Cotton-like high-durability full-polyester fabric and preparation method thereof

Abstract

The invention belongs to the technical field of textile materials, and discloses a cotton-like high-durability full-polyester fabric and a preparation method thereof.The cotton-like high-durability full-polyester fabric is formed by alternately weaving polyester fibers and white graphene fibers, the fabric adopts a parallel weaving technology that the white graphene fibers and the polyester fibers are blended, and the graphene component accounts for about 1-3% by weight; uniform distribution is achieved through a blending weaving technology, the composite fabric with lasting antistatic performance is formed, and the surface resistivity of the composite fabric is stabilized within the range of 106-108 ohms; the white graphene fiber is prepared by an independent spinning process. The conductive network is constructed through a parallel weaving process, so that the surface resistivity is stabilized within the range of 106-108 ohms. After 50 times of washing, the retention rate of a conductive path is 90% or above, the problems that a traditional conductive wire or coating is poor in treatment durability and prone to attenuation are thoroughly solved, electrostatic dust adsorption and body feeling discomfort are effectively avoided, and the user experience is remarkably improved.

Description

Technical Field

[0001] The invention belongs to the technical field of textile materials, and in particular relates to a cotton-like, highly durable, all-polyester fabric and a preparation method thereof. Background Art

[0002] Polyester fabric is a popular synthetic fiber fabric. It is made of polyester fiber as the base material through a precise textile process. Its biggest advantage is its excellent wrinkle resistance and shape retention. Therefore, it is suitable for processing bedding, etc.

[0003] Polyester fiber (polyester) is widely used in hotel linens due to its low cost, high strength, and easy care. However, traditional polyester fabrics have the following issues: Polyester fibers easily accumulate static electricity, which leads to dust absorption, discomfort, and a negative impact on the user experience. Currently, the industry mostly uses conductive yarn or antistatic coatings, but these suffer from poor durability and rapid degradation. Polyester fibers have a smooth, plastic-like surface and lack the skin-friendly and comfortable feel of cotton fabrics. While the sanding process improves tactile feel, it can also lead to fiber damage, high lint loss, and pilling, reducing fabric durability. Therefore, improvements are needed. Summary of the Invention

[0004] The object of the present invention is to provide a highly durable cotton-like all-polyester fabric and a preparation method thereof, so as to solve the problems raised in the above-mentioned background technology.

[0005] In order to achieve the above-mentioned objectives, the present invention provides the following technical solutions: a cotton-like, highly durable, all-polyester fabric, which is composed of a blend of polyester fibers and white graphene fibers. The fabric adopts a parallel weaving process of blending white graphene fibers and polyester fibers. The graphene component accounts for approximately 1 to 3% by weight and is evenly distributed through the blending weaving technology to form a composite fabric with long-lasting antistatic properties. Its surface resistivity is stable in the range of 10^6 to 10^8Ω.

[0006] Preferably, the white graphene masterbatch adopts a special surface treatment technology to make the graphene nanosheets uniformly dispersed in the polyester matrix, the whiteness of the fabric reaches above AATCC standard 110, and the whiteness decreases by no more than 5% after 100 washings.

[0007] Preferably, the polyester fiber yarn is subjected to physical friction modification treatment, and a specially designed ceramic friction device is used to controllably rub the fiber surface during the spinning process, so that fine hairs of 0.5-2 μm and irregular curl structures of 3-5 per mm are formed on the surface.

[0008] Preferably, the physical friction modification treatment adopts a multi-stage progressive friction process, the friction pressure is controlled at 0.2~0.5MPa, and the processing speed is 300~500m / min, so that the fabric hair loss rate is reduced to below 0.5% and the pilling level is increased by more than 1.5 levels.

[0009] Preferably, a 2 / 1 twill weave structure is adopted, the warp density is 100-120 strands / inch, the weft density is 80-90 strands / inch, the square meter weight is controlled within the range of 125-135gsm, the warp shrinkage rate is ≤2%, and the weft shrinkage rate is ≤1.5%.

