Unidirectional moisture-conducting fabric and production process thereof

Abstract

The invention discloses a one-way moisture-conducting fabric and a production process thereof. The fabric comprises a surface layer and an inner layer which are formed by knitting first yarns, second yarns and third yarns in the form of minimum circulation units, and a plurality of single-layer double-sided weft knitting tissue parts which are connected with the surface layer and the inner layer and enable a plurality of through transverse / longitudinal cavities to be formed between the surface layer and the inner layer, the minimum circulation unit comprises a surface layer plain stitch formed by weaving first yarns, an inner layer plain stitch formed by weaving third yarns, and a single-layer double-sided weft knitting stitch which is formed by looping second yarns at intervals of upper needles and continuously looping lower needles and is respectively connected with the surface layer plain stitch and the inner layer plain stitch, wherein the single-layer double-sided weft knitting stitch is formed by looping the second yarns at intervals of the upper needles and the lower needles; one of the first yarn and the second yarn is PBT / PET composite stretch yarn or elastic polyester yarn, the other one of the first yarn and the second yarn is special-shaped section polyester yarn or non-elastic polyester yarn, and the third yarn is polypropylene yarn. The process is simple, the gram weight of the fabric is effectively reduced on the premise of guaranteeing the one-way moisture conduction performance, and the snagging resistance and the pilling resistance of the fabric are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of knitted fabrics, in particular to a one-way moisture-conducting fabric and a production process thereof. Background Art

[0002] As a functional textile, the core technology of unidirectional moisture-conducting fabrics lies in achieving unidirectional transfer of sweat from the skin surface to the outside world through fabric structural design. Existing processes mainly create a wetting gradient through differentiated fiber arrangement or surface modification, so that the inner layer of hydrophilic fibers quickly absorbs sweat, while the outer layer of hydrophobic fibers promotes evaporation and diffusion. However, when fabrics develop towards lightweighting, the reduction in fiber density leads to insufficient structural support, which is manifested in a significant decrease in anti-snagging performance. Small fibers are more easily snagged by external forces. At the same time, the weakening of the cohesion between fibers makes the fabric more prone to pilling during friction, seriously affecting the appearance of the fabric. This contradiction between reduced weight and reduced mechanical properties has restricted the application of unidirectional moisture-conducting fabrics in high-end sportswear. Summary of the Invention

[0003] In view of the above problems, the purpose of the present invention is to provide a one-way moisture-conducting fabric and a production process thereof, so as to solve the problem that traditional one-way moisture-conducting fabrics are difficult to achieve both lightweight and anti-snagging and pilling performance.

[0004] In order to achieve the above-mentioned purpose, the technical solution proposed by the present invention is: A one-way moisture-conducting fabric, which includes a surface layer, an inner layer, and several single-layer double-sided weft-knitted tissue parts connecting the surface layer and the inner layer, which are knitted in a minimum cycle unit by a first yarn, a second yarn, and a third yarn. The single-layer double-sided weft-knitted tissue parts form a plurality of through transverse cavities and longitudinal cavities between the surface layer and the inner layer through the single-layer double-sided weft-knitted tissue parts. The minimum cycle unit includes: a surface layer plain needle tissue formed by knitting the surface layer with the first yarn below the needle into loops, an inner layer plain needle tissue formed by knitting the inner layer with the third yarn above the needle into loops, and a single-layer double-sided weft-knitted tissue part formed by knitting the second yarn above the needle into loops every other needle and the lower needle part into continuous loops. The single-layer double-sided weft-knitted tissue is respectively connected with the surface layer plain needle tissue and the inner layer plain needle tissue. One of the first yarn and the second yarn is PBT / PET composite stretch yarn or elastic polyester yarn, and the other is a polyester yarn with a special cross-section or a non-elastic polyester yarn. The third yarn is polypropylene yarn.

[0005] Preferably, the specification of the PBT / PET composite stretch yarn is 30D-50D, the specification of the special-section polyester yarn is 30D-50D, the specification of the polypropylene yarn is 35D-50D, the specification of the elastic polyester yarn is 45D-50D, and the specification of the non-elastic polyester is 30D-35D.

[0006] Preferably, the weight ratio of the first yarn, the second yarn and the third yarn is: 40%-47%: 11%-27%: 33%-42%.

[0007] Preferably, it further comprises conductive yarn, and at least a portion of the inner layer plain stitch is woven together with the third yarn and the conductive yarn.

[0008] Preferably, the single-layer double-sided weft knitted structure includes a first weaving path and a second weaving path arranged alternately; the first weaving path and the second weaving path are both configured so that the upper needle forms a loop every other needle and the lower needle has at least three consecutive loops, and the upper needle loop positions of the first weaving path and the second weaving path are complementary.

[0009] Preferably, the minimum cycle unit is composed of 14 stitches and 12 stitches, with 21 steps as a complete cycle, wherein: The 1st to 4th routes are all knitted with the second yarn; the odd-numbered needles of the 1st and 3rd routes are not knitted and the even-numbered needles are knitted into loops; the odd-numbered needles of the 2nd and 4th routes are all knitted into loops and the even-numbered needles are not knitted; the 1st to 9th needles of the 1st to 4th routes are not knitted and the 10th to 12th needles are knitted into loops; The 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th and 21st routes are all knitted with the first yarn, and all the lower needles are looped; The 6th, 8th, 10th, 12th, 14th, 16th, 18th and 20th stitches are all knitted with the third yarn, and all the upper needles are looped.

