Production method of wool-like terylene sofa fabric

Abstract

The invention relates to the technical field of textile fabric manufacturing, and discloses a wool-like polyester sofa fabric production method, which comprises the following components: a fluff layer, which is formed by polyester draw-textured yarns subjected to high temperature and high pressure dyeing; the base cloth layer is formed by interweaving body warp yarns and weft yarns; the functional backing layer is attached to the back surface of the base cloth layer and is formed through a curing reaction, and the functional backing layer is formed by reacting and curing the following raw materials in parts by weight: 60-85 parts of a main body polymer; 5 to 20 parts of a cross-linking agent; and 5-20 parts of an environment-friendly flame retardant containing phosphorus and / or nitrogen. According to the method, the dyeing procedure is preposed, the innovative back finishing process is adopted, the overall style quality of the wool-like fabric is remarkably improved, damp and hot mechanical treatment on the finished gray fabric is avoided, fluff of the fabric can be kept in the original optimal state formed in the weaving process, and the quality of the wool-like fabric is improved. And finally, a fluffy, three-dimensional, natural-luster and high-grade appearance with extremely soft and smooth hand feeling is presented.

Description

Technical Field

[0001] The invention relates to the technical field of textile fabric manufacturing, in particular to a production method of wool-like polyester sofa fabric. Background Art

[0002] In recent years, as consumers' demands for higher quality home living continue to rise, high-end wool-like fabrics, offering a superior appearance, comfortable feel, and exceptional durability, have gained widespread favor, particularly in upholstered furniture such as sofas and chairs. These fabrics utilize specialized weaving and finishing techniques to mimic the rich, plush feel, soft sheen, and warm touch of natural fur.

[0003] To enhance the commercial value and longevity of such suede fabrics, existing manufacturing processes typically focus on addressing a core technical challenge: how to securely attach the fuzz on the fabric's surface to the base fabric to prevent it from falling off during daily use and cleaning. This involves improving the fuzz's fastness. One common approach involves applying a functional coating composition to the fabric during the finishing stage to bond and secure the fuzz at its base.

[0004] However, traditional finishing processes often suffer from inherent flaws that are difficult to reconcile in practice. When the finishing process acts directly on the front of the fabric's pile, the liquid coating composition and mechanical forces such as scraping will inevitably soak, overwhelm, and bond the pile, causing the pile to become twisted and clumped, seriously damaging its fluffy and natural aesthetic and making the fabric feel stiff and rough. Furthermore, if the intense wet heat treatment process such as dyeing is placed after the grey fabric is formed in the entire production process, the high temperature and mechanical forces of the dyeing process will also pre-damage the already formed fragile pile structure, causing it to fall over and tangle, creating inherent difficulties in subsequently achieving a high-quality appearance.

[0005] Even some processes that attempt to apply a coating to the back of the fabric often fail due to the inherent performance limitations of the coating material. Traditional backing coatings often struggle to provide sufficient bonding strength while maintaining the overall softness of the fabric. To achieve the ideal hair-binding effect, the coating must be applied to a certain thickness, but this often results in a stiff and brittle backing layer, affecting the fabric's comfort and premium feel. Summary of the Invention

[0006] In view of the shortcomings of the existing technology, the present invention provides a method for producing wool-like polyester sofa fabric, and provides a high-performance wool-like fabric preparation method that can significantly improve the wool consolidation fastness without sacrificing the excellent suede style and soft feel of the fabric.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: A wool-like polyester sofa fabric, comprising: The fleece layer is made of polyester stretched textured yarn dyed under high temperature and high pressure; The base fabric layer is made of warp yarn and weft yarn interwoven together; The functional backing layer is attached to the back of the base fabric layer and is formed by a curing reaction. The functional backing layer is formed by curing the following raw materials in parts by weight: Main polymer: 60-85 parts; Cross-linking agent: 5-20 parts; Environmentally friendly flame retardant containing phosphorus and / or nitrogen: 5-20 parts; Furthermore, the pile layer is composed of polyester stretch-textured yarn pre-dyed through a high-temperature, high-pressure cheese dyeing process. This process ensures that the yarn is fully colored before being woven into the pile structure, fundamentally avoiding the subsequent mechanical damage to the delicate pile structure caused by the subsequent piece-dyeing process. As a result, the pile layer is able to maintain the original three-dimensional structure formed after weaving to the greatest extent possible, resulting in upright, uniform, and full-bodied pile, with a soft, natural macroscopic sheen and a soft, smooth touch.

[0008] The base fabric layer is composed of ground warp and weft yarns interwoven in a tightly woven structure. This layer serves as the backbone of the fabric, providing a stable weaving foundation for the pile layer above and a base for the functional backing layer described below. Its primary function is to impart the fabric with the necessary dimensional stability, tear resistance, and overall structural integrity, serving as the key link between the suede style and the backing's functionality.

[0009] The functional backing layer is firmly attached to the back of the base fabric layer by coating and thermal curing. It is an organic-inorganic hybrid network formed by an in-situ reaction of a reactive coating composition under thermal setting conditions. Its components, calculated by weight, are formed by the reaction and curing of the following raw materials: Main polymer: 60-85 parts; This component forms the foundation of the three-dimensional network structure, providing the toughness, elasticity, and film-forming properties necessary for the backing layer. Its molecular structure imparts a flexible, pliable quality to the cured coating, avoiding the stiff feel associated with traditional backing layers.