[0010] Preferably, the warp breaking strength is ≥749N, the weft breaking strength is ≥815N, the tearing strength is ≥45N in the warp direction and ≥50N in the weft direction, and the wear resistance reaches more than 5000 times.

[0011] Preferably, the pilling performance reaches level 4 to 5 (GB / T 4802.1-2008), the ironing-free performance reaches level 4 or above (AATCC 124), and the wrinkle recovery angle is ≥280°.

[0012] Preferably, the steps include: S1. Prepare polyester fiber and white graphene fiber respectively: Polyester fiber: Polyester chips with an intrinsic viscosity of 0.65-0.70 are melt-spun at 260-280°C and a spinning speed of 2800-3200 m / min; White graphene fiber: Graphene masterbatch is made into continuous fiber through an independent spinning process; After the polyester fiber and white graphene fiber are spun separately, they are prepared for weaving through a dual-channel winding system; S2, using a double-jet water jet loom, feeding white graphene fiber and polyester fiber alternately in a 1:1 ratio in the weft direction, with a warp tension of 25-30 cN and a weft tension of 15-20 cN, weaving a 2 / 1 twill weave; S3, the finishing adopts low temperature setting process (160~170℃, 30~40 seconds), and the final weight is 125~135gsm.

[0013] The beneficial effects of the present invention are as follows: 1. The conductive network constructed by the double-spray blending process in this invention stabilizes the surface resistivity within the range of 10^6~10^8Ω. After 50 washes, the conductive path retention rate exceeds 90%, which completely solves the problems of poor durability and easy attenuation of traditional conductive yarn or coating treatments, effectively avoids static dust absorption and physical discomfort, and significantly improves the user experience. 2. This invention utilizes a physical friction modification process, applying precisely controlled, multi-stage friction treatment to the fiber surface during the spinning stage, creating fine hairs of 0.5-2 μm and irregular curls of 3-5 per mm, perfectly simulating the surface morphology of cotton fibers. This process completely replaces the traditional finishing sanding process, not only imparting the soft, skin-friendly feel of natural cotton fabrics, but also avoiding the problems of fiber damage, high hair loss, and pilling caused by the sanding process. 3. By optimizing the fabric structure, utilizing a 2 / 1 twill weave and high-weight technology, this invention achieves a warp breaking strength of ≥749N and a weft breaking strength of ≥815N. Both tear strength and abrasion resistance far exceed industry standards. Combined with the physical modification process that protects fiber strength, the fabric maintains excellent physical properties even after frequent machine washing and long-term use, significantly extending the service life of hotel linens. 4. This invention uses a unique low-temperature setting process to impart excellent dimensional stability and wrinkle recovery to fabrics, achieving "dry-ready" quality and saving over 30% in ironing energy. A specially formulated white graphene masterbatch ensures fabric whiteness reaches AATCC grade 110 or higher, with a whiteness loss of no more than 5% after 100 washes, effectively resolving the graying problem associated with conventional gray graphene. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a schematic diagram of the preparation process of the present invention. DETAILED DESCRIPTION

[0015] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. 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.

[0016] Example 1 An embodiment of the present invention provides a cotton-like, highly durable, all-polyester fabric, which is woven from a blend of polyester fibers and white graphene fibers. The fabric adopts a parallel weaving process of blending white graphene fibers and polyester fibers. The graphene component accounts for approximately 1 to 3% by weight and is evenly distributed through the blending weaving technology to form a composite fabric with long-lasting antistatic properties. Its surface resistivity is stable in the range of 10^6 to 10^8Ω.

[0017] The three-dimensional conductive network structure formed through double-spray blending fundamentally solves the static electricity problem of polyester. Compared with traditional surface coatings or conductive yarn blends, this technology provides long-lasting and stable antistatic performance. After 50 washes, the resistivity remains above 90%, significantly extending the service life of the fabric while avoiding performance degradation caused by the loss of conductive components.

