Nylon fabric capable of preventing pattern from floating and discoloring and process for manufacturing sports cap by using nylon fabric

Abstract

The invention discloses a nylon fabric capable of preventing a pattern from floating and discoloring and a process for manufacturing a sports cap by using the nylon fabric, and relates to the technical field of clothing textile. The process comprises the following steps: firstly, mixing deionized water with polyethylene glycol 400 to form a transparent solution, then adding waterborne polyurethane emulsion, and stirring to obtain a transparent solution; then adding nano silicon dioxide and modified nano zinc oxide, carrying out ultrasonic dispersion, then adding an ultraviolet light absorber, epoxidized soybean oil and an organic silicon defoaming agent, stirring, and filtering to obtain an anti-discoloration composite coating solution; the preparation method comprises the following steps: pretreating a nylon 66 fabric base material to remove greasy dirt and floating dust, drying, coating the printing surface of the fabric with the obtained coating liquid by adopting a scraper coating machine, sequentially pre-drying, curing, cooling and sealing to obtain the anti-discoloration modified nylon fabric, cutting the anti-discoloration modified nylon fabric according to the sports cap pattern, printing and drying the printing area of the cap body cutting piece, and finally ironing and shaping to obtain the sports cap capable of preventing the pattern from floating and discoloration.

Description

Technical Field

[0001] This invention belongs to the field of clothing and textile technology, and in particular relates to a nylon fabric that prevents patterns from fading and changing color, and a process for manufacturing sports caps using the fabric. Background Technology

[0002] In the field of apparel and textile technology, nylon fabric is widely used in the manufacture of sports caps due to its lightweight, durability, and ease of dyeing. However, patterns on existing nylon fabrics are prone to discoloration and fading after prolonged exposure to ultraviolet rays, sweat, or frequent washing, severely affecting the product's appearance and lifespan. Traditional anti-discoloration treatments, such as ordinary coatings or chemical additives, suffer from problems such as short-lasting effects, easy peeling of the coating, or impact on fabric breathability and comfort. Furthermore, existing processes lack sufficient control over the dispersion of nanomaterials and the uniformity of the coating, leading to unstable protective performance and reduced clarity of pattern edges. Therefore, we propose a nylon fabric that prevents pattern discoloration and a process for manufacturing sports caps using this fabric. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution:

[0004] This invention relates to a nylon fabric for preventing pattern fading and discoloration, and a process for manufacturing sports caps using the fabric, comprising the following steps:

[0005] Step S1: Preparation of anti-discoloration composite coating liquid: First, deionized water and polyethylene glycol 400 are mixed to form a transparent solution, then water-based polyurethane emulsion is added and stirred, then nano-silica and modified nano-zinc oxide are added and ultrasonically dispersed, then ultraviolet absorber, epoxidized soybean oil and organosilicon defoamer are added and stirred, and after filtration, the anti-discoloration composite coating liquid is obtained.

[0006] Step S2: Anti-coloring modification treatment of nylon fabric: The nylon 66 fabric substrate is pretreated to remove oil and dust, and after drying, the coating liquid obtained in step S1 is applied to the printed surface of the fabric using a doctor blade coating machine. After pre-baking and curing, the fabric is cooled and sealed to obtain anti-coloring modified nylon fabric.

[0007] Step S3: Manufacturing a sports cap using anti-fading modified nylon fabric: Cut the anti-fading modified nylon fabric obtained in step S2 according to the sports cap pattern, print and dry the printed area of ​​the cap body piece, then sew the cap body, brim, sweatband and adjustment buckle in sequence, and finally iron and shape to obtain a sports cap that prevents the pattern from fading and changing color.

[0008] Further, the anti-discoloration composite coating liquid in step S1 comprises the following components by weight: 5-10 parts of nano-silica (particle size 15-20nm, hydrophilic modification), 3-8 parts of nano-zinc oxide (particle size 20-30nm, surface coated with silane coupling agent KH-550), 20-30 parts of waterborne polyurethane emulsion (solid content 35-40%, soft segment is polybutylene adipate), 2-5 parts of polyethylene glycol 400 (analytical grade), 1-3 parts of ultraviolet absorber UV-531, 1-4 parts of epoxidized soybean oil (industrial grade, epoxy value ≥6.0%), 30-50 parts of deionized water, and 0.1-0.3 parts of organosilicon defoamer (solid content 10%).

