Fabric containing modified basalt powder and preparation method thereof

Abstract

The invention discloses a fabric containing modified basalt powder and a preparation method of the fabric, and relates to the technical field of textiles, the fabric is formed by interweaving warp yarns and weft yarns, at least one of the warp yarns or the weft yarns is functional yarn containing the modified basalt powder, and the modified basalt powder is added into the functional yarn. The content of the modified basalt powder in the functional yarn is 0.1 wt%-5wt%; the content of silicon dioxide in the modified basalt powder is 50%-60%, the content of aluminum oxide is 12%-15%, and the content of magnesium oxide is 12%-15%; and by arranging the modified basalt powder, the stability and high efficiency of the far infrared performance are ensured.

Description

Technical Field

[0001] This invention relates to the field of textile technology, and more specifically, to a fabric containing modified basalt powder and its preparation method. Background Technology

[0002] Far-infrared rays have strong penetrating and radiating power, and are easily absorbed by objects and converted into internal energy. After being absorbed by the human body, far-infrared rays can resonate and activate water molecules in the body, thereby activating biological macromolecules such as proteins and putting cells in a high vibrational energy level. The resulting warming effect radiates from the inside out, which can promote blood circulation, enhance metabolism, and improve the body's immunity, thus playing a role in health care.

[0003] Based on the aforementioned needs, the market demand for clothing fabrics with far-infrared functionality is growing. Currently, research on such fabrics mainly focuses on adding functional materials, but this approach has significant limitations. For example, publication CN115679509A utilizes zinc oxide, cuprous oxide, and graphene to achieve far-infrared heating, but these materials themselves have colors (gray to black), making it impossible to produce light-colored or brightly colored fabrics, severely limiting their application scope. Another example is publication CN106245199A, which uses ceramic powder materials, but its complex composition and variable proportions lead to unstable far-infrared performance and poor product quality control.

[0004] Therefore, developing a new type of fabric that combines excellent and stable far-infrared performance, good mechanical properties, and unlimited color (can be dyed into light colors) has become an urgent technical problem to be solved in this field. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides a fabric containing modified basalt powder and its preparation method. Through structural design, the fabric's far-infrared performance is ensured to be excellent and stable.

[0006] The technical solution of this invention is: A fabric containing modified basalt powder, the fabric being woven from warp and weft yarns, wherein at least one of the warp or weft yarns is a functional yarn containing modified basalt powder, the content of the modified basalt powder in the functional yarn being 0.1wt% to 5wt%; the modified basalt powder having a silicon dioxide content of 50% to 60%, an aluminum oxide content of 12% to 15%, and a magnesium oxide content of 12% to 15%.

[0007] The present invention is further configured such that the particle size of the modified basalt powder is 0.2 to 3 micrometers.

[0008] The present invention is further configured such that the modified basalt powder is a powder that has undergone plasma surface treatment, and its surface contains one or more of the active groups of -C=O, -OH or -NH.

[0009] The technical solution of the present invention also includes a method for preparing a fabric containing modified basalt powder, the preparation method being as follows: S1, Preparation of modified basalt powder: The coarsely processed basalt powder is chemically purified to remove iron oxide and calcium oxide impurities, then ground to a particle size of 0.2-3 micrometers, and then subjected to plasma treatment to obtain modified basalt powder with active groups on the surface; S2, Masterbatch preparation: The modified basalt powder obtained in step S1 is mixed with polyethylene terephthalate (PET) chips at a weight ratio of 1:10 to 1:3, and then melt-blended, extruded, and pelletized to obtain basalt masterbatch. S3, spinning: The basalt masterbatch obtained in step S2 is mixed with polyester chips at a weight ratio of 1:99 to 1:6 and melt-spun to obtain modified basalt fiber filaments. S4, false twisting process: The fiber obtained in step S3 is subjected to false twisting deformation process to obtain modified basalt textured yarn; S5, Weaving: The modified basalt textured yarn is used as at least one of the warp or weft yarns and interwoven with other yarns to obtain a grey fabric; S6, Finishing: The greige fabric is scouring, dyeing and setting to obtain the fabric.

[0010] The present invention is further configured such that the chemical purification in step S1 includes: treating basalt powder with sodium dithionite solution at room temperature to reduce and remove ferric iron impurities; and removing calcium oxide impurities by water washing and filtration.

[0011] The present invention is further configured such that the grinding in step S1 includes: first, subjecting the chemically purified powder to a planetary mill to grind it to a particle size of 5-15 μm; then subjecting it to ultrafine grinding to grind it to a particle size of 0.2-3 μm.