[0010] Crosslinker: 5-20 phr; This component is key to achieving high consolidation strength. Under heat, it not only chemically crosslinks with the active groups of the main polymer but also undergoes hydrolysis and condensation, forming a dense and strong three-dimensional interpenetrating network. This network chemically anchors the roots of the fluff fibers at a microscopic level, imparting exceptional pull-out resistance.

[0011] Environmentally friendly flame retardant containing phosphorus and / or nitrogen: 5-20 parts; This component is physically dispersed and coated in the above-mentioned chemical cross-linking network, and through the phosphorus-nitrogen synergistic expansion and carbonization mechanism, it gives the fabric excellent flame retardant properties while meeting the requirements of environmental regulations.

[0012] The synergistic effect of these three components enables the final functional backing layer to provide strong consolidation force for the fluff while maintaining the overall softness and comfort of the fabric, achieving the unity of physical properties and aesthetic style.

[0013] Preferably, the main polymer in the functional backing layer is a hyperbranched polyurethane-organosiloxane copolymer.

[0014] Preferably, the crosslinking agent in the functional backing layer is an aminosilane coupling agent.

[0015] Preferably, the functional backing layer functions to consolidate the pile warp yarns in the pile layer.

[0016] A method for producing wool-like polyester sofa fabric comprises the following steps: S1: Yarn preparation and dyeing: polyester stretch textured yarn is selected as pile warp yarn, ground warp yarn and weft yarn, and the yarn is dyed using a high temperature and high pressure cheese yarn dyeing method; S2: warping: warping the dyed yarn, wherein the warping step includes wetting the yarn with water to eliminate static electricity; S3: Weaving: Using a double-layer fabric loom, the pile warp yarn, the ground warp yarn and the weft yarn are woven into a double-layer grey cloth, which is then split to form a single-layer grey cloth with pile; S4: backside glue coating and finishing: applying a layer of reactive organic-inorganic hybrid coating composition on the back side of the single-layer grey fabric by blade coating; S5: Heat setting: The coated grey fabric is heat-set to solidify the coating composition and fix the shape of the pile.

[0017] Preferably, the polyester stretched textured yarn in step S1 is a DTY heavy mesh; the specifications of the pile warp yarn are 450D / 144F, and the specifications of the ground warp yarn and weft yarn are 300D / 96F.

[0018] Preferably, the weaving in step S3 adopts a V-type, W-type or U-type consolidation method.

[0019] Preferably, the scraper spacing in the scraping method in step S4 is 8-15 mm.

[0020] Preferably, the heat setting temperature in step S5 is 110-140°C.

[0021] The present invention provides a method for producing wool-like polyester sofa fabrics. The method has the following beneficial effects: 1. This invention significantly enhances the overall style and quality of wool-like fabrics by pre-dyeing the dyeing process and employing an innovative back-finishing process. By avoiding the need for wet-heat mechanical treatment of the finished fabric and preventing the finishing fluid from coming into contact with the front of the pile, the pile of the fabric remains in its original optimal state during the weaving process. The result is a high-end appearance with a fluffy, three-dimensional texture, a natural luster, and an exceptionally soft and smooth feel, perfectly replicating the texture of natural fur.

[0022] 2. This invention significantly improves the fiber's bond strength, imparting exceptional durability to the fabric. The reactive organic-inorganic hybrid coating composition on the backside forms a dense, strong, three-dimensional interpenetrating network in situ during heat setting. This network firmly chemically anchors the roots of each individual fiber at a microscopic level. This powerful bond effectively resists shedding and collapsing of the fabric under repeated friction and daily use, significantly extending the product's service life.

[0023] 3. Through systematic process innovation, this invention fundamentally resolves the inherent and difficult-to-reconcile contradiction in traditional fabric finishing: improving physical properties while maintaining a stylish appearance. By limiting the chemical strengthening function entirely to the back of the fabric, while focusing the shaping and protection of the aesthetic style on the front, this invention cleverly achieves the technical effect of strengthening the back while leaving the front intact. This ensures that the fabric achieves high strength and fastness without compromising its appearance, style, and comfortable touch, achieving a perfect balance between the two.

[0024] 4. The organic-inorganic hybrid coating employed in this invention imparts a unique combination of rigidity and flexibility to the backing layer. The organic hyperbranched polymer backbone provides excellent resilience, allowing the fabric to quickly recover after compression, resulting in a soft, non-rigid feel. The inorganic silicon-oxygen network formed by cross-linking provides a strong support, creating a durable foundation for the pile to stand on. This synergistic effect results in a product that is both bony and soft, with performance far exceeding that of single-component coatings.