[0010] A production process for a one-way moisture-conducting fabric, characterized by comprising the following steps: S1. Prepare the required first yarn, second yarn and third yarn; S2, using a multi-needle double-sided circular knitting machine to weave a unidirectional moisture-conducting fabric; S3, Refining Scouring the grey fabric at 35-40℃ with a bath ratio of 1:8-1:10; S4, dyeing Add dispersing and leveling agent and chelating agent to water, heat it to 40-50℃, add dye, then heat it to 130℃ at a rate of 1.5℃ / min and keep it at that temperature for 40min, then cool it to 50-60℃ at a rate of 2℃ / min; S5. Finalization The dyed grey cloth is sent to the setting machine for setting. The temperature of the setting machine is set to 130±5℃, the overfeed amount is set to 3±0.5%, and the speed is set to 20±1m / min. During the setting process, the moisture-absorbing and perspiration-releasing finishing agent is evenly applied to the grey cloth through the padding device. After hot air drying, the setting is completed and the cloth is finally cooled and dropped.

[0011] Preferably, the minimum circulation unit of the one-way moisture-conducting fabric in step S2 has 21 routes, and each route is knitted with 14 upper needles and 12 lower needles; The needle arrangement mode of the needle dial and needle cylinder is rib-to-needle. The needle arrangement order of the needle dial is 12121212121212, and the needle arrangement order of the needle cylinder is 212121212333, among which 1, 2, and 3 correspond to needle lane 1, needle lane 2, and needle lane 3 respectively; The threading method of the 21 routes of the minimum cycle unit is: the second yarn is threaded on the 1st, 2nd, 3rd and 4th routes, the first yarn is threaded on the 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th and 21st routes, and the third yarn is threaded on the 6th, 8th, 10th, 12th, 14th, 16th, 18th and 20th routes; The 21-way triangle configuration of the minimum circulation unit is as follows: needle 1 of the 1st and 3rd needle dials does not work, and needle 2 forms a circle accordingly, needle 1 and needle 2 of the lower needle dial do not work, and needle 3 forms a circle accordingly; needle 1 of the 2nd and 4th needle dials forms a circle accordingly, and needle 2 does not work, needle 1 and needle 2 of the lower needle dial do not work, and needle 3 forms a circle accordingly; needle 1 and needle 2 of the 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th and 21st needle dials do not work, and needle 1, needle 2 and needle 3 of the syringe form a circle accordingly; needle 1 and needle 2 of the 6th, 8th, 10th, 12th, 14th, 16th, 18th and 20th needle dials form a circle accordingly, and needle 1, needle 2 and needle 3 of the syringe do not work.

[0012] Preferably, one of the first yarn and the second yarn is a PBT / PET composite stretch yarn, and the other is a polyester yarn with a special cross-section; or, one of the first yarn and the second yarn is an elastic polyester yarn, and the other is a polyester yarn with a special cross-section; The production of the PBT / PET composite stretch yarn includes the following steps: a. The PBT fiber and PET fiber were vacuum dried at 120-160 ° C for 4-8 hours; b. Using a twin-screw extruder, PBT fiber and PET fiber are melted separately and merged before the spinneret inlet, and then extruded and combined into a parallel structure of primary fibers; c. Blowing and cooling the spun fibers at a temperature of 20-25°C and a wind speed of 0.4-0.8 m / s; d. Spraying chemical fiber oil on the surface of the spun fiber; e. The spun fiber was subjected to multi-stage hot drawing with a total draw ratio of 3.0-3.8 to obtain a drawn fiber; f. Applying high-temperature steam at 110-130 ° C and a pressure of 0.25-0.35 MPa to the drawn fiber to form a temporary mechanical curl, and then passing through a 130-150 ° C oven for 10-30 minutes to form a spirally curled PBT / PET composite stretch yarn.

[0013] Preferably, when spinning the first and second yarns in step S1, a masterbatch of a nano-hydrophilic material having a mass fraction of 1%-5% is added for co-spinning, wherein the masterbatch of the nano-hydrophilic material is a masterbatch of silicon dioxide or graphene oxide with a particle size of 1-100 nanometers. When spinning the third yarn, a masterbatch containing a water repellent having a mass fraction of 3%-8% is added for co-spinning, wherein the masterbatch containing the water repellent is polydimethylsiloxane or reactive organosilicon powder.

[0014] Preferably, in step S3, water is first added to the rated water level at a dye-bath ratio of 1:12, 0.8 g / L of a dispersing and leveling agent and 0.3 g / L of a chelating agent are added to the water, and then the dye is added, wherein the dye consists of 60-70% by mass of an azo dye and 30-40% by mass of anthraquinone dye.

[0015] Preferably, in step S4, a quaternary ammonium salt antimicrobial agent is evenly applied to the grey cloth through a padding device during the shaping process.

[0016] By adopting the above technical solution, the beneficial effects of the present invention are: (1) The present invention effectively reduces the weight of the fabric and improves its anti-snagging and anti-pilling properties while ensuring the fabric's unidirectional moisture conduction performance through a unique double-layer composite woven structure and differentiated yarn combination.

[0017] (2) The production process of the one-way moisture-conducting fabric of the present invention is simple. The fabric can be woven on a multi-needle double-sided circular knitting machine, and the post-finishing process is short, which has the characteristics of simple production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a front schematic diagram of a one-way moisture-conducting fabric according to a preferred embodiment of the present invention.

[0019] Figure 2 for Figure 1 Schematic diagram of the AA section.

[0020] Figure 3 for Figure 1 Schematic diagram of the cross-section in the BB direction.

[0021] Figure 4 This is a weaving diagram of a preferred embodiment of the present invention.