[0009] Furthermore, step S1 includes the following steps:

[0010] Step S11: Take 30-50 parts of deionized water and pour it into a 500mL three-necked flask. Place it in a constant temperature water bath at 30-35℃. Turn on the electric stirrer (speed 300-400r / min) and slowly add 2-5 parts of polyethylene glycol 400. Stir for 15-20 minutes until completely dissolved to form a transparent solution A.

[0011] Step S12: Keep the stirring speed constant and slowly add 20-30 parts of waterborne polyurethane emulsion (solid content 35-40%, soft segment is polybutylene adipate) to solution A. The dropping speed is controlled at 1-2 mL / min. After the dropping is completed, continue stirring for 30-40 minutes to obtain milky white mixture B.

[0012] In step S13, stop stirring and add 5-10 parts of nano-silica (particle size 15-20nm, hydrophilic modified) and 3-8 parts of nano-zinc oxide (particle size 20-30nm, surface coated with silane coupling agent KH-550) to the mixture B in sequence. Then transfer the three-necked flask to an ultrasonic cell disruptor and ultrasonically disperse it for 25-30 minutes at a power of 300-350W to break up the nanoparticle aggregates and obtain suspension C.

[0013] Step S14: Return suspension C to the constant temperature water bath, restore the temperature to 30-35℃ and stir at 300-400r / min, add 1-3 parts of UV absorber UV-531 and 1-4 parts of epoxidized soybean oil (industrial grade, epoxy value ≥6.0%), stir for 20-25 minutes, then add 0.1-0.3 parts of organosilicon defoamer (solid content 10%), and continue stirring for 10-15 minutes to obtain a uniform anti-discoloration coating liquid.

[0014] Furthermore, in step S2, the anti-discoloration modification treatment of the nylon fabric also includes the following steps:

[0015] Step S21: Take 100 portions of nylon 66 fabric substrate (using plain weave fabric made of 70D / 24F semi-dull nylon 66 filament, with a basic weight of 120-140g / ㎡), soak it in deionized water at 50-55℃ for 20-25 minutes, add 0.5% (relative to the weight of the fabric) of neutral detergent, and gently stir to remove oil and dust from the surface of the fabric to complete the pretreatment.

[0016] Step S22: Place the pretreated fabric into a hot air circulating oven and dry it at 80-85℃ for 30-35 minutes until the fabric moisture content is ≤5%. After removing it, cool it to room temperature and lay it flat on the coating machine worktable.

[0017] Step S23: Use a doctor blade coating machine to coat one side of the dried fabric (the coated side is the side to be printed with the pattern later). Adjust the doctor blade gap to 80-100μm and control the coating machine speed to 1.5-2m / min to ensure that the coating liquid evenly covers the fabric surface.

[0018] Step S24: Immediately place the coated fabric into a pre-drying oven and pre-dry it at 60-65℃ for 40-45 minutes to allow most of the deionized water in the coating to evaporate and form a semi-cured coating.

[0019] Step S25: After pre-drying, transfer the fabric to a curing oven and cure it at 120-125℃ for 60-70 minutes to allow the waterborne polyurethane to fully cross-link and the nanoparticles to firmly bond with the fabric, thus obtaining the colorfast modified nylon fabric.

[0020] Furthermore, in step S3, manufacturing a sports cap using anti-fading modified nylon fabric also includes the following steps:

[0021] Step S31: According to the designed sports cap pattern (including four parts: cap body, brim, sweatband, and adjustment buckle patch), use a CNC cutting machine to cut the colorfast modified nylon fabric, ensuring that the cut edges are flat and the error is ≤0.5cm, to obtain the cut pieces of each part (2 cap body pieces, 1 brim piece, 1 sweatband piece, and 2 adjustment buckle patches).

