This invention gives the product the characteristics of heat preservation, far-infrared ray and negative ion release, UV resistance, high breathability, high elasticity, high stretchability, and high recovery. Background Technology

[0002] Currently, the market offers two methods: applying resin directly to the fabric surface in a single coating process or applying two layers of resin to the fabric in a first and second coating process. Both of these methods involve directly coating the fabric to improve its breathability and waterproofness, which are traditional processing methods. Moreover, the resin film is applied to ordinary fabric on one side or on both sides, which cannot achieve the functional characteristics of double-sided fabric. The selection of the intermediate layer resin film formation process is very important, as traditional film formation processes cannot obtain high breathability, high elasticity, high stretchability, and high recovery properties. Summary of the Invention

[0003] The main objective of this invention is to propose a patent application for a three-layer structure fabric with a continuous microporous PU resin film bonded to a heating fabric and a cooling fabric, and a method thereof.

[0004] A method for fabrics with a continuous microporous PU resin film bonded to a three-layer structure consisting of a heating fabric and a cooling fabric, the steps of which are as follows:

[0005] (1) Take the release paper: The release paper specifications are 16μ, 25G;

[0006] (2). PU resin: Selected from water-based PU resin or solvent-based PU resin, the selected water-based PU resin is 100%, melamine crosslinking agent is 1-3%, foaming agent is 1-5%, foam stabilizer is 3-8%, solvent-based PU resin coating processing liquid is: solvent-based PU resin 100%, isocyanate 2-5%, DMF 10-15%, MEK 45-60%;

[0007] (3) Foaming machine;

[0008] (4). PU resin foam shape;

[0009] (5) PU resin coating: The PU resin is formed into a foamed microporous structure and coated with a doctor blade at a speed of 20-25 m / min, with a coating amount of 5-200 g / m. 2The thickness on the release paper is approximately 1–0.08 μm;

[0010] (6) Formation of a PU resin gas film;

[0011] (7). Drying: 100℃±20℃;

[0012] (8). Heating the PU resin film: Heat the PU resin film at 120℃;

[0013] (9) Dot-like bonding process: Dot-like bonding of the upper fabric is performed on the surface of the continuous microporous PU resin film;

[0014] (10) Upper fabric: refers to polyester or nylon fabric coated with a volcanic rock agent layer on the back, and then bonded to a PU resin film;

[0015] (11). Release paper peeling: The bottom surface of the continuous microporous PU resin film is peeled off from the release paper;

[0016] (12). Continuous microporous PU resin membrane: thickness 0.1-0.2 mm, elongation 2.5-3, its cross-section consists of multiple PU resin bubbles.

[0017] Forming a trumpet shape;

[0018] (13). Dot-like bonding process: dot-like bonding of the underlying fabric is performed on the bottom surface of the continuous microporous PU resin film;

[0019] (14). Base fabric: It is made of polyester or nylon fabric with a xylitol coating on the back;

[0020] (15). Drying: 100℃±20℃; and

[0021] (16). Three-layer structure fabric: upper heating fabric, middle continuous microporous PU resin film and bottom cooling fabric.

[0022] The method of this invention involves coating a PU resin layer onto a PET film or release paper, forming a PU resin foam using a foaming machine, drying it to form a PU polyester film, then heating the surface of the PU polyester film to foam the PU resin into a funnel-shaped microporous structure, which then bonds with the upper and lower fabric layers. After curing, the PET film or release paper is peeled off, and a three-layer structure fabric is formed through lamination and transfer printing. The upper layer is a heat-generating fabric, which is a polyester or nylon woven with elastic fibers. A volcanic rock agent is coated on the back of the fabric and bonded to the PU microporous resin film. The middle layer is a PU resin film, which is a microporous polyurethane resin film bonded to the bottom cooling fabric. The bottom cooling fabric is a polyester or nylon fabric with elastic fibers, onto which xylitol liquid is impregnated, transferred, coated, and screen-printed onto the back. The microporous structure of the PU microporous resin membrane creates many microporous chambers that serve as interfaces for mixing hot and cold air. The volcanic rock layer of the surface heating fabric generates hot air which is absorbed and stored by the microporous chambers. The cooling layer of the bottom cooling fabric generates cold air when it comes into contact with body sweat, which is absorbed and stored by the microporous chambers.