[0018] Example 2 The white graphene masterbatch adopts special surface treatment technology to make the graphene nanosheets evenly dispersed in the polyester matrix. The whiteness of the fabric reaches above AATCC standard level 110, and the whiteness decreases by no more than 5% after 100 washes.

[0019] Among them, the innovative development of white graphene masterbatch overcomes the technical bottleneck of traditional gray graphene, which causes fabrics to turn gray. Through surface modification, nanoscale dispersion is ensured, maintaining the graphene's conductive properties while meeting the stringent whiteness requirements of hotel linens. The whiteness stability after washing is improved by over 40% compared to conventional products.

[0020] Example 3 The polyester fiber yarn is subjected to physical friction modification treatment, and a specially designed ceramic friction device is used to controllably rub the fiber surface during the spinning process, so that fine hairs of 0.5 to 2 μm and irregular curl structures of 3 to 5 per mm are formed on the surface.

[0021] Among them, this physical modification process constructs a cotton-like surface structure during the fiber forming stage. Compared with the post-finishing sanding process, it reduces fiber damage by 60% and controls the hair loss rate below 0.5%. At the same time, it makes the fabric have a contact warmth and moisture absorption and breathability similar to cotton fibers, achieving a perfect combination of "cotton feel" and "polyester performance".

[0022] Example 4 The physical friction modification treatment adopts a multi-stage progressive friction process, the friction pressure is controlled at 0.2-0.5 MPa, and the processing speed is 300-500 m / min, so that the fabric hair loss rate is reduced to below 0.5% and the pilling level is improved by more than 1.5 levels.

[0023] Among them, the innovative multi-level progressive friction system realizes precise control of the fiber surface structure. By optimizing the process parameters, while ensuring the cotton-like effect, the pilling level is increased to level 4~5 (GB / T 4802.1), far exceeding the industry standard, so that the fabric still maintains excellent appearance after long-term use.

[0024] Example 5 It adopts a 2 / 1 twill weave structure, with a warp density of 100~120 threads / inch and a weft density of 80~90 threads / inch. The grammage per square meter is controlled within the range of 125~135gsm, the warp shrinkage rate is ≤2%, and the weft shrinkage rate is ≤1.5%.

[0025] Among them, through innovative organizational structure design and high-weight technology, the breaking strength of the fabric is increased to 2~3 times that of traditional products (warp ≥749N), while the shrinkage rate is controlled at an extremely low level, ensuring dimensional stability in the hotel's frequent washing environment, significantly reducing the frequency of linen replacement and operating costs.

[0026] Example 6 The warp breaking strength is ≥749N, the weft breaking strength is ≥815N, the tearing strength is ≥45N in the warp direction, ≥50N in the weft direction, and the wear resistance reaches more than 5000 times.

[0027] The defined combination of mechanical properties gives the fabric exceptional durability, making it particularly suitable for the high-intensity use environments of hotels. Tested data shows that its service life is over three times that of ordinary polyester fabrics, significantly reducing hotel linen procurement costs.

[0028] Example 7 The pilling performance reaches level 4 to 5 (GB / T 4802.1~2008), the ironing-free performance reaches level 4 or above (AATCC 124), and the wrinkle recovery angle is ≥280°.

[0029] Among them, through comprehensive performance optimization, the effect of "perfect when used" is achieved: the pilling performance reaches the top level in the industry, the ironing-free feature that can be used right out of the oven can save more than 30% of ironing energy consumption, and the wrinkle recovery angle index ensures that the linens always maintain a crisp appearance, significantly improving the quality of hotel services.