[0022] Step S32: Pre-treat the printed area of ​​the hat body piece: Wipe the printed area with alcohol to remove surface dust, and then use a screen printing machine to print environmentally friendly water-based printing ink (compatible with the coating) on ​​the designated position of the piece. The printing pressure is controlled at 0.3-0.4MPa. After printing, put the piece into a low temperature oven at 40-45℃ and dry it for 25-30 minutes to complete the pattern setting.

[0023] Step S33: Use an industrial flat sewing machine to sew the hat body: Align the sides of the two hat body pieces, and overlock them with polyester thread. The seam allowance is 1.2-1.5cm, and the sewing speed is controlled at 2500-2800 stitches / minute to form a hollow hat body.

[0024] Step S34: Sewing the brim: Align the brim piece with the bottom edge of the main body of the hat. First, manually fix 3-4 positioning points, then use a flat sewing machine to sew the edges. The seam allowance should be 0.8-1cm to ensure that the brim is firmly connected to the hat body without wrinkles.

[0025] Step S35: Install the sweatband: Fold the raw edge of the sweatband piece inward by 0.5cm, press and shape it with an iron (temperature 110-120℃), and then attach the sweatband to the forehead area inside the hat body. Use a blind stitching process to avoid exposed stitches and improve wearing comfort.

[0026] Step S36: Install the adjustment buckle: Sew the adjustment buckle patch to the opening at the back of the hat, aligning the edge of the patch with the seam allowance of the hat body. Sew 2-3 reinforcing lines, and then fix the plastic adjustment buckle to the patch, ensuring that the adjustment buckle can open and close smoothly to fit different head circumferences.

[0027] Step S37: Place the sewn sports cap into a steam ironing machine and iron it for 10-15 seconds at a steam pressure of 0.2-0.3MPa and a temperature of 95-100℃, focusing on ironing the brim and the seams of the cap body to make the cap look crisp. Then let it cool naturally to room temperature to complete the preparation of the sports cap.

[0028] Furthermore, in step S1, the rotation speed of the electric stirrer is stably controlled at 300-400 r / min, with no fluctuations greater than ±5 r / min; the power output deviation of the ultrasonic cell disruptor is ≤10W, ensuring that the uniformity of nanoparticle dispersion is ≥95%.

[0029] Furthermore, in step S2, the plain weave density of the nylon 66 fabric substrate is 30-35 threads / cm in the warp and 28-32 threads / cm in the weft; the temperature uniformity error of the hot air circulating oven is ≤±2℃ to avoid local over- or under-drying of the fabric; the blade flatness deviation of the doctor blade coating machine is ≤0.02mm to ensure uniform coating thickness.

[0030] Furthermore, in step S3, the cutting accuracy error of the CNC cutting machine is ≤0.3cm, and the cutting speed can be adjusted between 0.8-1.2m / min according to the fabric thickness; the printing pressure stability deviation of the screen printing machine is ≤±0.02MPa, ensuring that the edge clarity of the printed pattern is ≥98%; the stitch length of the industrial flat sewing machine is adjustable within a range of 2-3mm to adapt to different fabric splicing requirements.

[0031] Furthermore, the degree of hydrophilic modification of the nano-silica is detected by a contact angle measuring instrument, and the contact angle is ≤30°; the gel content of the water-based polyurethane emulsion is ≥90%, ensuring the water wash resistance of the cured coating (after 20 washes at 50°C, the coating adhesion is ≥4).

[0032] The present invention has the following beneficial effects:

[0033] 1. This invention prepares an anti-discoloration composite coating liquid containing nano-silica and nano-zinc oxide, and uses ultrasonic dispersion technology to ensure uniform dispersion of nanoparticles, effectively improving the coating's ultraviolet absorption and scattering capabilities. This significantly enhances the lightfastness of nylon fabric patterns, preventing discoloration and fading caused by long-term exposure to ultraviolet light. At the same time, the epoxy soybean oil and water-based polyurethane in the coating form a dense network structure, further blocking the erosion of sweat and detergents, ensuring the patterns remain vibrant and extending the lifespan of sports caps. In addition, the synergistic effect of nanomaterials enhances the stability and durability of the coating.