[0025] 5. The preparation method of the present invention offers a high degree of process stability and controllability, facilitating high-quality industrial production. The pre-designed reactivity of the main polymer ensures stable performance and ease of handling during storage and application of the coating composition. Furthermore, the critical heat-setting step efficiently synchronizes the physical setting of the pile with the chemical curing of the backing, simplifying the process while ensuring high consistency in performance and style across batches. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 Schematic diagram of the production method of the present invention. DETAILED DESCRIPTION

[0027] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the present specification. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0028] Main raw materials and reagents: Unless otherwise specified, the reagents used in the examples and comparative examples of the present invention are all commercially available analytical grade or industrial grade products. Yarn and dyes: Polyester filament: Polyester low-stretch yarn (DTY) with a specification of 150D / 48F.

[0029] Disperse dyes: Disperse black ECT 300%.

[0030] Raw materials used in reactive coating compositions: Waterborne hyperbranched polyurethane-organosiloxane copolymer: prepared by ourselves. The specific preparation method is shown in Preparation Example 1.

[0031] γ-Aminopropyltriethoxysilane (APTES): CAS No.: 919-30-2, industrial grade, solid content ≥98%.

[0032] Melamine polyphosphate (MPP): CAS No.: 218768-84-4, flame retardant grade, phosphorus content ≥14%, nitrogen content ≥40%.

[0033] Deionized water: Conductivity ≤1 µS / cm, homemade in the laboratory.

[0034] Raw materials required for Preparation Example 1: Isophorone diisocyanate (IPDI): CAS No.: 4098-71-9, industrial grade.

[0035] Trimethylolpropane (TMP): CAS No.: 77-99-6, industrial grade.

[0036] Dimethylolpropionic acid (DMPA): CAS number: 4767-03-7, industrial grade.

[0037] α,ω-bis(3-aminopropyl)polydimethylsiloxane: CAS number: 106214-84-0, number average molecular weight Mn≈1000g / mol, industrial grade.

[0038] Triethylamine (TEA): CAS No.: 121-44-8, analytical grade.

[0039] Dibutyltin dilaurate (DBTDL): CAS number: 77-58-7, analytical grade.

[0040] Acetone: CAS number: 67-64-1, analytical grade.

[0041] Preparation Example 1: Preparation of aqueous hyperbranched polyurethane-organosiloxane copolymer emulsion In a 500 mL four-necked flask equipped with a mechanical stirrer, thermometer, reflux condenser, and nitrogen protection, add 75 g of isophorone diisocyanate (IPDI), 12 g of trimethylolpropane (TMP), 15 g of dimethylolpropionic acid (DMPA), and 120 g of acetone. Stirring was initiated, the temperature was raised to 60°C, and 0.1 g of dibutyltin dilaurate (DBTDL) was added dropwise as a catalyst. The reaction was continued at this temperature for 3 hours.

[0042] Subsequently, the reaction system was cooled to 50° C., and a mixed solution of 20 g of α,ω-bis(3-aminopropyl)polydimethylsiloxane and 20 g of acetone was slowly added dropwise. After the addition was completed, the reaction was continued for 2 hours to obtain a prepolymer with an isocyanate (-NCO) terminal group.

[0043] The prepolymer was cooled to 40°C, neutralized by the addition of 11.5 g of triethylamine, and stirred for 30 minutes. Finally, the prepolymer was slowly added to 250 g of deionized water under high-speed stirring (1000 rpm) for emulsification and dispersion. After dispersion, the acetone solvent was removed by vacuum distillation at 50°C to obtain a milky white, stable, aqueous hyperbranched polyurethane-organosiloxane copolymer emulsion. Its solids content was measured to be 35.2%, and its pH was 7.8.

[0044] Example 1: Yarn Preparation and Dyeing: DTY heavy-mesh polyester stretch textured yarn was used, with the pile warp yarn specification of 450D / 144F and the ground warp and weft yarn specifications of 300D / 96F. The yarn was dyed using the high-temperature and high-pressure cheese dyeing method at 130°C and kept warm for 50 minutes.

[0045] Warping: The dyed yarn is warped and wetted during the warping process. The warping speed is set at 300 m / min and the single yarn tension is controlled at 15 cN.

[0046] Weaving: Using a double-layer fabric loom, the yarn is woven into a double-layer fabric in a V-shaped consolidation method, and then split into a single-layer fabric with fluff.

[0047] Back glue finishing: Preparation of coating composition: A reactive coating composition is prepared, wherein the raw material components thereof are calculated in parts by weight: 75 parts of the aqueous hyperbranched polyurethane-organosiloxane copolymer prepared in Preparation Example 1, 12 parts of γ-aminopropyltriethoxysilane, and 13 parts of melamine polyphosphate.

[0048] Back scraping: The above composition was applied to the back of the grey cloth obtained in step 3 by scraping, with the scraper distance set to 12 mm.

[0049] Heat setting: The coated grey fabric is heat-set at a temperature of 140°C for 80 seconds.

[0050] After the above steps, the final wool-like polyester sofa fabric is obtained.

[0051] Example 2: Yarn Preparation and Dyeing: DTY heavy-mesh polyester stretch textured yarn was used, with the pile warp yarn specification of 450D / 144F and the ground warp and weft yarn specifications of 300D / 96F. The yarn was dyed using the high-temperature and high-pressure cheese dyeing method at 125°C and kept warm for 40 minutes.