[0012] The present invention is further configured such that the conditions for plasma treatment in step S1 are: DC voltage 400 V, power 1 kW, frequency 200 Hz, treatment time 2-3 min, and the treatment gas is air.

[0013] The present invention is further configured such that the melt blending conditions in step S2 are: blending temperature 250℃~270℃, screw speed 150~450rpm.

[0014] The present invention is further configured such that the melt spinning conditions in step S3 are: spinning temperature 285℃~295℃, spinning speed 2000~3500m / min, and draw ratio 2.0~3.0 times.

[0015] The present invention is further configured such that the conditions for the false twisting deformation process in step S4 are: friction disc speed 700-800 m / min; first heating box temperature 195-205℃; second heating box temperature 35-45℃ lower than the first heating box; D / Y ratio 0.7-0.8.

[0016] The beneficial technical effects of this invention are: The modified basalt powder ensures the stability and high efficiency of far-infrared performance; The modified basalt powder used is white or light-colored, and the fibers and fabrics made from it can be dyed in any light or bright color, which solves the color limitation problem caused by materials such as graphene and greatly expands the application field. The optimized plasma surface treatment process significantly improved the dispersibility of the powder in the polyester matrix and its affinity with the polyester bulk, preventing the deterioration of mechanical properties caused by powder agglomeration. The resulting functional yarn maintained a breaking strength of over 3.2 cN / dtex, fully meeting the requirements for textile processing and apparel. Detailed Implementation

[0017] In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the specific embodiments of the present invention will be described in further detail below with reference to specific examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0018] Example 1: A fabric containing modified basalt powder, the fabric being woven from warp and weft yarns, wherein at least one of the warp or weft yarns is a functional yarn containing modified basalt powder, the content of modified basalt powder in the functional yarn being 0.1 wt%; the modified basalt powder contains 50%–60% silica, 12%–15% alumina, and 12%–15% magnesium oxide, wherein the average particle size of the modified basalt powder is 1.5 μm.

[0019] The preparation method is as follows: S1, take coarsely processed basalt powder, treat it with sodium dithionite solution at room temperature to remove iron impurities, and wash and filter it with water to remove calcium impurities. The purified powder is first ball-milled (120 rpm revolution, 720 rpm rotation, 2.5 h) to 5-15 μm, and then ultra-fine ground to a particle size D50 of 1.5 μm. Subsequently, it is subjected to plasma treatment in air at DC voltage 400V, power 1kW, frequency 200Hz for 2.5 min to obtain modified basalt powder with surface rich in -OH groups (composition: SiO2 55%, Al2O3 14%, MgO 13%, others 18%). S2, the above powder is mixed with PET chips at a weight ratio of 1:10, melt-extruded and pelletized at 260°C and screw speed of 300 rpm to obtain basalt masterbatch; S3, the obtained masterbatch is mixed with polyester chips at a weight ratio of 1:99, and melt-spun at 285℃ with a spinning speed of 2500m / min and a draw ratio of 2.6 times to obtain pre-drawn yarn, such that the content of modified basalt powder in the yarn is about 0.1wt%; S4. The pre-drawn yarn is false-twisted, with a friction disc speed of 750 m / min, a first hot box temperature of 200℃, a second hot box temperature of 170℃, and a D / Y ratio of 0.74, to obtain modified basalt false-twisted textured yarn (DTY) with a density of 83.3 dtex. S5, using this DTY as the weft or warp yarn, interwoven with ordinary PET yarn to form a greige fabric; S6. The obtained greige fabric is scouring with scouring agent 2g / L, sodium carbonate 1.52g / L, and caustic soda 0.6g / L; high-pressure overflow dyeing machine is used for high-temperature dyeing at 130℃ and setting at 180℃ to obtain the entire fabric.

[0020] Example 2 differs from Example 1 in that the content of modified basalt powder in the yarn is changed to 1.5 wt%.

[0021] Example 3 differs from Example 1 in that the content of modified basalt powder in the yarn is changed to 3.0 wt%.

[0022] Example 4 differs from Example 1 in that the content of modified basalt powder in the yarn is changed to 5.0 wt%.

[0023] Comparative Example 1 differs from Example 1 in that the content of modified basalt powder in the yarn is changed to 0.05 wt%.

[0024] Comparative Example 2 differs from Example 1 in that the content of modified basalt powder in the yarn is changed to 7.0 wt%.

[0025] Comparative Example 3 differs from Example 2 in that the basalt powder is not subjected to plasma modification treatment.