[0034] 2. This invention optimizes the composition of the coating liquid and the curing process, enabling the anti-discoloration coating to firmly bond with the nylon fabric substrate. It exhibits excellent washability and adhesion, maintaining a coating adhesion level of 4 or higher even after 20 washes at 50°C. This effectively avoids the problem of easy peeling of traditional coatings. At the same time, the polyethylene glycol 400 and water-based polyurethane soft segments in the coating provide appropriate flexibility, maintaining the original breathability and comfort of the fabric without affecting the wearing experience of the sports cap. This solves the defect of traditional treatment methods that affect the comfort of the fabric. In addition, the coated fabric still retains its lightweight and durable characteristics, making it suitable for daily use of sports caps.

[0035] 3. This invention employs high-precision equipment for process control, such as an ultrasonic cell disruptor to ensure nano-dispersion uniformity ≥95%, a doctor blade coating machine to control coating thickness uniformity, and a screen printing machine to ensure the edge clarity of the printed pattern ≥98%. This achieves stable protective performance and high pattern clarity. The entire process, from coating preparation to fabric treatment and sports cap manufacturing, has precise parameter control at each stage, such as temperature, rotation speed, and pressure, ensuring consistent and reliable product quality. It is suitable for large-scale production. At the same time, this process improves production efficiency and product yield, and reduces the defect rate.

[0036] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0037] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 This is a schematic diagram of the process for manufacturing sports caps using a nylon fabric that prevents patterns from fading or changing color, according to the present invention. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] Please see Figure 1 As shown, the present invention relates to a nylon fabric for preventing pattern fading and discoloration, and a process for manufacturing sports caps using the fabric, comprising the following steps:

[0041] Step S1: Preparation of anti-discoloration composite coating liquid: First, deionized water and polyethylene glycol 400 are mixed to form a transparent solution, then water-based polyurethane emulsion is added and stirred, then nano-silica and modified nano-zinc oxide are added and ultrasonically dispersed, then ultraviolet absorber, epoxidized soybean oil and organosilicon defoamer are added and stirred, and after filtration, the anti-discoloration composite coating liquid is obtained.

[0042] Step S2: Anti-coloring modification treatment of nylon fabric: The nylon 66 fabric substrate is pretreated to remove oil and dust, and after drying, the coating liquid obtained in step S1 is applied to the printed surface of the fabric using a doctor blade coating machine. After pre-baking and curing, the fabric is cooled and sealed to obtain anti-coloring modified nylon fabric.

[0043] Step S3: Manufacturing a sports cap using anti-fading modified nylon fabric: Cut the anti-fading modified nylon fabric obtained in step S2 according to the sports cap pattern, print and dry the printed area of ​​the cap body piece, then sew the cap body, brim, sweatband and adjustment buckle in sequence, and finally iron and shape to obtain a sports cap that prevents the pattern from fading and changing color.

[0044] Further, the anti-discoloration composite coating liquid in step S1 comprises the following components by weight: 5-10 parts of nano-silica (particle size 15-20nm, hydrophilic modification), 3-8 parts of nano-zinc oxide (particle size 20-30nm, surface coated with silane coupling agent KH-550), 20-30 parts of waterborne polyurethane emulsion (solid content 35-40%, soft segment is polybutylene adipate), 2-5 parts of polyethylene glycol 400 (analytical grade), 1-3 parts of ultraviolet absorber UV-531, 1-4 parts of epoxidized soybean oil (industrial grade, epoxy value ≥6.0%), 30-50 parts of deionized water, and 0.1-0.3 parts of organosilicon defoamer (solid content 10%).

[0045] Furthermore, step S1 includes the following steps:

[0046] Step S11: Take 30-50 parts of deionized water and pour it into a 500mL three-necked flask. Place it in a constant temperature water bath at 30-35℃. Turn on the electric stirrer (speed 300-400r / min) and slowly add 2-5 parts of polyethylene glycol 400. Stir for 15-20 minutes until completely dissolved to form a transparent solution A.