[0052] Warping: The dyed yarn is warped and wetted during the warping process. The warping speed is set at 200 m / min and the single yarn tension is controlled at 10 cN.

[0053] Weaving: Using a double-layer fabric loom, the yarn is woven into a double-layer fabric in a W-shaped consolidation method, and then split into a single-layer fabric with a pile.

[0054] Back glue finishing: Preparation of coating composition: A reactive coating composition is prepared, wherein the raw material components thereof are calculated by weight and include: 60 parts of the aqueous hyperbranched polyurethane-organosiloxane copolymer prepared in Preparation Example 1, 5 parts of γ-aminopropyltriethoxysilane, and 5 parts of melamine polyphosphate.

[0055] Back scraping: The above composition was applied to the back of the grey cloth obtained in step 3 by scraping, with the scraper distance set to 8 mm.

[0056] Heat setting: The coated grey fabric is heat-set at a temperature of 140°C for 70 seconds.

[0057] After the above steps, the final wool-like polyester sofa fabric is obtained.

[0058] Example 3: Yarn Preparation and Dyeing: DTY heavy-mesh polyester stretch textured yarn was used, with the pile warp yarn specification of 450D / 144F and the ground warp and weft yarn specifications of 300D / 96F. These yarns were dyed using the high-temperature and high-pressure cheese dyeing method at 135°C for 60 minutes.

[0059] Warping: The dyed yarn is warped and wetted during the warping process. The warping speed is set at 400 m / min and the single yarn tension is controlled at 20 cN.

[0060] Weaving: Using a double-layer fabric loom, the yarn is woven into a double-layer fabric in a U-shaped consolidation method, and then split into a single-layer fabric with fluff.

[0061] Back glue finishing: Preparation of coating composition: A reactive coating composition is prepared, wherein the raw material components thereof are calculated by weight and include: 85 parts of the aqueous hyperbranched polyurethane-organosiloxane copolymer prepared in Preparation Example 1, 20 parts of γ-aminopropyltriethoxysilane, and 20 parts of melamine polyphosphate.

[0062] Back scraping: The above composition was applied to the back of the grey cloth obtained in step 3 by scraping, with the scraper distance set to 15 mm.

[0063] Heat setting: The coated grey fabric is heat-set at a temperature of 140°C for 90 seconds.

[0064] Comparative Example 1: Compared with Example 1, the difference is that the back-side glue coating and finishing in step 4 is changed to applying the same reactive coating composition on the front side of the single-layer grey cloth with fuzz by blade coating, and the rest are the same.

[0065] Comparative Example 2: Compared with Example 1, the difference is that the reactive coating composition prepared in step 4 does not contain γ-aminopropyltriethoxysilane, and is composed of 75 parts of aqueous hyperbranched polyurethane-organosiloxane copolymer and 13 parts of melamine polyphosphate, and the rest are the same.

[0066] Comparative Example 3: Compared with Example 1, the difference is that the heat setting treatment in step 5 is omitted, the grey cloth after the glue coating in step 4 is naturally dried at room temperature, and the rest are the same.

[0067] Comparative Example 4: Compared with Example 1, the difference is that the reactive coating composition prepared in step 4, its raw material components, calculated by weight, include: 75 parts of aqueous hyperbranched polyurethane-organosiloxane copolymer, 3 parts of γ-aminopropyltriethoxysilane, 13 parts of melamine polyphosphate, and the rest are the same.

[0068] Comparative Example 5: Compared with Example 1, the difference is that the reactive coating composition prepared in step 4 has the following raw material components, calculated by weight: 90 parts of aqueous hyperbranched polyurethane-organosiloxane copolymer, 12 parts of γ-aminopropyltriethoxysilane, and 13 parts of melamine polyphosphate, and the rest are the same.

[0069] Comparative Example 6: Compared with Example 1, the difference is that: the yarn preparation and dyeing in step 1 are not performed, and the undyed yarn is directly used in the subsequent warping and weaving processes; after completing the weaving and slitting in step 3 and before performing the back gluing in step 4, the obtained single-layer grey fabric is piece-dyed using the high-temperature and high-pressure overflow dyeing method, and the rest are the same.

[0070] Test Example 1: Test on the influence of finishing process position on suede style Purpose of the test: This test aims to quantitatively and qualitatively evaluate the significant differences between the "back finishing" process of the present invention (Example 1) and the traditional "front finishing" process (Comparative Example 1) in maintaining and improving the style of the front pile of the fabric by combining objective instrument observation with subjective sensory evaluation by professionals, thereby verifying the beneficial effects of the core innovation of the present invention.

[0071] The test samples are as follows: Sample A: a fabric prepared according to the method of Example 1.

[0072] Sample B: a fabric prepared according to the method of Comparative Example 1.

[0073] Test environment and equipment: Test environment: Constant temperature and humidity laboratory, temperature (20±2)℃, relative humidity (65±5)%. All samples were equilibrated in this environment for 24 hours before testing.

[0074] Evaluators: 5 professional technicians with more than 5 years of experience in textile sensory evaluation.

[0075] Main equipment: Standard light source color matching light box (light source: D65).

[0076] Stereo microscope (magnification: 10-50x).