[0026] Comparative Example 4 differs from Example 2 in that the average particle size of the modified basalt powder is 5 μm.

[0027] Comparative Example 5 differs from Example 2 in that graphene powder with an average particle size D50 of 1.5 μm is added instead of basalt modified powder.

[0028] Comparative Example 6 differs from Example 1 in that no functional powders are added.

[0029] All the above embodiments and comparative examples were subjected to detailed testing. The test methods and standards were referenced to the standard SS138-1975 "Determination of breaking strength and elongation at break of single yarn" for yarn breaking strength test and GB / T30127-2013 "Test and evaluation of far-infrared performance of textiles" for far-infrared heating performance test.

[0030] The test data table is as follows: Sample number Powder type / processing method Powder particle size (μm) Powder content in yarn (wt%) Yarn breaking strength (cN / dtex) Far-infrared radiation temperature rise (Δ°C) Far-infrared emissivity (ε) Yarn appearance Example 1 Modified basalt (plasma treatment) 1.5 0.1 3.85 3.1 0.92 White, glossy Example 2 Modified basalt (plasma treatment) 1.5 1.5 3.75 3.8 0.94 White, glossy Example 3 Modified basalt (plasma treatment) 1.5 3.0 3.55 4.2 0.95 White, slightly glossy Example 4 Modified basalt (plasma treatment) 1.5 5.0 3.20 4.5 0.96 White, mostly matte Comparative Example 1 Modified basalt (plasma treatment) 1.5 0.05 3.90 1.2 0.83 White, glossy Comparative Example 2 Modified basalt (plasma treatment) 1.5 7.0 2.50 (Fragile) 4.7 0.96 White, rough and matte Comparative Example 3 Basalt (unplasma treated) 1.5 1.5 3.40 (Uneven distribution) 2.5 0.89 White, with blemishes Comparative Example 4 Modified basalt (plasma treatment) 5 1.5 3.10 (Many feathers) 2.0 0.87 White, rough Comparative Example 5 graphene 1.5 1.5 3.70 4.0 0.95 Dark gray with a metallic sheen Comparative Example 6 none - 0 4.10 0.8 0.82 White, glossy The data analysis is as follows: Comparing Examples 1-4 with Comparative Examples 1, 2, and 6: Far-infrared performance: As the content of modified basalt powder increased from 0.1% to 5.0%, the far-infrared radiation temperature rise and emissivity significantly improved (ΔT increased from 3.1°C to 4.5°C, ε increased from 0.92 to 0.96), proving that its functionality is positively correlated with the powder content. The performance of Comparative Example 1 (0.05%) is close to that of the blank control (Comparative Example 6), indicating that it is ineffective at too low a content; although the performance of Comparative Example 2 (7.0%) is high, it has no practical application value.

[0031] Mechanical Properties: The breaking strength of the yarn gradually decreased with increasing powder content because inorganic powder disrupts the continuity of the polymer structure. While the strength of Examples 1-4 (3.85-3.20 cN / dtex) was lower than that of pure PET yarn (Comparative Example 6, 4.10 cN / dtex), it remained within an acceptable range for application. However, the strength of Comparative Example 2 (7.0%) dropped sharply to 2.50 cN / dtex, making spinning difficult and causing yarn breakage, thus justifying the 5.0 wt% upper limit stated in the specification.

[0032] Comparison of Example 2 and Comparative Example 3: Using powder that has not undergone plasma treatment (Comparative Example 3), due to its high surface energy and easy agglomeration, it is dispersed very unevenly in the yarn, resulting in two major problems: Deterioration of mechanical properties: Agglomerates become stress defect points, leading to a decrease in strength (3.40 vs 3.75 cN / dtex).

[0033] Functional performance degradation: Agglomerated powder cannot function uniformly, resulting in significantly lower far-infrared performance compared to samples with the same content treated by plasma (ΔT 2.5°C vs 3.8°C; ε ​​0.89 vs 0.94). This demonstrates that plasma treatment, by introducing active groups and improving the compatibility and dispersibility of the powder with the polyester matrix, is a key step in achieving high performance in this invention.

[0034] Example 2 was compared with Comparative Example 4: Using powder with an excessively large particle size (5-10 μm) (Comparative Example 4) severely impaired the spinnability and mechanical properties of the yarn (strength 3.10 cN / dtex), and also significantly reduced far-infrared performance (ΔT 2.0°C). This is because large-particle-size powder also becomes a defect point, and its small specific surface area results in low efficiency in absorbing and reflecting far-infrared radiation. This demonstrates the necessity of finely grinding the powder to 0.2-3 μm.

