Double-effect constant temperature warm-keeping fabric with integrated velvet and preparation process thereof

Abstract

The present application relates to the technical field of fabric, in particular to a double-effect constant-temperature warm-keeping fabric with integrated pile and a preparation process thereof. The fabric comprises, from the surface to the inside, a smooth layer, a constant-temperature layer and a pile layer in sequence. The inner surface of the pile layer is provided with pile cells, the pile cells are provided with piles, and the pile cells are provided with pile channels. In dynamic constant temperature, the shape memory polyester fiber, the radial fiber and the constant-temperature layer pores are used to form an air-keeping layer at low temperature, and the polyester hollow fiber is used to strengthen the warm-keeping effect. At high temperature, the pile cells expand to guide the pile channels, and the constant-temperature layer pores form a three-dimensional ventilation network to discharge hot air and moisture, so as to realize precise temperature control. In terms of comfort and appearance, the surface layer has the characteristics of smoothness, wear resistance and anti-pilling, and the appearance when worn is improved. The inner layer of the pile is opened and fiberized and is treated with organic silicon soft finishing, so as to realize skin-friendly and non-irritating.

Description

Technical Field

[0001] This invention relates to the field of fabric technology, specifically to a one-piece fleece dual-effect constant temperature thermal insulation fabric and its preparation process. Background Technology

[0002] The thicker the thermal fabric, the better. The best thermal fabric maintains a comfortable body temperature while also being aesthetically pleasing and lightweight. Fleece fabrics, which have a fleece layer added to the back or interlayer of the main fabric to enhance warmth, are widely used in winter clothing and home furnishings. These include polyester-based fleece, lightweight and breathable for outdoor use; polyester brushed fleece, highly insulating and often used in home furnishings; composite fleece, which requires hot melt adhesive to bond the fabric to the fleece layer; velvet, a blend of silk and cotton suitable for winter clothing; and velvet blends of mulberry silk and rayon, suitable for decorative purposes. However, existing fleece fabrics rely solely on a static fleece layer for warmth, resulting in poor breathability. At low temperatures, heat easily escapes through fabric gaps, while at high temperatures, sweat cannot escape, and the fabric cannot dynamically adjust to body temperature. Summary of the Invention

[0003] One objective of this invention is to solve at least the above-mentioned problems through an integrated fleece dual-effect constant temperature thermal insulation fabric and its preparation process.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a one-piece fleece dual-effect constant temperature and heat insulation fabric, which includes a smooth layer, a constant temperature layer and a fleece layer from the outside to the inside. The inner surface of the fleece layer is distributed with fleece grids, and fleece is distributed on the fleece grids. Fleece channels are provided between the fleece grids.

[0005] Preferably, the knitted fabric of the smooth layer is plain weave, the knitted fabric of the constant temperature layer is rib weave, and the knitted fabric of the pile layer is plush weave, with the fiber bundles in the plush weave inserted into the ground weave loops to form pile.

[0006] Preferably, the ribbed yarn is made of a blend of polyester hollow fibers and soluble fibers.

[0007] Preferably, the raw material for soluble fibers is soluble polyvinyl alcohol.

[0008] Preferably, the fiber bundles of the plush tissue include radial fibers and shape memory polyester fibers, with a weight ratio of 7:2 to 8:2. The radial fibers include alternating soluble and insoluble low-melting-point components.

[0009] Preferably, the raw material for the soluble component is soluble polyvinyl alcohol, and the raw material for the insoluble low-melting-point component is low-melting-point polyester.

[0010] The manufacturing process of the one-piece fleece dual-effect constant temperature thermal insulation fabric includes the following steps:

[0011] Step a, Raw material pretreatment: The fibers of each layer of fabric are opened, impurities removed, and blended separately;

[0012] Step b, Functional spinning: The yarns of each layer are prepared using a composite spinning process;

[0013] Step c, Knitting: Use a jacquard knitting machine to knit a fabric with a three-layer structure;

[0014] Step d, Pile Channel Shaping: Form pile channels on the inner surface of the pile layer;

[0015] Step e, Pore Forming and Pile Opening: Pores are formed on the constant temperature layer through a descaling process, and the pile of the pile layer is opened.

[0016] Step f: Post-processing.

[0017] Preferably, step d, the shaping of the fluff channel specifically includes the following steps:

[0018] Mesh mold preparation: Prepare a hot press mold with mesh protrusions on the bottom;

[0019] Preheating: Lay the woven fabric with the pile facing up on the conveyor belt of the hot press setting machine, and preheat it at 80-90℃ for 5-8 seconds in the preheating station to soften the low melting point fibers.