[0077] High-definition digital camera.

[0078] The experimental steps are as follows: Sample preparation: Cut three 30cm x 30cm specimens from the center of each of Sample A and Sample B and number them anonymously (e.g., A1, A2, A3 and B1, B2, B3).

[0079] Macro sensory evaluation: The numbered samples were randomly arranged on the gray observation platform of the standard light source color matching light box.

[0080] Five evaluators independently observed and touched the fleece surfaces of all samples.

[0081] Evaluators are required to score the three indicators of "fluffiness", "glossiness" and "feel" according to the following standards (1-5 points, including decimals, the higher the score, the better the performance).

[0082] Fluffiness rating criteria: 1 point (severely compacted, no fluffiness), 3 points (somewhat fluffiness, but small gaps between the hairs), 5 points (very fluffiness, the hairs stand upright and the gaps are even).

[0083] Glossiness rating criteria: 1 point (dull gloss, gummy or blackish), 3 points (natural gloss, but slightly uneven), 5 points (soft and natural gloss, even and full).

[0084] Hand feel rating criteria: 1 point (stiff and rough), 3 points (acceptable, slightly stiff), 5 points (very soft, smooth, and elastic).

[0085] Collect rating sheets from all personnel.

[0086] Microscopic morphology observation and recording: Three observation points were randomly selected from each specimen.

[0087] Place the sample under a stereo microscope and adjust it to 20x magnification for observation.

[0088] Focus on observing the morphology of the villi and record whether there is any phenomenon of tangling (multiple villi stuck together into a bundle), adhesion (the roots of the villi are glued together by the glue layer) or compaction (a large area of ​​villi is covered by the glue layer to form a hard lump).

[0089] The typical form of each observation point is photographed and archived using a high-definition digital camera.

[0090] Data processing and analysis: For each sensory evaluation index of each sample, the average score of the five evaluators was calculated.

[0091] Organize the observation records of microscopic morphology and make a qualitative description of the "villous adhesion situation".

[0092] Summarize all results in a data table.

[0093] Experimental data: Table 1: Comparison of test results on the effect of finishing process position on suede style

[0094] The above test results intuitively and clearly demonstrate the crucial role of the finishing process employed in this invention in preserving the fabric's final style. The fabric produced in Example 1 exhibits exceptional bulk, a soft, natural sheen, and a smooth, supple feel due to its innovative coating method, which applies only to the backside of the fabric. This method ensures that the down fibers on the front side of the fabric never come into contact with the liquid coating composition during the entire chemical finishing process, and also avoids the direct effects of mechanical effects such as scraping. As a result, the naturally upright three-dimensional physical structure of the down, meticulously constructed during the front-end weaving and slitting steps, is preserved intact and ultimately stabilized during heat setting, resulting in an optimal wool-like appearance.

[0095] In stark contrast, the results of Comparative Example 1 reveal the inherent flaws of traditional front-facing finishing processes. When the coating composition is applied directly to the surface of the pile, the wetting effect of the liquid and the mechanical pressure of the scraper inevitably cause the pile to fall over, twist, and tangle. More critically, the subsequent heat-setting step not only fails to restore the original shape, but instead permanently "locks" this damaged, clumped and adhered state through chemical cross-linking reactions. The cured polymer forms rigid connections between the piles, which is the root cause of the pile's rough feel, dull gloss, and macroscopic loss of fluffiness.

[0096] By limiting the functional coating finish to the backside of the fabric, this invention cleverly decouples the dual objectives of enhancing physical properties from maintaining aesthetic appeal. This involves more than simply changing the finishing location; rather, it incorporates a systematic process design approach, ensuring that the strengthening effect of the back-end chemical consolidation is precisely applied to the pile roots and base fabric structure, while the superior suede finish achieved by the front-end physical shaping is perfectly presented. This approach fundamentally addresses the technical challenges of traditional processes in balancing performance and appearance, and is key to achieving high-performance wool-like fabrics.

[0097] Test Example 2: Testing of the integrity of reactive coating systems on the fastness of pile fixation Purpose of the test: This test is designed to verify the integrity of the "reactive coating system" in the present invention - that is, the synergistic chemical reaction between the main polymer and the crosslinker under heat setting conditions - which is critical for achieving high hair fastness by quantitatively measuring the pull-out force of a single hair.

[0098] The test samples are as follows: Sample A: Fabric prepared according to the method of Example 1 (with a complete reaction system).

[0099] Sample C: a fabric prepared according to the method of Comparative Example 2 (lacking a cross-linking agent).

[0100] Sample D: a fabric prepared according to the method of Comparative Example 3 (without heat setting and curing).

[0101] Test environment and equipment: Test environment: Constant temperature and humidity laboratory, temperature (20±2)℃, relative humidity (65±5)%. All samples were equilibrated in this environment for 24 hours before testing.

[0102] Main equipment: Electronic single yarn strength tester (model: YG020, range: 0-500cN, accuracy: 0.01cN).

[0103] Special lint clamps (the upper clamp is a micro tweezers clamp, and the lower clamp is a platform to fix the fabric).

[0104] Stereo microscope.