[0035] Example 2 is compared with Comparative Example 5: The present invention (Example 2) is comparable to or even better than the graphene material (Comparative Example 5) in far-infrared performance.

[0036] The key difference between the two lies in the fact that the yarn produced by this invention is white and can be easily dyed into any light or bright color, making it widely applicable; while graphene yarn is dark gray, with limited color options, and cannot be used on light-colored fabrics at all. This highlights the significant advantage of this invention in solving the technical problem of "color limitations."

[0037] In summary, the modified basalt powder content range (0.1-5.0 wt%) described in this invention represents the optimal balance between spinnability (strength) and functionality (far-infrared performance).

[0038] Chemical purification, fine grinding, and plasma treatment—this combination of modification techniques is indispensable for obtaining high-performance, highly stable functional yarns.

[0039] This invention successfully achieves the goals of excellent far-infrared performance, reliable mechanical properties, and unlimited color, with overall performance surpassing existing technical solutions.

[0040] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A fabric containing modified basalt powder, characterized in that: The fabric is made of interwoven warp and weft yarns, and at least one of the warp or weft yarns is a functional yarn containing modified basalt powder. The modified basalt powder content in the functional yarn is 0.1wt% to 5wt%. The modified basalt powder contains 50% to 60% silicon dioxide, 12% to 15% aluminum oxide, and 12% to 15% magnesium oxide.

2. The fabric containing modified basalt powder according to claim 1, characterized in that: The modified basalt powder has a particle size of 0.2–3 micrometers.

3. The fabric containing modified basalt powder according to claim 1, characterized in that: The modified basalt powder is a powder that has undergone plasma surface treatment, and its surface contains one or more of the active groups -C=O, -OH or -NH.

4. A method for preparing a fabric containing modified basalt powder, used for preparing the fabric according to any one of claims 1-8, characterized in that: S1, Preparation of modified basalt powder: The coarsely processed basalt powder is chemically purified to remove iron oxide and calcium oxide impurities, then ground to a particle size of 0.2-3 micrometers, and then subjected to plasma treatment to obtain modified basalt powder with active groups on the surface; S2, Masterbatch preparation: The modified basalt powder obtained in step S1 is mixed with polyethylene terephthalate (PET) chips at a weight ratio of 1:10 to 1:3, and then melt-blended, extruded, and pelletized to obtain basalt masterbatch. S3, spinning: The basalt masterbatch obtained in step S2 is mixed with polyester chips at a weight ratio of 1:99 to 1:6 and melt-spun to obtain modified basalt fiber filaments. S4, false twisting process: The fiber obtained in step S3 is subjected to false twisting deformation process to obtain modified basalt textured yarn; S5, Weaving: The modified basalt textured yarn is used as at least one of the warp or weft yarns and interwoven with other yarns to obtain a grey fabric; S6, Finishing: The greige fabric is scouring, dyeing and setting to obtain the fabric.

5. The method for preparing a fabric containing modified basalt powder according to claim 4, characterized in that: The chemical purification in step S1 includes: treating basalt powder with sodium dithionite solution at room temperature to reduce and remove ferric iron impurities; and removing calcium oxide impurities by water washing and filtration.

6. The method for preparing a fabric containing modified basalt powder according to claim 4, characterized in that: The grinding process in step S1 includes: first, grinding the chemically purified powder into a planetary mill until the particle size is 5-15 μm; then, performing ultrafine grinding until the particle size is 0.2-3 μm.

7. The method for preparing a fabric containing modified basalt powder according to claim 4, characterized in that: The conditions for plasma treatment in step S1 are: DC voltage 400V, power 1kW, frequency 200Hz, treatment time 2~3min, and the treatment gas is air.

8. The method for preparing a fabric containing modified basalt powder according to claim 4, characterized in that: The conditions for melt blending in step S2 are: blending temperature 250℃~270℃, screw speed 150~450rpm.

9. The method for preparing a fabric containing modified basalt powder according to claim 4, characterized in that: The conditions for melt spinning in step S3 are: spinning temperature 285℃~295℃, spinning speed 2000~3500m / min, and draw ratio 2.0~3.0 times.

10. The method for preparing a fabric containing modified basalt powder according to claim 4, characterized in that: The conditions for the false twisting deformation process described in step S4 are: friction disc speed 700-800 m / min; first heating box temperature 195-205℃; second heating box temperature 35-45℃ lower than the first heating box; D / Y ratio 0.7-0.8.