[0022] Figure 5 This is a triangle configuration diagram of a preferred embodiment of the present invention.

[0023] Figure 6 This is a micrograph of the PBT / PET composite stretch yarn in Example 1.

[0024] Figure 7 Schematic diagram of the special-shaped cross section in Example 2.

[0025] Figure 8 Schematic diagram of the special-shaped cross section in Example 3.

[0026] Among them: 1. Surface layer; 11. Surface layer plain stitch; 2. Inner layer; 21. Inner layer plain stitch; 3. Single-layer double-sided weft knitted structure; 31. Single-layer double-sided weft knitted structure; 4. Longitudinal cavity; 5. Transverse cavity; 6. Hollow cavity; 7. Branch; 8. Bifurcation. DETAILED DESCRIPTION

[0027] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0028] Example 1 Combine Figures 1 to 6 The present invention discloses a one-way moisture-conducting fabric, comprising a surface layer 1, a lining layer 2, and a plurality of single-layer double-face weft-knitted sections 3 connecting the surface layer 1 and the lining layer 2, formed by knitting a first yarn, a second yarn, and a third yarn in a minimum cycle unit. The single-layer double-face weft-knitted sections 3 form a plurality of through-holes 5 and 4 between the surface layer 1 and the lining layer 2. The minimum cycle unit comprises a surface layer plain stitch 11 formed by knitting the surface layer 1 with the first yarn in a loop, a lining layer plain stitch 21 formed by knitting the lining layer 2 with the third yarn in a loop, and a single-layer double-face weft-knitted section 3 formed by knitting the second yarn in a loop with alternate stitches and a portion of the lower stitches in a continuous loop. The single-layer double-face weft-knitted sections 31 are respectively connected to the surface layer plain stitch 11 and the lining layer plain stitch 21. One of the first yarn and the second yarn is a PBT / PET composite stretch yarn or an elastic polyester yarn, the other is a special-section polyester yarn or a non-elastic polyester yarn, and the third yarn is a polypropylene yarn.

[0029] Polypropylene yarn is a lightweight, high-strength synthetic fiber with excellent abrasion resistance and elasticity. Polypropylene yarn has very low hygroscopicity, with virtually no moisture absorption, and its moisture regain under normal atmospheric conditions is close to zero. However, it has a wicking effect, transferring water vapor through the capillaries within the fiber without actually absorbing any moisture. Its fiber properties contribute to its unidirectional moisture conduction function. Polypropylene yarn also exhibits excellent physical antibacterial and UV resistance.

[0030] This invention utilizes differentiated yarn combinations combined with a unique single-layer, double-faced weft-knitted section 3 to connect the inner layer 2 and the outer layer 1. The design of the single-layer, double-faced weft-knitted section 31, with alternate stitches on the upper and continuous stitches on some of the lower stitches, reduces yarn usage and enhances interlayer bonding. This results in a single-layer structure at the junction between the outer layer 1 and the inner layer 2 (i.e., the single-layer, double-faced weft-knitted section 3), while the non-junction sections are double-layered. This creates interconnected longitudinal and transverse cavities 4 and 5, effectively reducing the fabric's weight while ensuring unidirectional moisture conduction. This improves its resistance to snagging and pilling, making the fabric lighter and more breathable, while maintaining both lightweight and structural stability. Furthermore, the polypropylene yarn imparts excellent physical antibacterial and UV protection to the fabric. Testing has shown that the fabric achieves a 7a antibacterial rating, achieves qualified natural UV protection, and provides over 40% thermal insulation.

[0031] The present invention preferably uses PBT / PET composite stretch yarn, special-shaped cross-section polyester yarn, and polypropylene yarn to weave the one-way moisture-conducting fabric of the present invention. On the one hand, the capillary effect of the cross-sectional structure of the PBT / PET composite stretch yarn and the special-shaped cross-section polyester yarn can enhance moisture conduction efficiency. The polypropylene yarn can form a dense hydrophobic network in the inner layer 2, quickly conducting sweat from the skin side to the outer side of the fabric, achieving a one-way moisture-conducting function. The one-way perspiration index can still reach level 5 after 150 washes, and can continuously maintain efficient one-way moisture-conducting performance, providing the human body with a dry and comfortable wearing experience. On the other hand, the combination of the fabric structure and the special yarn makes the fabric surface smoother and tighter, reducing friction and hooking between fibers, and can effectively improve the fabric's anti-snagging and anti-pilling capabilities, with anti-pilling reaching level 4 and anti-snagging reaching levels 2-3.

[0032] In this embodiment, the first yarn is 30D-50D special-section polyester yarn, the second yarn is 30D-50D PBT / PET composite stretch yarn, and the third yarn is 35D-50D polypropylene yarn. This combination of yarn specifications and fabric structure can make the fabric weight reach 95-126g / m 2 The low weight reaches the level 4 anti-pilling standard, achieving a synergistic improvement in lightness and durability.

[0033] The weight ratio of the first yarn, the second yarn, and the third yarn is preferably 40%-47%: 11%-27%: 33%-42%. This ratio scheme reduces the weight of the fabric while ensuring unidirectional moisture conduction performance and structural stability.