[0105] The experimental steps are as follows: Sample preparation: Cut out specimens of 10 cm x 10 cm from samples A, C, and D respectively.

[0106] Fix the sample flatly on the lower clamp platform of the electronic single yarn strength tester with the pile side facing up.

[0107] Test operation: With the help of a stereo microscope, a single villus with good growth condition and no obvious tilt was randomly selected from the central area of ​​the specimen.

[0108] Use micro forceps (upper grip) to carefully grasp the tip of the villus, ensuring a firm grip without damaging the villus.

[0109] Set the tensile speed of the tensile testing machine to 20 mm / min.

[0110] Start the instrument and stretch the upper clamp upward vertically at a constant speed until the hair is completely pulled out from the base cloth.

[0111] The instrument automatically records and displays the peak force value during this process, which is the consolidation strength of the hair (unit: centinewon, cN).

[0112] Move the sample position and repeat the above operation.

[0113] Data collection and processing: For each sample (A, C, D), 50 independent single hair pull-out force tests were performed.

[0114] Eliminate invalid data caused by clamping slippage or hair breaking during the test.

[0115] Calculate the average value of the valid test data for each sample as the average pile fastness of the sample.

[0116] All valid data points were recorded for subsequent analysis.

[0117] Experimental data: Table 2: Test results of the effects of different coating systems on the fastness of pile fixation

[0118] The test data in Table 2 strongly reveal the underlying mechanism of the present method in achieving high fuzz fastness. The fundamental reason for the extremely high individual fuzz fastness achieved in Example 1 lies in a synergistic chemical reaction activated by heat on the backside of the fabric. Under the high-temperature conditions of heat setting, the main polymer and the crosslinker (γ-aminopropyltriethoxysilane) undergo a highly efficient crosslinking reaction. Simultaneously, the siloxane groups of the crosslinker hydrolyze and condense, forming a dense, tough, three-dimensional interpenetrating network in situ between the fuzz roots and the base fabric yarns. This chemical network acts like microscopic "cement," firmly anchoring the roots of each fuzz to the base fabric structure, thereby providing strong pull-out resistance.

[0119] The results of Comparative Example 2 clearly demonstrate the indispensable role of a crosslinker in the above system. In the absence of a crosslinker, even after the same heat-setting treatment, the main polymer merely forms a physical, uncrosslinked film on the back of the fabric. The bonding between this film and the fibers stems primarily from weak physical adsorption, such as van der Waals forces, rather than strong chemical bonding. Consequently, its ability to bind the fuzz is significantly reduced, resulting in a bond strength far lower than that of Example 1. This clearly demonstrates that chemical crosslinking is the key to achieving high bond strength.

[0120] Furthermore, the results of Comparative Example 3 highlight the dual mechanism of action of the heat-setting step. When heat-setting is omitted, the fuzz solidification strength is minimized, demonstrating that even if all chemical components are present, chemical crosslinking cannot occur without sufficient thermal energy to activate the reaction. The coating composition dries onto the back of the fabric as a mere physical mixture, producing virtually no effective solidification. Therefore, the heat-setting step in this invention not only physically sets the fabric but also serves as a key switch for triggering the chemical solidification reaction on the back surface, ensuring the entire reactive coating system transitions from a "mixture" to a "high-performance network structure."

[0121] Test Example 3: Test on the influence of coating composition ratio on comprehensive performance Purpose of the test: This test aims to demonstrate the rationality and superiority of the coating composition ratio range described in the present invention through a comprehensive evaluation of the fuzz fastness and overall fabric softness. Specifically, it verifies the negative impact of too low a crosslinker dosage or too high a main polymer dosage on the final product performance.

[0122] The test samples are as follows: Sample A: Fabric prepared according to the method of Example 1 (the ratio is within the preferred range).

[0123] Sample E: a fabric prepared according to the method of Comparative Example 4 (the amount of cross-linking agent used is lower than the lower limit).

[0124] Sample F: a fabric prepared according to the method of Comparative Example 5 (the amount of the main polymer is higher than the upper limit).

[0125] Test environment and equipment: Test environment: Constant temperature and humidity laboratory, temperature (20±2)℃, relative humidity (65±5)%. All samples were equilibrated in this environment for 24 hours before testing.

[0126] Main equipment and personnel: Electronic single yarn strength tester (model: YG020, range: 0-500cN).

[0127] Digital fabric stiffness meter (Handle-O-Meter).

[0128] 5 professional technicians with more than 5 years of experience in textile sensory evaluation.

[0129] The experimental steps are as follows: Sample preparation: Several specimens were cut from samples A, E, and F for different tests.

[0130] The specimen size for the pile fastness test is 10 cm x 10 cm.

[0131] The size of the specimen used for fabric stiffness test is 20cm x 20cm, and 3 pieces are prepared for each sample.

[0132] Fluff fastness test: The operation method of this test is exactly the same as the steps in Test Example 2.

[0133] Each sample (A, E, F) was tested for 50 independent single-hair pullout force tests.

[0134] Calculate the average of the valid test data for each sample and record it as the average pile fastness.

[0135] Fabric stiffness test: A digital fabric stiffness tester was used and the test slit width was set to 10 mm.