[0030] Example 8 The following steps are involved: S1. Prepare polyester fiber and white graphene fiber respectively: Polyester fiber: Polyester chips with an intrinsic viscosity of 0.65-0.70 are melt-spun at 260-280°C and a spinning speed of 2800-3200 m / min; White graphene fiber: Graphene masterbatch is made into continuous fiber through an independent spinning process; After the polyester fiber and white graphene fiber are spun separately, they are prepared for weaving through a dual-channel winding system; S2, using a double-jet water jet loom, feeding white graphene fiber and polyester fiber alternately in a 1:1 ratio in the weft direction, with a warp tension of 25-30 cN and a weft tension of 15-20 cN, weaving a 2 / 1 twill weave; S3, the finishing adopts low temperature setting process (160~170℃, 30~40 seconds), and the final weight is 125~135gsm.

[0031] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0032] 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 highly durable cotton-like polyester fabric, characterized by: The all-polyester fabric is composed of polyester fibers and white graphene fibers woven alternately. The fabric adopts a parallel weaving process of blending white graphene fibers and polyester fibers. The graphene component accounts for approximately 1 to 3% by weight and is evenly distributed through blending weaving technology to form a composite fabric with long-lasting antistatic properties. Its surface resistivity is stable in the range of 10^6 to 10^8Ω.

2. The cotton-like, highly durable, all-polyester fabric according to claim 1, characterized in that: The white graphene fiber is prepared through an independent spinning process, has a fiber diameter of 50-200 nm, and the whiteness of the fabric reaches above AATCC standard level 110.

3. The cotton-like, highly durable, all-polyester fabric according to claim 2, characterized in that: The polyester fiber yarn is subjected to physical friction modification treatment, and a specially designed ceramic friction device is used to controllably rub the fiber surface during the spinning process, so that fine hairs of 0.5 to 2 μm and irregular curl structures of 3 to 5 per mm are formed on the surface.

4. The cotton-like, highly durable, all-polyester fabric according to claim 3, characterized in that: The physical friction modification treatment adopts a multi-stage progressive friction process, the friction pressure is controlled at 0.2-0.5 MPa, and the processing speed is 300-500 m / min, so that the fabric hair loss rate is reduced to below 0.5% and the pilling level is improved by more than 1.5 levels.

5. The cotton-like, highly durable, all-polyester fabric according to claim 4, characterized in that: It adopts a 2 / 1 twill weave structure, with a warp density of 100~120 threads / inch and a weft density of 80~90 threads / inch. The grammage per square meter is controlled within the range of 125~135gsm, the warp shrinkage rate is ≤2%, and the weft shrinkage rate is ≤1.5%.

6. The cotton-like, highly durable, all-polyester fabric according to claim 5, characterized in that: The warp breaking strength is ≥749N, the weft breaking strength is ≥815N, the tearing strength is ≥45N in the warp direction, ≥50N in the weft direction, and the wear resistance reaches more than 5000 times.

7. The cotton-like, highly durable, all-polyester fabric according to claim 6, characterized in that: The pilling performance reaches level 4 to 5 (GB / T 4802.1~2008), the ironing-free performance reaches level 4 or above (AATCC 124), and the wrinkle recovery angle is ≥280°.

8. The cotton-like, highly durable, all-polyester fabric and its preparation method according to claim 7, characterized in that: The following steps are involved: S1. Prepare polyester fiber and white graphene fiber respectively: Polyester fiber: Polyester chips with an intrinsic viscosity of 0.65-0.70 are melt-spun at 260-280°C and a spinning speed of 2800-3200 m / min; White graphene fiber: Graphene masterbatch is made into continuous fiber through an independent spinning process; After the polyester fiber and white graphene fiber are spun separately, they are prepared for weaving through a dual-channel winding system; S2, using a double-jet water jet loom, feeding white graphene fiber and polyester fiber alternately in a 1:1 ratio in the weft direction, with a warp tension of 25-30 cN and a weft tension of 15-20 cN, weaving a 2 / 1 twill weave; S3, the finishing adopts low temperature setting process (160~170℃, 30~40 seconds), and the final weight is 125~135gsm.

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