[0034] Combine Figure 4In some preferred embodiments of the present invention, the single-layer double-sided weft knitted tissue 31 includes a plurality of first and second knitting paths alternately arranged. The first and second knitting paths are both configured so that the upper needle forms a loop with every other needle and the lower needle has at least three consecutive loops, and the upper needle loop positions of the first and second knitting paths are complementary. It is understandable that the number of knitting paths and the number of needles in each path of the surface layer plain knitted tissue 11, the inner layer plain knitted tissue 21, and the single-layer double-sided weft knitted tissue 31 can be adjusted according to actual needs and do not constitute a limitation to the present invention. Figure 4 In the embodiment shown, the minimum cycle unit is composed of 14 stitches and 12 stitches, with 21 steps forming a complete cycle, wherein: The first four stitches are knitted with the second yarn. The odd-numbered stitches in the first and third stitches are not knitted, and the even-numbered stitches are knitted. The odd-numbered stitches in the second and fourth stitches are knitted, and the even-numbered stitches are not knitted. The first nine stitches in the first four stitches are not knitted, and the stitches in the tenth to twelfth stitches are knitted. The fifth, seventh, ninth, eleventh, thirteenth, fifteenth, seventeenth, nineteenth, and twenty-first stitches are knitted with the first yarn, with all the stitches knitted and no knitting. The sixth, eighth, tenth, twelfth, fourteenth, sixteenth, eighteenth, and twenty-first stitches are knitted with the third yarn, with all the stitches knitted and no knitting.

[0035] The present invention also discloses a production process of the one-way moisture-conducting fabric, which includes the following steps: S1. Prepare the required first yarn, second yarn and third yarn For example, in this embodiment, the first yarn is a 50D / 36F special-section polyester yarn, the second yarn is a 50D / 36F PBT / PET composite stretch yarn, and the third yarn is a 50D / 48F polypropylene yarn. The weight ratio of the first yarn, the second yarn, and the third yarn is 40.2%, 26.2%, and 33.6%.

[0036] Special-section polyester yarns are shaped (i.e., non-circular) in cross-section. These yarns are extruded using specially designed spinnerets. Traditional circular spinnerets are replaced with Y-shaped, cross-shaped, C-shaped, multi-lobed (e.g., four-lobed, six-lobed), flat ribbon-shaped, and hollow, multi-grooved shapes. After the molten polyester is extruded through these shaped orifices and solidifies after cooling, longitudinal microgrooves or grooves form on the fiber surface. These grooves form natural capillary channels, significantly increasing the fiber's specific surface area and facilitating the absorption and transport of liquids.

[0037] PBT / PET composite stretch yarn is made by combining PBT and PET fibers through a composite spinning process, tightly bonding them lengthwise. This production process creates a spiral crimp, which creates a more complex network of capillary pores between the fibers, significantly increasing the fabric's bulk and moisture absorption capacity. The crimped structure encourages the hydrophilic components to align in specific directions, or creates moisture-conducting pathways between the fibers through capillary action.

[0038] In a preferred embodiment, the PBT / PET composite stretch yarn adopts a special-shaped cross section: a cross-shaped cross-shaped spiral yarn formed by spinning, and the electron microscopic structure is as follows: Figure 6 As shown, its transverse cross-section is cross-shaped and spirally curved along the length of the fiber. The capillary pores of this shape have better unidirectional moisture conduction performance.

[0039] The specific production process of PBT / PET composite stretch yarn is as follows: a. Vacuum dry the PBT and PET fibers (in this example, 60% PBT and 40% PET) at 120-160°C for 4-8 hours. After vacuum drying, reduce the moisture content of the PBT and PET fibers to ≤50 ppm to prevent hydrolysis and degradation during high-temperature spinning. Incomplete drying can lead to molecular chain breakage, which can easily cause fiber breakage during spinning.

[0040] b. Use a twin-screw extruder to melt PBT fiber and PET fiber separately, and merge them in front of the spinneret inlet. After extrusion, they are combined into primary fibers with a parallel structure.

[0041] When melting PBT and PET fibers, the PBT and PET screw zones require precise temperature control. The melting point difference between PBT and PET is as much as 40°C, necessitating independent temperature control to prevent thermal oxidation and yellowing of the PBT. The PBT screw zone is maintained at 230-245°C, while the PET screw zone is maintained at 275-290°C. At the outlet, the melt passes through a precision filter (≥20μm) to remove impurities before entering the spinneret.

[0042] The spinneret is equipped with spinnerets with an aspect ratio of L / D ≥ 2.5 to minimize elastic disturbances in the melt. Molten PBT and PET fibers are injected separately. During extrusion, the viscosity difference between the two melts is controlled to ≤ 20% to prevent flow imbalance. A compatibilizer (such as an epoxy-modified polymer) can be added during extrusion to reduce interfacial defects. After extrusion, a single, parallel-structured primary fiber is formed.

[0043] c. Blow air to cool the spun fibers at a temperature of 20-25°C and a wind speed of 0.4-0.8 m / s. Cool the spun fibers by blowing air from both sides to prevent differences in cooling rates from causing asymmetric fiber skin-core structures and affecting curling performance.

[0044] d. Spray a chemical fiber oil onto the surface of the spun fiber. This can be a composite oil containing an antistatic agent and a sizing agent (such as a polyether / silicone oil emulsion), with an oil application rate of 0.2-0.5 wt%. This step smoothes the fiber surface, improves its softness and gloss, suppresses static electricity on the fiber surface, prevents pilling and fuzzing, reduces the friction coefficient during spinning and weaving, and improves production efficiency. The oil application rate should be controlled at 0.2-0.5 wt%. Avoid excessive application, as excessive application will cause excessive chemical oil to adhere to the fiber surface, damaging the internal fiber structure and strength.