[0136] A 20cm x 20cm sample is pushed into the test slit along the warp and weft directions respectively. The instrument records the force resisting bending, which is the stiffness value (unit: mN). The higher the value, the stiffer the fabric.

[0137] For each specimen, the warp and weft directions were tested 3 times each, and the total average value of the warp and weft stiffness of the sample was calculated.

[0138] Sensory flexibility evaluation: Samples A, E, and F were randomly numbered and distributed to 5 evaluators.

[0139] Evaluators independently fold, bend, and rub the samples repeatedly, focusing on evaluating the overall flexibility of the fabric and the feel of the backing layer.

[0140] Rate the "touch and feel" according to the following criteria (1-5 points, with higher scores representing better performance): Rating criteria: 1 point (very stiff, the backing feels noticeably brittle or cracks when bent), 3 points (average flexibility, the backing feels slightly stiff), 5 points (very soft and elastic, the backing is integrated with the surface layer, and there is no discomfort).

[0141] Collect the rating sheets of all personnel and calculate the average score for each sample.

[0142] Experimental data: Table 3: Test results of the effects of different coating ratios on the comprehensive properties of fabrics

[0143] The test results in Table 3 profoundly reveal the importance of precise ratios between the components of the coating composition of the present invention, as well as the inherent connection between this ratio and the overall performance of the final product. The mechanism by which Example 1 achieves both excellent fuzz fastness and exceptional hand-tenderness lies in its ratio striking a critical balance. At this ratio, the amount of crosslinker is sufficient to fully chemically crosslink with the reactive sites of the main polymer, forming a strong and resilient three-dimensional network that effectively anchors the fuzz. Simultaneously, the total amount of polymer is just right, preventing the backing layer formed after curing from being excessively thick, thereby preserving the overall softness of the fabric.

[0144] The results of Comparative Example 4 clearly demonstrate that when the crosslinker dosage is insufficient, even with a moderate amount of the main polymer, an effective crosslinked network cannot be established. The mechanism is that the low crosslinking density results in a loose and weak polymer network, significantly weakening its ability to wrap and anchor the fluff fibers. This is directly reflected in a sharp drop in the fluff's anchoring strength. Although the stiffness value is low, this is not due to excellent flexibility, but rather to the backing layer's failure to form an effective support structure, as evidenced by its low hand feel score.

[0145] In contrast, the results of Comparative Example 5 show the other extreme. When the main polymer dosage is too high, although a network of sufficient strength can be formed to maintain a high degree of hair consolidation, the cost is a serious deterioration in the overall performance of the fabric. The mechanism is that the excessive film-forming substance forms an overly thick, overly hard rigid coating on the back of the fabric. This coating greatly restricts the free space for the fabric fibers to move, resulting in a sharp increase in the stiffness value, and the fabric loses the softness and comfortable touch that it should have as a sofa fabric. Therefore, the present invention ensures that while providing a strong hair-fixing ability, it also perfectly takes into account the flexibility of the fabric and a high-end sensory experience.

[0146] Test Example 4: Test on the Effect of Dyeing Process on the Final Suede Quality Purpose of the test: This test aims to verify the superiority of the "cheese pre-dyeing" process, which places the dyeing process before weaving, in protecting and presenting the final fabric suede quality compared to the traditional "piece dyeing" process through a combination of macroscopic sensory evaluation and objective instrumental measurement.

[0147] The test samples are as follows: Sample A: Fabric prepared according to the method of Example 1 (pre-dyed cheese yarn).

[0148] Sample H: a fabric prepared according to the method of Comparative Example 6 (post-dyed by piece dyeing).

[0149] Comparative Example 6 is not numbered in the document. This is a logical continuation and can be named sequentially in actual writing. For clarity, it is referred to as Sample H here.

[0150] Test environment and equipment: Test environment: Constant temperature and humidity laboratory, temperature (20±2)℃, relative humidity (65±5)%. All samples were equilibrated in this environment for 24 hours before testing.

[0151] Main equipment and personnel: Standard light source color matching light box (light source: D65).

[0152] Digital fabric pile height measuring instrument (accuracy: 0.01mm).

[0153] Stereo microscope (magnification: 10-50x).

[0154] 5 professional technicians with more than 5 years of experience in textile sensory evaluation.

[0155] The experimental steps are as follows: Sample preparation: Three 30cm x 30cm specimens were cut from the center of each of Sample A and Sample H and numbered anonymously.

[0156] Villus height and uniformity test: Use a digital fabric pile height meter.

[0157] 20 different test points were randomly selected on each sample and their pile height was measured.

[0158] Record all data and calculate the average villus height and standard deviation of villus height for each sample. The standard deviation is used to quantify the uniformity of villus height, with smaller values ​​indicating better uniformity.

[0159] Sensory evaluation of suede quality: Arrange the numbered samples randomly in a standard light source color matching light box.

[0160] Five evaluators independently observed and touched the fleece surfaces of all samples.

[0161] Evaluators are required to score the two indicators of "suede smoothness" and "style fullness" according to the following standards (1-5 points, the higher the score, the better the performance).