[0020] Hot pressing boundary setting: The preheated fabric is sent into the hot pressing station. The position of the fabric is calibrated by the photoelectric positioning system so that the grid protrusion of the hot pressing mold is aligned with the preset position and then pressed down. The temperature is 120-130℃, the pressure is 0.2-0.3Mpa, and the time lasts for 8-10s.

[0021] Cooling and pile finishing: After hot pressing, the grid is immediately sent to the cold air cooling station and cooled at a temperature of 20-25℃ and a wind speed of 3m / s to allow the grid boundary to solidify quickly. Then, the pile inside the grid is lightly brushed by a soft brush combing machine to make the pile stand up and be uniform.

[0022] Preferably, in step e, an alkaline scalding process is used: the dissolving solution is a 3%-5% sodium hydroxide aqueous solution with a pH of 12-13, a bath ratio of 1:15-1:20, and the solution is kept at 85-90℃ for 8-10 minutes with a stirring speed of 50 r / min. After scalding, the fabric is rinsed three times with warm water at 50-60℃ to remove residual sodium hydroxide and stabilize the pH value of the fabric at 6.5-7.5.

[0023] Preferably, in step f, the post-processing includes the following steps:

[0024] Anti-pilling finishing: Immerse the fabric in an anti-pilling agent with a mass concentration of 4%-6% for 15 minutes at room temperature, and then dry it at 100℃ for 20 minutes;

[0025] Softening treatment: Immerse the fabric in a 3%-5% concentration of silicone softener at 40-50℃ for 20 minutes, dehydrate, and then dry at 80-90℃.

[0026] Antibacterial finishing: Immerse the fabric in a 1%-2% silver ion antibacterial agent solution at room temperature for 20 minutes, then dry at 100℃;

[0027] Pre-shrink finishing: In a pre-shrinking machine, pre-shrink at 80-90℃ for 3-5 minutes.

[0028] As described above, the integrated fleece dual-effect constant temperature thermal insulation fabric and its preparation process provided by the present invention have the following beneficial effects: In terms of dynamic temperature control, relying on shape memory polyester fibers, radial fibers, and the pores of the constant temperature layer, the fleece grid shrinks at low temperatures to form a close-fitting air insulation layer, and the hollow polyester fibers enhance the heat-locking effect. At high temperatures, the fleece grid expands to open the fleece channels, forming a three-dimensional breathable network with the pores of the constant temperature layer to expel heat and moisture, achieving precise temperature control; In terms of comfort and appearance, the surface nylon plain weave ensures smooth, wear-resistant, and anti-pilling properties, while improving the aesthetics of wearing it as an outer garment. The inner fleece is softened by fiber opening and silicone treatment, achieving a skin-friendly and non-irritating feel; In terms of structural and functional durability, the three-layer structure woven in one go by a jacquard knitting machine avoids the bulkiness caused by multiple sewing layers. The mesh heat pressing and dissolving process ensures that the fleece channels are stable and do not decay. Detailed Implementation

[0029] The present invention will be further described below through specific embodiments.

[0030] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0031] This invention relates to a one-piece fleece dual-effect constant temperature thermal insulation fabric, which comprises, from the outside in, a smooth layer, a constant temperature layer, and a fleece layer. The inner surface of the fleece layer has a fleece grid, and the fleece grid is covered with fleece fibers. Fleece channels are formed between the fleece grids. This one-piece fleece dual-effect constant temperature thermal insulation fabric adopts a one-piece knitted structure of "outer smooth layer, middle constant temperature layer, and inner fleece layer," woven in a single knitting process to avoid the bulkiness caused by multiple layers of stitching. The outer smooth layer is anti-pilling, smooth, and wear-resistant, enhancing its aesthetic appeal. The middle constant temperature layer is a crucial layer for warmth and breathability. The inner fleece layer, through grooved treatment, forms fleece channels, creating gaps between the skin and the fabric for breathability and perspiration. When the temperature is low, the fabric's three-dimensional fleece grid effectively stores body heat; when the temperature is high, the fleece channels between the fleece grids effectively disperse excess heat from the body, maintaining a constant body temperature. When the temperature drops, the fleece lattice contracts according to the temperature response characteristics and fluffiness of the shape memory fiber, tightly wrapping the warm air around the body to form a "close-fitting air insulation layer." At the same time, the fine fleece inside further prevents heat loss, enhancing the warmth retention effect. When the temperature rises, after the body sweats, the heat from the body surface causes the fleece lattice to expand slightly. The fleece channels formed by the "groove treatment" between the lattices expand, allowing excess heat and moisture to escape through the channels. When the body surface temperature drops, the fleece lattice contracts again to lock in warmth, achieving "intelligent constant temperature."