[0045] e. The spun fibers are subjected to multi-stage hot drawing with a total draw ratio of 3.0-3.8 to produce drawn fibers. The total draw ratio is controlled within this range. A higher draw ratio can lead to PBT breakage, while a lower draw ratio can result in insufficient crimping. During the drawing process, infrared thermal imaging is used for online monitoring to ensure that the surface temperature of the hot rollers is uniform, with an axial temperature difference of ≤3°C.

[0046] f. Applying high-temperature steam at 110-130 ° C and a pressure of 0.25-0.35 MPa to the drawn fiber to form a temporary mechanical curl, and then passing through a 130-150 ° C oven for 10-30 minutes to form a spirally curled PBT / PET composite stretch yarn.

[0047] S2. Weaving A multi-track double-sided circular knitting machine is used for knitting, and two needle tracks of the needle disk and three needle tracks of the needle cylinder of the multi-track double-sided circular knitting machine are involved in the knitting.

[0048] The smallest loop unit of this one-way moisture-conducting fabric has 21 routes, each of which is knitted with 14 upper needles and 12 lower needles.

[0049] The needle arrangement mode of the needle dial and needle cylinder is rib-to-needle. The needle arrangement order of the needle dial is 12121212121212, and the needle arrangement order of the needle cylinder is 212121212333, among which 1, 2, and 3 correspond to needle lane 1, needle lane 2, and needle lane 3 respectively; The threading method of the 21 routes of the minimum cycle unit is: the second yarn is threaded on the 1st, 2nd, 3rd and 4th routes, the first yarn is threaded on the 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th and 21st routes, and the third yarn is threaded on the 6th, 8th, 10th, 12th, 14th, 16th, 18th and 20th routes.

[0050] The 21-way triangle configuration of the minimum cyclic unit is as follows Figure 3As shown, "∨" and "∧" indicate knitting, and "-" indicates no knitting. For the 1st and 3rd needle dials, needle 1 does not work, and needle 2 forms a knit accordingly. Needles 1 and 2 of the lower needle dial do not work, and needle 3 forms a knit accordingly. For the 2nd and 4th needle dials, needle 1 forms a knit accordingly, and needle 2 does not work. Needles 1 and 2 of the lower needle dial do not work, and needle 3 forms a knit accordingly. For the 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th, and 21st needle dials, needles 1 and 2 do not work, and needles 1, 2, and 3 of the cylinder form a knit accordingly. For the 6th, 8th, 10th, 12th, 14th, 16th, 18th, and 20th needle dials, needles 1 and 2 form a knit accordingly, and needles 1, 2, and 3 of the cylinder do not work.

[0051] S3. Refining The grey cloth is refined at 35-40°C with a bath ratio of 1:8-1:10. The refining agent is a mixed solution of 0.8-1.2% anionic degreasing agent and 0.3-0.5% polypropylene yarn special cleaning agent.

[0052] Scouring can remove impurities and grease from the grey fabric fibers, thereby increasing their hygroscopicity and avoiding affecting the uniformity of subsequent dyeing.

[0053] S4, dyeing First, add water to the rated water level at a dye bath ratio of 1:12, then add 0.8g / L of dispersing and leveling agent and 0.3g / L of chelating agent to the water, heat it to 40℃ and add the dye, then heat it to 130℃ at a heating rate of 1.5℃ / min and keep it warm for 40min, then cool it to 60℃ at a rate of 2℃ / min.

[0054] The dye is composed of 60-70% azo dye and 30-40% anthraquinone dye. This two-component dye system combines the advantages of both types of dyes, compensating for the shortcomings of a single dye. During the dyeing process, the rapid diffusion of the azo dye during the low-temperature heating stage improves the color yield of the fabric. During the high-temperature insulation stage, the enhanced vibration of the anthraquinone dye molecules enhances its permeability and improves the color fastness of the fabric.

[0055] S5. Finalization The dyed grey cloth is sent to the setting machine for setting. The temperature of the setting machine is set to 130±5℃, the overfeed amount is set to 3±0.5% to prevent weight loss, and the speed is set to 20±1m / min. During the setting process, the moisture-absorbing and perspiration-releasing finishing agent and quaternary ammonium salt antibacterial agent are evenly applied to the grey cloth through the padding device. After hot air drying, the setting is completed and the cloth is finally cooled and dropped.

[0056] Finishing the greige fabric with a moisture-wicking finish can further enhance the fabric's moisture-wicking properties. Meanwhile, quaternary ammonium antimicrobial agents provide broad-spectrum antimicrobial activity, effectively inhibiting bacterial growth and reducing odor, extending the life of the textile.

[0057] The performance test results of the one-way moisture-conducting fabric of this embodiment produced by the process of the present invention are shown in the following table:

[0058] Example 2 The yarn configuration of this embodiment is different from that of the first embodiment. The first yarn of this embodiment is 30D-50D / 36FPBT / PET composite stretch yarn, the second yarn is 30D-50D / 36F special-section polyester yarn, and the third yarn is 35D-50D / 48F polypropylene yarn.

[0059] The surface layer 1 utilizes the elastic shrinkage characteristics of PBT / PET composite stretch yarn to dynamically adjust its fit with the inner layer 2, eliminating the thickness redundancy caused by the gap between layers, thereby reducing the overall thickness of the fabric. At the same time, the elastic surface layer 1 generates pressure transmission to the inner layer 2 when stretched, forming a certain restraint effect, which can improve the tear resistance of the inner layer 2 and maintain the overall ductility of the fabric.

[0060] In order to improve the unidirectional moisture conduction performance of the fabric of this embodiment, the production process of this embodiment is as follows: S1. Prepare the required first yarn, second yarn and third yarn The first yarn is 30D-50D / 36F PBT / PET composite stretch yarn, the second yarn is 30D-50D / 36F special-section polyester yarn, and the third yarn is 35D-50D / 48F polypropylene yarn.