[0162] Scoring criteria for pile smoothness: 1 point (severe lodging and tangling), 3 points (slight lodging, basically smooth), 5 points (very smooth, pile is upright and uniform).

[0163] Scoring criteria for style fullness: 1 point (thin style, no three-dimensional sense), 3 points (some fullness), 5 points (very full and rich style, with strong three-dimensional sense).

[0164] Collect the scoring sheets of all personnel and calculate the average score of each indicator for each sample.

[0165] Microscopic morphology observation: Place the sample under a stereo microscope and adjust it to 20x magnification for observation.

[0166] Focus on observing and recording the arrangement of the villi fibers, whether there are large areas of lodging, entanglement or distortion, and take photos of typical areas.

[0167] Experimental data: Table 4: Test results of the effects of different dyeing processes on the final suede quality

[0168] The test data in Table 4 clearly demonstrates the advanced nature of the present invention's pre-dyeing process. The high average pile height, excellent uniformity, and superior sensory scores achieved in Example 1 are fundamentally due to the use of a cheese pre-dyeing process. This design allows the velvet fabric, which already has a precise three-dimensional structure, to completely avoid the impact of high temperature, high humidity, and intense mechanical forces in the subsequent piece-dyeing process. As a result, the physical form of the pile, meticulously constructed during the weaving and slitting stages, is fully preserved, and its original height, uprightness, and uniformity remain intact, laying a solid foundation for the ultimate presentation of a smooth, rich, high-quality velvet style.

[0169] In contrast, the results of Comparative Example 6 reveal the inherent flaws of the traditional piece-dyeing process. When the undyed grey fabric is placed in the dyeing machine for post-dyeing, its hair undergoes prolonged immersion in the high-temperature dye liquor, as well as repeated mechanical rubbing and scouring caused by the dye liquor circulation. The destructive mechanism of this process is that it causes the polyester hair to irreversibly fall over, tangle, and deform, fundamentally destroying the three-dimensional structure of the fabric surface. This directly leads to a significant reduction in the hair height and extremely uneven texture, resulting in a flat, messy appearance that lacks the desired wool-like texture.

[0170] In summary, the innovative process of this invention embodies a systematic approach to structural preservation. By relocating the wet heat treatment (dyeing), which has the greatest impact on fiber structure, to before weaving, it ensures that all subsequent steps protect and optimize the already-formed suede structure. This approach mechanically mitigates the risk of damage to the suede's appearance during post-finishing, ensuring that the excellent physical form imparted by the front-end process is intactly transferred to the final product. This is the key to achieving the technical effect of a smooth, rich suede surface.

[0171] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A wool-like polyester sofa fabric, characterized in that: include: The fleece layer is made of polyester stretched textured yarn dyed under high temperature and high pressure; The base fabric layer is made of warp yarn and weft yarn interwoven together; The functional backing layer is attached to the back of the base fabric layer and is formed by a curing reaction. The functional backing layer is formed by curing the following raw materials in parts by weight: Main polymer: 60-85 parts; Cross-linking agent: 5-20 parts; Environmentally friendly flame retardant containing phosphorus and / or nitrogen: 5-20 parts.

2. The wool-like polyester sofa fabric according to claim 1, characterized in that: The main polymer in the functional backing layer is a hyperbranched polyurethane-organic siloxane copolymer.

3. The wool-like polyester sofa fabric according to claim 1, characterized in that: The crosslinking agent in the functional backing layer is an aminosilane coupling agent.

4. The wool-like polyester sofa fabric according to claim 1, characterized in that: The function of the functional backing layer is to consolidate the pile warp yarns in the pile layer.

5. A method for producing a wool-like polyester sofa fabric according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1: Yarn preparation and dyeing: polyester stretch textured yarn is selected as pile warp yarn, ground warp yarn and weft yarn, and the yarn is dyed using a high temperature and high pressure cheese yarn dyeing method; S2: warping: warping the dyed yarn, wherein the warping step includes wetting the yarn with water to eliminate static electricity; S3: Weaving: Using a double-layer fabric loom, the pile warp yarn, the ground warp yarn and the weft yarn are woven into a double-layer grey cloth, which is then split to form a single-layer grey cloth with pile; S4: backside glue coating and finishing: applying a layer of reactive organic-inorganic hybrid coating composition on the back side of the single-layer grey fabric by blade coating; S5: Heat setting: The coated grey fabric is heat-set to solidify the coating composition and fix the shape of the pile.

6. The method for producing a wool-like polyester sofa fabric according to claim 5, characterized in that: The polyester stretched textured yarn in step S1 is a DTY heavy mesh; the specifications of the pile warp yarn are 450D / 144F, and the specifications of the ground warp yarn and weft yarn are 300D / 96F.

7. The method for producing a wool-like polyester sofa fabric according to claim 5, characterized in that: The weaving in step S3 adopts a V-type, W-type or U-type consolidation method.

8. The method for producing a wool-like polyester sofa fabric according to claim 5, characterized in that: The scraper distance of the scraper coating method in step S4 is 8-15 mm.

9. The method for producing a wool-like polyester sofa fabric according to claim 5, characterized in that: The heat setting temperature in step S5 is 110-140°C.

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