[0023] The water-based PU resin is selected from 100% polyurethane resin (PU), 1-3% melamine-based crosslinking agent, 1-5% foaming agent, and 3-8% foam stabilizer. The solvent-based PU resin coating solution consists of 100% solvent-based PU resin, 2-5% isocyanate, 10-15% DMF, and 45-60% MEK. This foam coating process utilizes a foaming machine to add PU resin to generate foam, which is then coated onto PET film or release paper to create a PU resin gas film. After drying and extrusion at 60-150℃, a water-based PU resin film is formed on the PET film or release paper, resulting in a continuous microporous PU resin film. The cross-section forms a continuous membrane with large, medium, and small pores. The continuous microporous PU resin membrane forms a shape with multiple large, medium, and small pores, with pore sizes ranging from 0.6μm to 90μm. The overall shape forms a funnel-shaped pore structure from top to bottom. When external hot air passes through the upper fabric, it first enters the large pore membrane → medium pore membrane → small pore membrane. When the human body temperature rises and passes through the bottom fabric, it first enters the small pore membrane → medium pore membrane → large pore membrane, retaining body temperature within the multiple large, medium, and small pore membranes to achieve a heat preservation effect. The bottom small pore membrane layer can resist the entry of external cold and hot air into the human body, resulting in a cool and comfortable effect for the bottom fabric.

[0024] The product of this invention uses a continuous microporous PU resin film, which is a breathable PU film. It is manufactured using a special foaming process to create a microporous structure in the PU resin film. When bonded to knitted or plain fabrics, it does not cause a stuffy feeling. In other words, while general PU or TPU film-bonded products have good waterproof properties, they feel stuffy to wear. The PU resin film used in this invention has a continuous microporous structure, allowing body heat or water vapor to slowly escape from the body without causing stuffiness. Furthermore... The air inside the microporous structure has a warming effect, and air is an excellent thermal insulation material. The pores of the microporous structure are generally between 0.6μm and 90μm. Therefore, this PU resin film has a warming effect. Commercially available PU resin or TPU resin film fabric bonding products, although waterproof and breathable, feel stuffy like wearing plastic skin. When wearing the bonding product of this invention, it is breathable and warm when climbing mountains. Generally, it uses NYLON fabric with a denier of 15 or less for bonding products, and there is no need to wear a raincoat when it rains.

[0025] The product bonded by this invention has a full feel and good elasticity, which is incomparable to the thinness of general PU resin film or TPU resin film bonded products. The thickness of PU resin film or TPU resin film is about 0.01mm to 0.02mm.

[0026] The characteristics of the continuous microporous PU resin film used in the bonding product of this invention are as follows:

[0027] 1. The thickness of the continuous multi-microporous PU resin film for bonding fabrics in this invention is in the range of 0.2mm to 0.5mm. It has excellent thickness and elasticity in bonding products. TPU resin film bonding products are continuous films, so they feel harder and lack thickness.

[0028] 2. The continuous multi-microporous PU resin film for bonding fabrics of the present invention has a tensile strength (kg / 2.54cm) of 1.2 to 2.4, an elongation (%) of 350 ± 50, and an air permeability (CMF) of 220 to 300.

[0029] 3. The continuous multi-microporous PU resin film laminated to the fabric of the present invention has a windproof value of 3.5 CFM as measured by the ASTM-D737 method. The windproof value is approximately 14 for plain woven fabric, approximately 30 for circular knitted fabric, and approximately 14 for fine knitted fabric.

[0030] 4. The PU resin film of the fabric in this invention is a continuous microporous layer, which has a rich feel and a smooth texture.

[0031] 5. The PU resin film for bonding fabrics of the present invention is an environmentally friendly continuous microporous PU resin film, which is different in material from the films of other products. In order to protect the earth, it is hoped that downstream manufacturers will use the PU resin film for bonding fabrics of the present invention.

[0032] 6. The continuous microporous PU resin film for bonding fabrics of the present invention is suitable for use in rhythmic clothing or other sportswear or trousers.

[0033] The characteristics of the three-layer structure fabric of this invention—heat-generating fabric, continuous microporous PU resin membrane, and cooling fabric—are as follows:

[0034] (1). Upper fabric: The heating fabric refers to polyester or nylon with added elastic fibers to form a fabric. A layer of volcanic rock agent is coated on the back of the fabric and then bonded to a PU microporous resin film.

[0035] (2) Intermediate layer continuous microporous PU resin membrane: composed of multiple large, medium and small pores distributed in the cross section, with a thickness of 0.2mm to 0.5mm, an elongation strength (kg / 2.54cm) of 1.2 to 2.4, an elongation (%) of 350±50, and an air permeability (CMF) of 220 to 300. It has high air permeability, high elasticity, high stretch and high recovery characteristics.