[0032] The smooth layer is knitted with a plain weave, the temperature-regulating layer with a rib weave, and the pile layer with a plush weave. Fiber bundles in the plush weave are inserted into the ground weave loops to form pile. The plain weave yarn is made of nylon 66 abrasion-resistant fiber, with a single filament fineness of 2.2-2.8 dtex, a breaking strength ≥5.5 cN / dtex, and a breaking elongation of 25%-30%. The spun yarn has a count of 20-24S and a twist of 380-420 twists / meter. The yarn is produced using ring spinning, with a yarn evenness CV value ≤8%, ensuring the fabric's anti-pilling and abrasion resistance. The smooth layer uses a plain weave to make the front of the fabric smooth and flat, enhancing its appearance when worn as outerwear. The thermostatic layer uses a rib weave, which has greater elasticity and better extensibility. The soluble fibers in its yarns are dissolved after a decanting process, creating pores in the thermostatic layer for breathability and sweat wicking. The fleece layer uses a long-pile fleece weave, in which the fleece fibers are heat-set to form fleece channels, creating gaps between the skin and the fabric for breathability and sweat wicking. The soluble components in the fleece fibers are dissolved after a decanting process, causing the fleece fibers to open and repairing the fiber agglomeration caused by the heat-setting process.

[0033] Ribbed yarn is made from a blend of polyester hollow fibers and soluble fibers. The hollow fiber has a hollowness of 35%-45% and a single filament fineness of 1.8-2.2 dtex. It is blended with soluble fibers at a mass ratio of 7:3-8:2 to produce yarn with a count of 28-32S and a twist of 320-350 twists / meter. The yarn is produced using Siro spinning technology with a spinning tension of 25-30 cN and a blend uniformity ≥95%, avoiding uneven dissolution caused by soluble fiber agglomeration. The hollow fiber has good thermal insulation properties, and the dissolved soluble fibers create pores in the constant temperature layer, thus providing both insulation and good air permeability.

[0034] The raw material for soluble fibers is soluble polyvinyl alcohol. Soluble polyvinyl alcohol has a degree of polymerization of 1200-1300, a degree of alcoholysis of 78%±2%, and a solubility of ≥98% in water at 85-90℃.

[0035] The fiber bundles of the plush structure consist of radial fibers and shape memory polyester fibers, with a weight ratio of 7:2 to 8:2. The radial fibers include alternating soluble and insoluble low-melting-point components. The low-melting-point copolyester has a melting point of 110-130℃, lower than the 255℃ of conventional polyester, facilitating low-temperature heat setting. After heat setting, the dimensions of the pile channel boundaries are stable. The radial fiber bundles consist of 6-8 alternating soluble PVA components and low-melting-point polyester components. The fiber bundles form pile at the pile layer. The pile forms pile channels after heat setting. The insoluble low-melting-point components in the pile corresponding to the pile channels melt and bond with the fibers of the ground loop of the plush structure to form solid fiber strips. Although the soluble components do not melt, they are encapsulated within the solid fiber strips during the melting process of the insoluble low-melting-point components and are dissolved in the subsequent dissolution process, thus forming pores on the solid fiber strips. As described above, the formation of solid fiber strips within the pile channels reduces their breathability to some extent. Furthermore, unshaped pile can harden and clump together under heat, reducing its fluffiness. To address this issue, this invention incorporates a dissolution process after heat setting. The solid fiber strips in the pile channels dissolve due to the dissolution of their soluble components, forming pores that, together with the pores of other fabric layers, create gas exchange channels. The soluble components in the fiber bundles of the pile layer dissolve, further opening the radial fibers and creating a dense, soft, and non-irritating inner layer. The fine pile acts like a net, supporting a hollow, fluffy structure that traps warm air on the skin, forming a close-fitting air-insulating layer that locks in warmth. Shape memory polyester fibers are added to the fiber bundles, with a memory temperature of 32°C. When the skin temperature is below 32°C, the shape memory fibers gradually shrink to a "pre-shaped state," causing the pile to contract tightly and trap air. When the temperature exceeds 32°C, the shape memory fibers gradually return to their expanded state.

[0036] The raw material for the soluble component is soluble polyvinyl alcohol, and the raw material for the insoluble low-melting-point component is low-melting-point polyester. The degree of polymerization of soluble polyvinyl alcohol is 1200-1300, the degree of alcoholysis is 78%±2%, and the solubility in water at 85-90℃ is ≥98%.