[0047] Step S12: Keep the stirring speed constant and slowly add 20-30 parts of waterborne polyurethane emulsion (solid content 35-40%, soft segment is polybutylene adipate) to solution A. The dropping speed is controlled at 1-2 mL / min. After the dropping is completed, continue stirring for 30-40 minutes to obtain milky white mixture B.

[0048] In step S13, stop stirring and add 5-10 parts of nano-silica (particle size 15-20nm, hydrophilic modified) and 3-8 parts of nano-zinc oxide (particle size 20-30nm, surface coated with silane coupling agent KH-550) to the mixture B in sequence. Then transfer the three-necked flask to an ultrasonic cell disruptor and ultrasonically disperse it for 25-30 minutes at a power of 300-350W to break up the nanoparticle aggregates and obtain suspension C.

[0049] Step S14: Return suspension C to the constant temperature water bath, restore the temperature to 30-35℃ and stir at 300-400r / min, add 1-3 parts of UV absorber UV-531 and 1-4 parts of epoxidized soybean oil (industrial grade, epoxy value ≥6.0%), stir for 20-25 minutes, then add 0.1-0.3 parts of organosilicon defoamer (solid content 10%), and continue stirring for 10-15 minutes to obtain a uniform anti-discoloration coating liquid.

[0050] Furthermore, in step S2, the anti-discoloration modification treatment of the nylon fabric also includes the following steps:

[0051] Step S21: Take 100 portions of nylon 66 fabric substrate (using plain weave fabric made of 70D / 24F semi-dull nylon 66 filament, with a basic weight of 120-140g / ㎡), soak it in deionized water at 50-55℃ for 20-25 minutes, add 0.5% (relative to the weight of the fabric) of neutral detergent, and gently stir to remove oil and dust from the surface of the fabric to complete the pretreatment.

[0052] Step S22: Place the pretreated fabric into a hot air circulating oven and dry it at 80-85℃ for 30-35 minutes until the fabric moisture content is ≤5%. After removing it, cool it to room temperature and lay it flat on the coating machine worktable.

[0053] Step S23: Use a doctor blade coating machine to coat one side of the dried fabric (the coated side is the side to be printed with the pattern later). Adjust the doctor blade gap to 80-100μm and control the coating machine speed to 1.5-2m / min to ensure that the coating liquid evenly covers the fabric surface.

[0054] Step S24: Immediately place the coated fabric into a pre-drying oven and pre-dry it at 60-65℃ for 40-45 minutes to allow most of the deionized water in the coating to evaporate and form a semi-cured coating.

[0055] Step S25: After pre-drying, transfer the fabric to a curing oven and cure it at 120-125℃ for 60-70 minutes to allow the waterborne polyurethane to fully cross-link and the nanoparticles to firmly bond with the fabric, thus obtaining the colorfast modified nylon fabric.

[0056] Furthermore, in step S3, manufacturing a sports cap using anti-fading modified nylon fabric also includes the following steps:

[0057] Step S31: According to the designed sports cap pattern (including four parts: cap body, brim, sweatband, and adjustment buckle patch), use a CNC cutting machine to cut the colorfast modified nylon fabric, ensuring that the cut edges are flat and the error is ≤0.5cm, to obtain the cut pieces of each part (2 cap body pieces, 1 brim piece, 1 sweatband piece, and 2 adjustment buckle patches).

[0058] Step S32: Pre-treat the printed area of ​​the hat body piece: Wipe the printed area with alcohol to remove surface dust, and then use a screen printing machine to print environmentally friendly water-based printing ink (compatible with the coating) on ​​the designated position of the piece. The printing pressure is controlled at 0.3-0.4MPa. After printing, put the piece into a low temperature oven at 40-45℃ and dry it for 25-30 minutes to complete the pattern setting.