[0061] The special-shaped cross-section polyester yarn is a special-shaped cross-section (i.e. non-circular cross-section) yarn. The special-shaped cross-section of this embodiment is a special-shaped cross-section yarn that is extruded using a specially designed spinneret. The fiber cross-section is as follows: Figure 7 The dart-shaped fiber with hollow grooves shown has a hollow cavity 6 in the center and three protruding branches 7 extending from its edges, curving clockwise. This cross-section includes four flow channels, one of which is the hollow cavity 6, and the other channels are formed between the three branches 7. These channels form natural capillary channels, significantly increasing the fiber's specific surface area, facilitating liquid adsorption and transport, and resulting in superior flow-conducting performance.

[0062] When spinning the first and second yarns, a masterbatch of a nano-hydrophilic material is added at a mass fraction of 3%-8% for co-spinning. The masterbatch of the nano-hydrophilic material is a silica or graphene oxide masterbatch with a particle size of 1-100 nanometers. This co-spinning process modifies the first and second yarns to increase their hydrophilicity. This modification is achieved from within the fibers, resulting in a more durable, washable, and superior finish. The specific steps are as follows: S11. Pretreat silica or graphene oxide with a particle size of 1-100 nm with a coupling agent in a high-speed mixer at a temperature of 80-100°C for 20-30 min. The coupling agent is a silane coupling agent used for surface modification of nanomaterials.

[0063] S12. Prepare high-concentration hydrophilic masterbatch (mass concentration of 10–30%) by mixing the pretreated silica or graphene oxide with a carrier resin (e.g., low-melting-point PET) using a twin-screw pelletizer.

[0064] S13. The first yarn or the second yarn is sliced ​​and dehydrated in a vacuum drum dryer. The slices are mixed with the hydrophilic masterbatch of step S12 in proportion. The amount of the masterbatch added is 1-5% of the mass fraction of the slices. The amount added here should not be too high, as it affects the spinnability.

[0065] S14. The mixed material is fed into a screw extruder for melting, using a high shear twin-screw extruder to ensure uniform dispersion of the modifier.

[0066] S15. The melt is extruded through a metering pump and a spinneret, and is cooled by side blowing during extrusion.

[0067] S16. Multi-stage hot roller drawing, the first roller is 80-90℃, the second roller is 120-130℃, and the total drawing ratio is 3-4.

[0068] When spinning the third yarn, a masterbatch containing a water repellent (polydimethylsiloxane or reactive silicone micropowder) is added at a mass fraction of 3%-8% for co-spinning. This enhances the third yarn's durable, washable water repellency, avoiding environmental and washability issues associated with post-finishing.

[0069] The specific steps are as follows: S11. Prepare polydimethylsiloxane or reactive organosilicon powder with a carrier resin (such as PET-g-MAH) and a dispersant by twin-screw extrusion (temperature: 220–250°C) to produce a masterbatch with a mass concentration of 15–25%.

[0070] S12. The third yarn is sliced ​​and dehydrated in a vacuum drum dryer. The slices are mixed with the masterbatch of step S11 in proportion, and the amount of the masterbatch added is 3-8% of the mass fraction of the slices.

[0071] S14. The mixed material is fed into a screw extruder for melting.

[0072] S15. The melt is extruded through a metering pump and a spinneret, cooled by side air during extrusion. The humidity of the side air is controlled at 60–70% RH.

[0073] S16. Multi-stage hot roller drafting: the first roller is 70–80°C; the second roller is 100–110°C. The hot roller temperature is controlled to prevent excessive migration of the water repellent to the fiber surface due to excessive temperature. The total draft ratio is 3-4.

[0074] S2. Weaving A multi-track double-sided circular knitting machine is used for knitting, wherein two needle tracks of the needle disk and three needle tracks of the needle cylinder of the multi-track double-sided circular knitting machine are involved in knitting. The knitting method is the same as that of the first embodiment.

[0075] S3. Refining The grey cloth is refined at 35-40°C with a bath ratio of 1:8-1:10. The refining agent is a mixed solution of 0.8-1.2% anionic degreasing agent and 0.3-0.5% polypropylene yarn special cleaning agent.

[0076] Scouring can remove impurities and grease from the grey fabric fibers, thereby increasing their hygroscopicity and avoiding affecting the uniformity of subsequent dyeing.

[0077] S4, dyeing First, add water to the rated water level at a dye bath ratio of 1:12, then add 0.8g / L of dispersing and leveling agent and 0.3g / L of chelating agent to the water, heat it to 40℃ and add the dye, then heat it to 130℃ at a heating rate of 1.5℃ / min and keep it warm for 40min, then cool it to 60℃ at a rate of 2℃ / min.

[0078] The dye is composed of 60-70% azo dye and 30-40% anthraquinone dye. This two-component dye system combines the advantages of both types of dyes, compensating for the shortcomings of a single dye. During the dyeing process, the rapid diffusion of the azo dye during the low-temperature heating stage improves the color yield of the fabric. During the high-temperature insulation stage, the enhanced vibration of the anthraquinone dye molecules enhances its permeability and improves the color fastness of the fabric.

[0079] S5. Finalization The dyed grey cloth is sent to the setting machine for setting. The temperature of the setting machine is set to 130±5℃, the overfeed amount is set to 3±0.5% to prevent weight loss, and the speed is set to 20±1m / min. During the setting process, the moisture-absorbing and perspiration-releasing finishing agent and quaternary ammonium salt antibacterial agent are evenly applied to the grey cloth through the padding device. After hot air drying, the setting is completed and the cloth is finally cooled and dropped.