[0037] The manufacturing process of the one-piece fleece dual-effect constant temperature thermal insulation fabric includes the following steps:

[0038] Step a, Raw material pretreatment: The fibers of each layer of fabric are opened, impurities removed, and blended separately;

[0039] Step b, Functional spinning: The yarns of each layer are prepared using a composite spinning process;

[0040] Step c, Knitting: Use a jacquard knitting machine to knit a fabric with a three-layer structure;

[0041] Step d, Pile Channel Shaping: Form pile channels on the inner surface of the pile layer;

[0042] Step e, Pore Forming and Pile Opening: Pores are formed on the constant temperature layer through a descaling process, and the pile of the pile layer is opened.

[0043] Step f, finishing. To create grooves inside the fabric, a fleece mill can also be used for processing. This process hooks, curls, and shapes the fabric fibers through a specific structure, ultimately creating a fleece effect. Applying fleece processing technology to the groove processing of the inner fleece surface of the fabric of this invention allows the inner surface of the fabric to transform from flat to fluffy fleece, thus forming grooves between the fleece fibers. However, grooves created using fleece processing have some drawbacks: the formation of the grooves is random, making it impossible to form regular patterns, and the stability of the grooves is poor. As the fleece fibers on both sides of the groove gradually loosen during use, the groove also disappears, leading to a decrease in the fabric's heat insulation and breathability. Therefore, this invention employs a composite process of heat setting and dissolving some fiber components to overcome the above defects.

[0044] Step d, the shaping of the fluff channel specifically includes the following steps:

[0045] Mesh mold preparation: Prepare a hot press mold with mesh protrusions on the bottom;

[0046] Preheating: Lay the woven fabric with the pile facing up on the conveyor belt of the hot press setting machine, and preheat it at 80-90℃ for 5-8 seconds in the preheating station to soften the low melting point fibers.

[0047] Hot pressing boundary setting: The preheated fabric is sent into the hot pressing station. The position of the fabric is calibrated by the photoelectric positioning system so that the grid protrusion of the hot pressing mold is aligned with the preset position and then pressed down. The temperature is 120-130℃, the pressure is 0.2-0.3Mpa, and the time lasts for 8-10s.

[0048] Cooling and pile finishing: Immediately after hot pressing, the fibers are sent to a cold air cooling station at a temperature of 20-25℃ and a wind speed of 3m / s to cool them, allowing the mesh boundaries to solidify quickly. Then, a soft brush carding machine is used to gently brush the pile within the mesh, making the pile upright and uniform. The low-melting-point fibers in contact with the mesh protrusions melt and bond with the ground loop fibers of the long-pile structure, forming solid fiber strips. The pile in other areas does not directly contact the mold, ultimately forming a mesh-like groove on the pile surface. These grooves are interconnected, forming pile channels.

[0049] In step e, an alkaline descaling process is used: the dissolving solution is a 3%-5% sodium hydroxide aqueous solution with a pH of 12-13, a bath ratio of 1:15-1:20, and the temperature is maintained at 85-90℃ for 8-10 minutes with a stirring speed of 50 r / min. After descaling, the fabric is rinsed three times with warm water at 50-60℃ to remove residual sodium hydroxide, stabilizing the pH value of the fabric at 6.5-7.5. The soluble polyvinyl alcohol fibers in the constant temperature layer completely dissolve, forming interconnected pores with a diameter of 5-10 μm and a porosity of 25%-30%. The soluble polyvinyl alcohol component in the radial fibers of the pile layer dissolves, and the solid fiber strips solidified in the pile channels form pores. The fiber bundles open into fine pile with a single filament fineness of 1.5-2.0 dtex, repairing the fiber agglomeration problem caused by heat setting, and increasing the bulkiness to 15-20 cm³ / g.

[0050] In step f, post-processing includes the following steps:

[0051] Anti-pilling finishing: Immerse the fabric in an anti-pilling agent with a mass concentration of 4%-6% for 15 minutes at room temperature, and then dry it at 100℃ for 20 minutes; the anti-pilling grade after treatment reaches 4.5 or above.

[0052] Softening treatment: Immerse the fabric in a 3%-5% concentration of silicone softener at 40-50℃ for 20 minutes, dehydrate, and dry at 80-90℃; the fabric hand feel softness score is ≥90 points.

[0053] Antibacterial finishing: Immerse the fabric in a 1%-2% silver ion antibacterial agent at room temperature for 20 minutes and dry at 100℃; the antibacterial rate reaches over 99%, and the antibacterial rate is still ≥90% after 20 washes.