[0059] Step S33: Use an industrial flat sewing machine to sew the hat body: Align the sides of the two hat body pieces, and overlock them with polyester thread. The seam allowance is 1.2-1.5cm, and the sewing speed is controlled at 2500-2800 stitches / minute to form a hollow hat body.

[0060] Step S34: Sewing the brim: Align the brim piece with the bottom edge of the main body of the hat. First, manually fix 3-4 positioning points, then use a flat sewing machine to sew the edges. The seam allowance should be 0.8-1cm to ensure that the brim is firmly connected to the hat body without wrinkles.

[0061] Step S35: Install the sweatband: Fold the raw edge of the sweatband piece inward by 0.5cm, press and shape it with an iron (temperature 110-120℃), and then attach the sweatband to the forehead area inside the hat body. Use a blind stitching process to avoid exposed stitches and improve wearing comfort.

[0062] Step S36: Install the adjustment buckle: Sew the adjustment buckle patch to the opening at the back of the hat, aligning the edge of the patch with the seam allowance of the hat body. Sew 2-3 reinforcing lines, and then fix the plastic adjustment buckle to the patch, ensuring that the adjustment buckle can open and close smoothly to fit different head circumferences.

[0063] Step S37: Place the sewn sports cap into a steam ironing machine and iron it for 10-15 seconds at a steam pressure of 0.2-0.3MPa and a temperature of 95-100℃, focusing on ironing the brim and the seams of the cap body to make the cap look crisp. Then let it cool naturally to room temperature to complete the preparation of the sports cap.

[0064] Furthermore, in step S1, the rotation speed of the electric stirrer is stably controlled at 300-400 r / min, with no fluctuations greater than ±5 r / min; the power output deviation of the ultrasonic cell disruptor is ≤10W, ensuring that the uniformity of nanoparticle dispersion is ≥95%.

[0065] Furthermore, in step S2, the plain weave density of the nylon 66 fabric substrate is 30-35 threads / cm in the warp and 28-32 threads / cm in the weft; the temperature uniformity error of the hot air circulating oven is ≤±2℃ to avoid local over- or under-drying of the fabric; the blade flatness deviation of the doctor blade coating machine is ≤0.02mm to ensure uniform coating thickness.

[0066] Furthermore, in step S3, the cutting accuracy error of the CNC cutting machine is ≤0.3cm, and the cutting speed can be adjusted between 0.8-1.2m / min according to the fabric thickness; the printing pressure stability deviation of the screen printing machine is ≤±0.02MPa, ensuring that the edge clarity of the printed pattern is ≥98%; the stitch length of the industrial flat sewing machine is adjustable within a range of 2-3mm to adapt to different fabric splicing requirements.

[0067] Furthermore, the degree of hydrophilic modification of the nano-silica is detected by a contact angle measuring instrument, and the contact angle is ≤30°; the gel content of the water-based polyurethane emulsion is ≥90%, ensuring the water wash resistance of the cured coating (after 20 washes at 50°C, the coating adhesion is ≥4).

[0068] One specific application of this embodiment is:

[0069] Step 1:

[0070] 1.1 Raw material ratio:

[0071] Nano-silica (particle size 18nm, hydrophilic modification, contact angle 25°): 8 parts;

[0072] Nano zinc oxide (particle size 25nm, surface coated with silane coupling agent KH-550): 5 parts;

[0073] Waterborne polyurethane emulsion (solid content 38%, soft segment is polybutylene adipate, gel content 92%): 25 parts;

[0074] Polyethylene glycol 400 (analytical grade): 3 parts;

[0075] UV absorber UV-531: 2 parts;

[0076] UV absorber UV-531: 2 parts;

[0077] Epoxidized soybean oil (industrial grade, epoxy value 6.2%): 2.5 parts;

[0078] Deionized water: 40 parts;

[0079] Organosilicon defoamer (10% solid content): 0.2 parts;

[0080] 1.2 Preparation process:

[0081] Step S11: Take 40 parts of deionized water and pour it into a 500mL three-necked flask. Place it in a 32℃ constant temperature water bath, turn on the electric stirrer (speed 350r / min, fluctuation ±3r / min), slowly add 3 parts of polyethylene glycol 400, and stir for 18 minutes until completely dissolved to form a transparent solution A.