[0036] (3) Bottom fabric: refers to polyester or nylon fabric with added elastic fibers, which is impregnated with xylitol liquid, transferred, coated, or screen-printed onto the back of the fabric and then bonded with PU microporous resin film. Attached Figure Description

[0037] Figure 1 This is a flowchart illustrating the three-layer structure of the fabric—a continuous microporous PU resin film bonded to a heating element, a cooling fabric, and the method thereof—as described in this invention.

[0038] Figure 2 This is one of the schematic cross-sectional views of the water-based continuous microporous PU resin membrane in the three-layer fabric structure of the present invention.

[0039] Figure 3 This is the second schematic diagram of the cross-section of the water-based continuous microporous PU resin membrane in the three-layer structure fabric of the present invention.

[0040] Figure 4 This is a schematic diagram showing the disassembly and bonding of the three-layer structure fabric of the present invention.

[0041] Figure 5 This is a schematic diagram of the three-layer fabric structure of the present invention.

[0042] Figure 6 This is an example diagram of the present invention, showing a continuous microporous PU resin film bonded to a heat-generating and cooling fabric structure.

[0043] Symbol explanation:

[0044] 1' A three-layer fabric with a continuous microporous PU resin film bonded to a heating fabric and a cooling fabric.

[0045] A. Release paper; B. PU resin coating; C. Foaming machine; D. PU resin foam shape;

[0046] EPU resin coating; FPU resin gas film; G, Q drying; H extrusion;

[0047] I. PU resin film + release paper; I1, I2: flow direction; J. PU resin film heating;

[0048] K,O dot-matrix bonding process; L upper fabric; M release paper peeling; N continuous microporous PU resin layer;

[0049] P - Base fabric; P1 - Polyester or nylon fabric coated with xylitol layer; R - Three-layer structure fabric;

[0050] S Sun; S1 contains polyester or nylon (20 denier) with added elastic fibers;

[0051] S2 contains polyester or nylon (20 denier) with added elastic fibers in the weft direction; S3 contains a volcanic rock layer.

[0052] S4 contains elastic fibers added to polyester or nylon yarn (20 denier);

[0053] S5 contains polyester or nylon yarn (20 denier) with added elastic fibers in the weft direction.

[0054] S6 Xylitol layer; T Human body; Wn Multiple porous membrane; Vn Several trumpet-shaped porous membranes

[0055] V-shaped perforated membrane; V1 large-pore membrane; V2 medium-pore membrane; V3 small-pore membrane.

[0056] V' Small pore membrane; Y1 Light energy; Y11 Far-infrared rays; Y2 Anti-UV reflection rays; Y3 Cooling rays Detailed Implementation

[0057] The foregoing description and other technical contents, features and effects of the present invention will be clearly presented in the following detailed description of the preferred embodiments with reference to the accompanying drawings.

[0058] This invention relates to a three-layer structure fabric consisting of a continuous microporous PU resin film bonded to a heating fabric and a cooling fabric, and a method thereof. Figure 1The process mainly involves coating a PU resin layer B onto a PET film or release paper A, forming a PU resin foam D using a foaming machine C, applying a PU resin coating layer E to form a PU resin gas film F, drying G, and extruding H to form a water-based PU resin film + release paper I, then heating the surface J of the PU resin film, and bonding it to the upper fabric L via dot-adhesion K. After curing, the PET film or release paper is peeled off M to form a PU resin film N (intermediate layer), which is then bonded to the bottom fabric P via dot-adhesion O. The bottom fabric is made of polyester or nylon cooling yarn S5 or polyester or nylon fabric coated with a xylitol layer P1, and then dried Q to form a three-layer structure fabric R.

[0059] The preferred embodiment of the manufacturing method includes the following steps:

[0060] (1). Take PET film or release paper A: PET film or release paper specifications 16μ, 25G.

[0061] (2). PU Resin B: Selected from water-based PU resins, its selected water-based PU resin coating processing solution: PU resin 100, melamine-based crosslinking agent 1-3%, foaming agent 1-5%, and foam stabilizer 3-8%. Solvent-based PU resin coating processing solution: solvent-based PU resin 100, isocyanate 2-5%, DMF 10-15%, and MEK 45-60%.

[0062] (3). Foaming machine C.

[0063] (4). PU resin foam shape D.

[0064] (5) PU resin coating layer E: The PU resin is formed into a foamed microporous structure and coated with a doctor blade at a speed of 20-25 m / min, with a coating amount of 5-200 g / m. 2 The thickness on the release paper is approximately 1–0.08 μm.

[0065] (6) Formation of PU resin gas film F.

[0066] (7). Drying G: 100℃±20℃.

[0067] (8). Heating PU resin film I: Take a PU resin film and heat it at 120℃.