[0080] Finishing the greige fabric with a moisture-wicking finish can further enhance the fabric's moisture-wicking properties. Meanwhile, quaternary ammonium antimicrobial agents provide broad-spectrum antimicrobial activity, effectively inhibiting bacterial growth and reducing odor, extending the life of the textile.

[0081] Example 3 This embodiment differs primarily from the first embodiment in the yarn configuration. In this embodiment, the first yarn is a 50D / 36F profiled-cross-section polyester yarn, the second yarn is a 30D / 36F PBT / PET composite stretch yarn, and the third yarn is a 50D / 48F polypropylene yarn. The weight ratio of the first, second, and third yarns is 44.9%, 17.6%, and 37.5%.

[0082] The fiber cross-section of the special-shaped cross-section polyester yarn of this embodiment is as follows: Figure 8 As shown, the irregular cross-section features a central hollow cavity 6, with 6-8 radiating branches 7 extending outward from the edges. The branches 7 branch out at their ends, forming two or three forks 8. These branches 7 form microgrooves on the fiber surface, enhancing the capillary effect and promoting rapid moisture absorption and diffusion, achieving efficient moisture absorption and quick-drying. They also form a mechanical interlocking network within the yarn, creating multiple points of contact between fibers, strengthening fiber cohesion and locking them more tightly together. This reduces the risk of fibers being snagged or slipping due to external forces, thereby improving resistance to snagging or pilling. Furthermore, the hollow cavity 6 increases the internal voids within the fibers, further enhancing moisture absorption.

[0083] Example 4 The main difference between this embodiment and the first embodiment is that the first yarn is different. The first yarn of this embodiment is made of 45D-50D / 36F elastic polyester.

[0084] Example 5 The main difference between this embodiment and the fourth embodiment is that the second yarn is different. The second yarn of this embodiment is 30D-35D / 36F non-elastic polyester yarn.

[0085] Example 6 The one-way moisture-conducting fabric of this embodiment (such as the one-way moisture-conducting fabric of embodiments 1 to 5) is also woven with conductive yarn, and the conductive yarn and polypropylene yarn are woven together in the inner layer 2. The conductive yarn can be woven into some of the inner layer plain stitches 21, or it can be woven into all of them.

[0086] Conductive yarn is a composite blend of conductive materials such as silver-plated fibers and ordinary fibers. It eliminates charge accumulation through static leakage or corona discharge. Adding conductive yarn to the one-way moisture-conducting fabric of the present invention can prevent static electricity generation and improve the wearability of the fabric.

[0087] Although the present invention has been particularly shown and described in conjunction with preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made to the present invention without departing from the spirit and scope of the invention as defined in the appended claims, and all such changes are within the scope of protection of the present invention.

Claims

1. A one-way moisture-conducting fabric, characterized in that: The invention comprises a surface layer (1), an inner layer (2), and a plurality of single-layer double-sided weft knitted tissue parts (3) connecting the surface layer (1) and the inner layer (2), formed by cyclically knitting a first yarn, a second yarn, and a third yarn in a minimum cycle unit. The single-layer double-sided weft knitted tissue parts (3) form a plurality of through-going transverse cavities (5) and longitudinal cavities (4) between the surface layer (1) and the inner layer (2); The minimum circulation unit comprises: a surface layer plain needle structure (11) formed by knitting a surface layer (1) with the first yarn below the needle, an inner layer plain needle structure (21) formed by knitting an inner layer (2) with the third yarn above the needle, and a single-layer double-sided weft knitted structure (31) formed by knitting a single-layer double-sided weft knitted structure part (3) with the second yarn above the needle and the lower needle part continuously knitted, wherein the single-layer double-sided weft knitted structure (31) is connected to the surface layer plain needle structure (11) and the inner layer plain needle structure (21) in a series. One of the first yarn and the second yarn is PBT / PET composite stretch yarn or elastic polyester yarn, the other is special-section polyester yarn or non-elastic polyester yarn, and the third yarn is polypropylene yarn.

2. The one-way moisture-conducting fabric according to claim 1, characterized in that: The specification of the PBT / PET composite stretch yarn is 30D-50D; The specification of the special-shaped cross-section polyester yarn is 30D-50D; The specification of the polypropylene yarn is 35D-50D; The specification of the elastic polyester yarn is 45D-50D; The specification of the non-elastic polyester yarn is 30D-35D.

3. The one-way moisture-conducting fabric according to claim 1, characterized in that: The weight ratio of the first yarn, the second yarn and the third yarn is: 40%-47%: 11%-27%: 33%-42%.

4. The one-way moisture-conducting fabric according to claim 1, characterized in that: It also includes conductive yarn, and at least a portion of the inner layer plain knitted structure is woven together with the third yarn and the conductive yarn.

5. The one-way moisture-conducting fabric according to claim 1, characterized in that: The single-layer double-sided weft knitted structure includes a first knitting path and a second knitting path arranged alternately; the first knitting path and the second knitting path are both configured so that the upper needle forms a loop every other needle and the lower needle has at least three consecutive loops, and the upper needle loop positions of the first knitting path and the second knitting path are complementary.