[0082] Step S12: While maintaining a rotation speed of 350 r / min, add 25 parts of aqueous polyurethane emulsion dropwise to solution A at a rate of 1.5 mL / min. After the addition is complete, continue stirring for 35 minutes to obtain a milky white mixture B.

[0083] Step S13: Stop stirring, add 8 parts of nano-silica and 5 parts of nano-zinc oxide to the mixture B in sequence, transfer the three-necked flask to an ultrasonic cell disruptor (power 320W, output deviation 8W), and ultrasonically disperse for 28 minutes to break up the nanoparticle agglomerates and obtain suspension C (nanoparticle dispersion uniformity 96%).

[0084] Step S14: Return suspension C to a 32℃ constant temperature water bath, resume stirring at 350r / min, add 2 parts of UV absorber UV-531 and 2.5 parts of epoxidized soybean oil, stir for 22 minutes, add 0.2 parts of organosilicon defoamer, continue stirring for 12 minutes, and filter to obtain a uniform anti-discoloration composite coating liquid.

[0085] Step Two:

[0086] 2.1 Nylon 66 fabric base material: Plain weave fabric made of 70D / 24F semi-dull nylon 66 filament, weight 130g / ㎡, warp weave density 32 threads / cm, weft weave density 30 threads / cm;

[0087] Hot air circulating oven: Temperature uniformity error ±1.5℃;

[0088] Scraper coating machine: Scraper blade edge flatness deviation 0.015mm;

[0089] 2.2 Step S21: Take 100 parts of nylon 66 fabric substrate, soak it in deionized water at 52℃ for 22 minutes, add 0.5% (relative to the weight of the fabric) of neutral detergent, gently stir to remove surface oil and dust, and complete the pretreatment.

[0090] Step S22: Place the pretreated fabric into a hot air circulating oven and dry it at 82°C for 32 minutes. The moisture content of the fabric is 4% (≤5%). After cooling to room temperature, remove the fabric and lay it flat on the coating machine worktable.

[0091] Step S23: Use a doctor blade coating machine to coat the "subsequent printing side" of the dried fabric on one side. Adjust the doctor blade gap to 90μm and control the coating machine running speed to 1.8m / min to ensure that the coating liquid evenly covers the fabric surface.

[0092] Step S24: Immediately place the coated fabric into a pre-drying oven and pre-dry at 62°C for 42 minutes to allow most of the deionized water in the coating to evaporate and form a semi-cured coating.

[0093] Step S25: Transfer the pre-dried fabric to a curing oven and cure at 123°C for 65 minutes to allow the waterborne polyurethane to fully cross-link and the nanoparticles to firmly bond with the fabric, thus obtaining a colorfast modified nylon fabric.

[0094] Step 3:

[0095] 3.1 CNC cutting machine: cutting accuracy error 0.2cm, cutting speed 1.0m / min (adapted to the fabric thickness of this embodiment);

[0096] Screen printing machine: Printing pressure stability deviation ±0.01MPa;

[0097] Industrial flatbed sewing machine: stitch length adjustment range 2.5mm;

[0098] Environmentally friendly water-based printing inks: compatible with anti-fading coatings;

[0099] Polyester thread: suitable for sewing nylon fabrics;

[0100] Plastic adjustment buckle: Smooth opening and closing, suitable for head circumferences of 54-60cm;

[0101] 3.2 Step S31: According to the sports cap pattern (including the cap body, brim, sweatband, and adjustment buckle patch), use a CNC cutting machine to cut the color-resistant modified nylon fabric to obtain 2 cap body pieces, 1 brim piece, 1 sweatband piece, and 2 adjustment buckle patches. The cut edges are flat with an error of 0.2cm.

[0102] Step S32: Wipe the printed area of ​​the hat body piece with alcohol to remove dust, and use a screen printing machine to print environmentally friendly water-based printing ink on the designated position with a printing pressure of 0.35MPa; after printing, put the piece into a 42℃ low temperature oven and dry for 28 minutes to complete the pattern setting (pattern edge clarity 99%).