[0068] (9) Dot-like bonding process K: Dot-like bonding of the upper fabric is performed on the surface of the PU resin film.

[0069] (10). Upper fabric L: refers to polyester or nylon fabric coated with a volcanic rock agent layer on the back, and then bonded to a PU resin film.

[0070] (11). Release paper peeling M: The bottom surface of the PU resin film is peeled off from the release paper.

[0071] (12). PU resin film N: thickness 0.1~0.2mm, elongation 2.5~3, its cross-section is a continuous microporous PU resin multiple bubbles forming a trumpet shape.

[0072] (13). Dot-like bonding process: Dot-like bonding of the underlying fabric is performed on the bottom surface of the continuous microporous PU resin film.

[0073] (14). The bottom fabric P is a polyester or nylon fabric with a xylitol coating on the back.

[0074] (15). Drying G: 100℃±20℃.

[0075] (16). Three-layer structure fabric R: the upper layer is a heat-generating fabric, the middle layer is a continuous microporous PU resin film, and the bottom layer is a cooling fabric.

[0076] Please see as follows Figure 2 Figure 3 shows a cross-sectional view of the PU resin film N. The continuous multi-microporous PU resin film N consists of multiple porous membranes Wn and several trumpet-shaped porous membranes Vn, as shown in Figure 3. Figure 3 The PU resin film N shown is a funnel-shaped perforated membrane V. This funnel-shaped perforated membrane V is composed of a large-pore membrane V1, a medium-pore membrane V2, and a small-pore membrane V3. External hot air flows through the upper fabric L in the direction I1 and enters the PU resin film N through the large-pore membrane V1 → medium-pore membrane V2 → small-pore membrane V3. Human body temperature flows through the bottom fabric P and enters the PU resin film N through the small-pore membrane V3 → medium-pore membrane V2 → large-pore membrane V1. This retains the human body temperature T in multiple membranes, achieving a heat preservation effect. The bottom small-pore membrane layer V' can resist the entry of external hot air into the human body T, resulting in a cooling effect on the bottom fabric P.

[0077] Please see Figure 4 As shown in Figure 5, the upper fabric L is dot-bonded to the surface of the continuous microporous PU resin film N using a dot-bonding process K. Additionally, a dot-bonded process O is performed on the bottom layer of the continuous microporous PU resin film N to bond with the bottom fabric P. This forms a three-layer fabric R consisting of the upper fabric L, the middle continuous microporous PU resin film N, and the bottom fabric P. Figure 5 As shown, the upper fabric L is made of polyester or nylon (20 denier) with added elastic fibers in the warp direction (S1) and polyester or nylon (20 denier) with added elastic fibers in the weft direction (S2). A volcanic rock agent layer (S3) is coated on the back of the fabric. The lower fabric P is made of polyester or nylon yarn (20 denier) with added elastic fibers in the warp direction (S4) and polyester or nylon yarn (20 denier) with added elastic fibers in the weft direction (S5). A xylitol layer (S6) is coated on the back of the fabric.

[0078] like Figure 6 The fabric shown has a three-layer structure 1' consisting of a PU resin film bonded to a heating fabric and a cooling fabric. The heating fabric K' releases far-infrared rays Y11 when it receives sunlight S light energy Y1, and generates anti-UV reflective rays Y2 when it is exposed to ultraviolet radiation. The cooling fabric generates cooling rays Y3 that come into contact with the human body T.

[0079]

Example

[0080] Take 16μm, 50G release paper or PET film, 80% polyester fabric (60D×60D), 100% water-based PU resin, 3% melamine-based crosslinking agent, 5% foaming agent, and 8% foam stabilizer, and mix them to produce foam-shaped PU resin. Apply the mixture at a coating weight of 120g / m². 2 The coating machine operates at a speed of 25 m / min, coating a foam-shaped PU resin onto a release paper to a thickness of 0.08 μm. After drying at 80℃ for 1 minute and extrusion, a multi-bubble, trumpet-shaped water-based PU resin film and release paper are formed. The PU resin film (0.6 μm to 90 μm) is then heated to 120℃ and bonded to an upper layer of polyester yarn (70 denier / 68 strands) as the weft yarn. A volcanic rock agent layer is then coated on the back and bonded to the microporous resin film. After curing, the release paper is peeled off to form the final PU resin film. The middle layer (0.15mm thick) has an elongation of 2.6 times. It is woven with the bottom layer of polyester yarn (135 denier / 68 strands) using a dot-bonding process, and then bonded with a xylitol coating on the back. After drying at 80°C for 1 minute, a three-layer structure fabric is formed: 80% polyester with 20% elastic fiber, 100% PU resin film in the middle layer, and 80% polyester with 20% elastic fiber in the bottom layer. The three-layer structure fabric was tested according to Annexes 1 and 2, and the results are shown in Table 1. Air permeability was measured using ASTM-D737 method, yielding 23 CFM. Water absorption was measured using AATCC 79 method, yielding 3 seconds. Elastic recovery was tested using BS EN ISO 2093201:2020, yielding 97.5% warp recovery and 95.8% weft recovery after 30 minutes, and 95.4% warp recovery and 94.6% weft recovery after 1 minute. The far-infrared emissivity was measured to be 0.81 using the FTTS-FA-010-2007 4.1 method.