6. The one-way moisture-conducting fabric according to any one of claims 1 to 5, characterized in that: The minimum cycle unit is composed of 14 stitches and 12 stitches, with 21 steps as a complete cycle, wherein: The 1st to 4th routes are all knitted with the second yarn; the odd-numbered needles of the 1st and 3rd routes are not knitted and the even-numbered needles are knitted into loops; the odd-numbered needles of the 2nd and 4th routes are all knitted into loops and the even-numbered needles are not knitted; the 1st to 9th needles of the 1st to 4th routes are not knitted and the 10th to 12th needles are knitted into loops; The 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th and 21st routes are all knitted with the first yarn, and all the lower needles are looped; The 6th, 8th, 10th, 12th, 14th, 16th, 18th and 20th stitches are all knitted with the third yarn, and all the upper needles are looped.

7. A process for producing a one-way moisture-conducting fabric according to any one of claims 1 to 6, characterized in that: The process includes the following steps: S1. Prepare the required first yarn, second yarn and third yarn; S2, using a multi-needle double-sided circular knitting machine to weave a unidirectional moisture-conducting fabric; S3, Refining Scouring the grey fabric at 35-40℃ with a bath ratio of 1:8-1:10; S4, dyeing Add dispersing and leveling agent and chelating agent to water, heat it to 40-50℃, add dye, then heat it to 130℃ at a rate of 1.5℃ / min and keep it at that temperature for 40min, then cool it to 50-60℃ at a rate of 2℃ / min; S5. Finalization The dyed grey cloth is sent to the setting machine for setting. The temperature of the setting machine is set to 130±5℃, the overfeed amount is set to 3±0.5%, and the speed is set to 20±1m / min. During the setting process, the moisture-absorbing and perspiration-releasing finishing agent is evenly applied to the grey cloth through the padding device. After hot air drying, the setting is completed and the cloth is finally cooled and dropped.

8. The production process of the one-way moisture-conducting fabric according to claim 7, characterized in that: The minimum circulation unit of the one-way moisture-conducting fabric in step S2 has 21 routes, and each route is knitted with 14 upper needles and 12 lower needles; The needle arrangement mode of the needle dial and needle cylinder is rib-to-needle. The needle arrangement order of the needle dial is 12121212121212, and the needle arrangement order of the needle cylinder is 212121212333, among which 1, 2, and 3 correspond to needle lane 1, needle lane 2, and needle lane 3 respectively; The threading method of the 21 routes of the minimum cycle unit is: the second yarn is threaded on the 1st, 2nd, 3rd and 4th routes, the first yarn is threaded on the 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th and 21st routes, and the third yarn is threaded on the 6th, 8th, 10th, 12th, 14th, 16th, 18th and 20th routes; The 21-way triangle configuration of the minimum circulation unit is as follows: needle 1 of the 1st and 3rd needle dials does not work, and needle 2 forms a circle accordingly, needle 1 and needle 2 of the lower needle dial do not work, and needle 3 forms a circle accordingly; needle 1 of the 2nd and 4th needle dials forms a circle accordingly, and needle 2 does not work, needle 1 and needle 2 of the lower needle dial do not work, and needle 3 forms a circle accordingly; needle 1 and needle 2 of the 5th, 7th, 9th, 11th, 13th, 15th, 17th, 19th and 21st needle dials do not work, and needle 1, needle 2 and needle 3 of the syringe form a circle accordingly; needle 1 and needle 2 of the 6th, 8th, 10th, 12th, 14th, 16th, 18th and 20th needle dials form a circle accordingly, and needle 1, needle 2 and needle 3 of the syringe do not work.

9. The production process of the one-way moisture-conducting fabric according to claim 7, characterized in that: One of the first yarn and the second yarn is a PBT / PET composite stretch yarn, and the other is a polyester yarn with a special cross-section; or one of the first yarn and the second yarn is an elastic polyester yarn, and the other is a polyester yarn with a special cross-section; The production of the PBT / PET composite stretch yarn includes the following steps: a. The PBT fiber and PET fiber were vacuum dried at 120-160 ° C for 4-8 hours; b. Using a twin-screw extruder, PBT fiber and PET fiber are melted separately and merged before the spinneret inlet, and then extruded and combined into a parallel structure of primary fibers; c. Blowing and cooling the spun fibers at a temperature of 20-25°C and a wind speed of 0.4-0.8 m / s; d. Spraying chemical fiber oil on the surface of the spun fiber; e. The spun fiber was subjected to multi-stage hot drawing with a total draw ratio of 3.0-3.8 to obtain a drawn fiber; f. Applying high-temperature steam at 110-130 ° C and a pressure of 0.25-0.35 MPa to the drawn fiber to form a temporary mechanical curl, and then passing through a 130-150 ° C oven for 10-30 minutes to form a spirally curled PBT / PET composite stretch yarn.

10. The production process of the one-way moisture-conducting fabric according to claim 7, characterized in that: When spinning the first yarn and the second yarn in step S1, a masterbatch of a nano-hydrophilic material having a mass fraction of 1%-5% is added for blending and spinning; the masterbatch of the nano-hydrophilic material is a silicon dioxide or graphene oxide masterbatch with a particle size of 1-100 nanometers; When spinning the third yarn, a masterbatch containing a water repellent agent with a mass fraction of 3% to 8% is added for blending and spinning, wherein the masterbatch containing the water repellent agent is polydimethylsiloxane or reactive organic silicon powder; In step S3, water is first added to the rated water level at a dye bath ratio of 1:12, 0.8 g / L of a dispersing and leveling agent and 0.3 g / L of a chelating agent are added to the water, and then the dye is added, wherein the dye consists of 60-70% by mass of an azo dye and 30-40% by mass of anthraquinone dye; in the step S4, a quaternary ammonium antibacterial agent is evenly applied to the grey cloth through a padding device during the setting process.

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