[0054] Pre-shrink finishing: In the pre-shrinking machine, the fabric is pre-shrinked at 80-90℃ for 3-5 minutes, and the pre-shrinking rate is controlled at 3%-5% to avoid deformation of the fabric after washing. The size change rate after washing is ≤2%.

[0055] The above are merely some specific embodiments of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention using this concept shall be considered as infringing upon the protection scope of the present invention.

Claims

1. A preparation process of integrated double-effect constant-temperature warm-keeping fabric with pile, comprising the following steps: Step a, raw material pretreatment: fibers of each layer of fabric are respectively opened, impurity removed and blended; Step b, functional spinning: yarns of each layer are prepared by using composite spinning process; Step c, knitting weaving: using jacquard knitting machine to weave, preparing fabric with three-layer structure; Step d, pile channel shaping: shaping pile channel on inner surface of pile layer; Step e, pore shaping and pile opening: forming pores on constant-temperature layer and opening pile of pile layer by degumming process; Step f, post-treatment; In the step d, the pile channel shaping specifically comprises the following steps: Grid mold preparation: preparing hot-pressing mold, the bottom of which is provided with grid protrusions; Preheating: after weaving, the fabric with pile upward is laid on the conveying belt of hot-pressing shaping machine, preheating at 80-90℃ for 5-8s in preheating station to preliminarily soften low-melting-point fibers; Hot-pressing boundary shaping: after preheating, the fabric is sent into hot-pressing station, the position of the fabric is calibrated by photoelectric positioning system, the grid protrusions of hot-pressing mold are aligned with the preset position and then pressed down, the temperature is 120-130℃, the pressure is 0.2-0.3Mpa, and the time lasts for 8-10s; Cooling and pile finishing: immediately after hot-pressing, the fabric is sent into cold air cooling station to cool under the condition of temperature 20-25℃ and wind speed 3m / s, so that the grid boundary is quickly solidified, and then the pile in the grid is lightly brushed by soft hair brush carding machine to make the pile straight and uniform; The integrated double-effect constant-temperature warm-keeping fabric comprises smooth layer, constant-temperature layer and pile layer from outside to inside, the inner surface of the pile layer is distributed with pile grid, the pile grid is distributed with pile, and the pile channel is arranged between the pile grids; the knit fabric organization of the smooth layer is plain weave, the knit fabric organization of the constant-temperature layer is rib weave, and the knit fabric organization of the pile layer is plush weave, the fiber bundle in the plush weave is padded into ground weave loop to form pile; the yarn of the rib weave is blended from polyester hollow fiber and soluble fiber; the fiber bundle of the plush weave comprises radial fiber and shape memory polyester fiber.

2. The process for preparing the integrated double-effect constant temperature warm-keeping fabric according to claim 1, characterized in that: The raw material of the soluble fiber is soluble polyvinyl alcohol.

3. The process for preparing the integrated fleece dual-effect constant temperature thermal fabric according to claim 1, characterized in that: The weight ratio of the radial fiber and the shape memory polyester fiber is 7:2-8:2, and the radial fiber comprises alternately distributed soluble component and non-soluble low-melting-point component.

4. The process for preparing the integrated fleece dual-effect constant temperature thermal fabric according to claim 3, characterized in that: The raw material of the soluble component is soluble polyvinyl alcohol, and the raw material of the non-soluble low-melting-point component is low-melting-point polyester.

5. The process for preparing the integrated fleece dual-effect constant temperature thermal fabric according to claim 1, characterized in that: In the step e, the alkali degumming process is used: the dissolving solution is sodium hydroxide aqueous solution with mass concentration of 3%-5%, pH is 12-13, bath ratio is 1:15-1:20, the temperature is 85-90℃, the time is 8-10min, the stirring speed is 50r / min, after degumming, the fabric is rinsed with 50-60℃ warm water for 3 times to remove residual sodium hydroxide, so that the pH value of the fabric is stabilized at 6.5-7.

5.

6. The process for preparing the one-piece double-effect constant temperature warm-keeping fabric with velvet according to claim 1, characterized in that: In the step f, the post-treatment comprises the following steps: Anti-pilling finishing: the fabric is immersed in anti-pilling agent with mass concentration of 4%-6%, normal temperature soaking for 15min, and then drying at 100℃ for 20min; Soft finishing: the fabric is immersed in silicone softener with mass concentration of 3%-5% at 40-50℃ for 20min, and then dehydrated and dried at 80-90℃; Antibacterial finishing: the fabric is immersed in silver ion antibacterial agent with mass concentration of 1%-2% at room temperature for 20min, and then dried at 100℃; Pre-shrinking finishing: the fabric is pre-shrunk in a pre-shrinking machine at 80-90℃ for 3-5min.