[0081] Table 1

[0082]

[0083] As can be seen from the above embodiments of the present invention, the measured physical property data show that the fabric has excellent functional properties as listed in the table above.

[0084] However, the above description is only a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. Any simple equivalent changes and modifications made in accordance with the scope of the patent application and the description of the invention shall still fall within the scope of the patent of the present invention.

[0085] This invention relates to a three-layer structure fabric consisting of a continuous microporous PU resin film bonded to a heating fabric and a cooling fabric, and a method thereof, which meets the requirements for patent application. Therefore, a patent application is hereby filed in accordance with the law.

Claims

1. A method for bonding a continuous microporous PU resin film to a three-layer structure fabric comprising a heating fabric, a cooling fabric, and a heat-generating fabric, characterized in that, The steps of the method are as follows: (1) Take the release paper: Release paper specifications are 16μm, 25g; (2). PU resin: Selected from water-based PU resin or solvent-based PU resin, the selected water-based PU resin is 100%, melamine crosslinking agent is 1~3%, foaming agent is 1~5%, foam stabilizer is 3~8%, and solvent-based PU resin coating processing fluid is: solvent-based PU resin 100%, isocyanate 2~5%, DMF 10~15%, MEK 45~60%; (3) Use a foaming machine to add PU resin to generate foam; (4) PU resin coating: The PU resin is foamed into micropores and coated with a doctor blade at a speed of 20~25m / min, with a coating amount of 5~200g / m. 2 Thickness of 0.08~1 μm on release paper; (5) Formation of a PU resin film; (6) Drying: 100℃±20℃; (7) Heating the PU resin film: Heat the PU resin film at 120℃; (8) Dot-bonding process: Dot-bonding of the upper fabric onto the surface of the continuous microporous PU resin film; (9) Top layer fabric: refers to polyester or nylon fabric coated with a volcanic rock agent layer on the back, and then bonded to a continuous microporous PU resin film; (10) Release paper peeling: The bottom surface of the continuous microporous PU resin film is peeled off from the release paper; (11). Continuous microporous PU resin membrane: thickness 0.1~0.2mm, elongation 2.5~3, its cross-section is composed of multiple continuous large, medium and small pore membranes, and the continuous microporous PU resin membrane forms a shape of multiple large, medium and small pore membranes, with the pore size ranging from 0.6μm to 90μm, and the overall shape forms a trumpet-shaped pore from top to bottom; (12) Dot-bonding process: Dot-bonding of the underlying fabric is performed on the bottom surface of the continuous microporous PU resin film; (13) Base fabric: It is made of polyester or nylon fabric with a xylitol coating on the back; (14). Drying: 100℃±20℃; and (15). Three-layer structure fabric: upper fabric, middle continuous microporous PU resin film and bottom fabric.

2. A three-layer fabric with a continuous microporous PU resin film bonded to a heating fabric and a cooling fabric, prepared by the method described in claim 1, characterized in that... It is composed of an upper fabric layer, a middle continuous microporous PU resin film layer, and a bottom fabric layer, wherein, - Upper fabric: a fabric woven from warp polyester or nylon yarn and weft polyester or nylon yarn, with a volcanic rock agent coating on the back; - Intermediate Layer: Continuous microporous PU resin membrane refers to a membrane with a cross-section consisting of multiple continuous large, medium, and small pores. The pore size ranges from 0.6μm to 90μm, and the overall shape forms a funnel-shaped porous resin membrane from top to bottom; and - Bottom fabric: A fabric woven from warp polyester or nylon yarn and weft polyester or nylon yarn, with a xylitol coating on the back; The upper fabric is dot-bonded to the surface of the continuous microporous PU resin film, and the lower fabric is dot-bonded to the bottom layer of the continuous microporous PU resin film to form a three-layer structure fabric.

3. A three-layer fabric with a continuous microporous PU resin film bonded to a heating fabric and a cooling fabric as described in claim 2, characterized in that, The three-layer fabric had an air permeability of 3.5 CFM as measured by the ASTM-D737 method.

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