[0103] Step S33: Sew the hat body using an industrial flat sewing machine. Align the sides of the two hat body pieces and overlock them with polyester thread. The seam allowance is 1.3cm and the sewing speed is 2600 stitches / minute to form the hollow hat body body.

[0104] Step S34: Align the brim piece with the bottom edge of the main body of the hat, fix 3 positioning points by hand, and sew the edges with a flat sewing machine with a seam allowance of 0.9cm to ensure a firm and wrinkle-free connection;

[0105] Step S35: Fold the raw edge of the sweatband piece inward by 0.5cm and press it with a 115℃ iron to shape it; attach the sweatband to the inside of the hat body at the forehead position and sew it using a blind stitch technique to avoid the stitches being exposed;

[0106] Step S36: Sew the adjustment buckle patch to the opening at the back of the hat, aligning the edge of the patch with the seam allowance of the hat body, and sew two reinforcing lines; fix the plastic adjustment buckle to the patch and test that the adjustment buckle opens and closes smoothly;

[0107] Step S37: Place the sewn sports cap into a steam iron and iron it for 12 seconds at a steam pressure of 0.25MPa and a temperature of 98℃, paying special attention to ironing the brim and seams; after ironing, allow it to cool naturally to room temperature to obtain a sports cap that prevents the pattern from fading or changing color.

[0108] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0109] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A process for preventing pattern bloom discoloration of nylon fabric and manufacturing sports cap using the fabric, characterized in that: It comprises the following steps: Step S1: preparation of the anti-fading composite coating solution: first, mix deionized water and polyethylene glycol 400 to form a transparent solution, then add water-based polyurethane emulsion and stir, then add nano-silicon dioxide and modified nano-zinc oxide and disperse by ultrasonic, then add ultraviolet absorber, epoxy soybean oil and silicone defoaming agent and stir, filter to obtain the anti-fading composite coating solution; Step S2: anti-fading modification treatment of nylon fabric: the nylon 66 fabric substrate is pretreated to remove oil dirt and dust, dried, and then the coating solution obtained in step S1 is coated on the fabric printing surface by using a doctor blade coating machine, and then pre-baking, curing, cooling and sealing are sequentially performed to obtain the anti-fading modified nylon fabric; Step S3: use the anti-fading modified nylon fabric to manufacture sports hats: the anti-fading modified nylon fabric obtained in step S2 is cut according to the paper pattern of the sports hat, the printing area of the hat body piece is printed and dried, then the hat body, the brim, the sweat band and the adjusting buckle are sequentially sewn, and finally the anti-fading sports hat is obtained after ironing and shaping.

2. A process for preventing pattern discoloration of nylon fabric and manufacturing sports cap using the fabric thereof according to claim 1, wherein, The anti-fading composite coating solution in step S1 comprises the following components by weight: 5-10 parts of nano-silicon dioxide, 3-8 parts of nano-zinc oxide, 20-30 parts of water-based polyurethane emulsion, 2-5 parts of polyethylene glycol 400, 1-3 parts of ultraviolet absorber UV-531, 1-4 parts of epoxy soybean oil, 30-50 parts of deionized water, and 0.1-0.3 parts of silicone defoaming agent.

3. The process as claimed in claim 1, wherein the nylon fabric is prevented from discoloration due to pattern bleeding and the process for manufacturing sports cap using the fabric is provided. The step S1 comprises the following steps: Step S11, pour 30-50 parts of deionized water into a 500 mL three-necked flask, place it in a 30-35℃ constant temperature water bath, start the electric stirrer, slowly add 2-5 parts of polyethylene glycol 400, stir for 15-20 minutes until completely dissolved, form a transparent solution A; Step S12, keep the stirring speed unchanged, slowly add 20-30 parts of water-based polyurethane emulsion to solution A, the dropwise adding speed is controlled at 1-2 mL / min, continue stirring for 30-40 minutes after dropwise adding is completed, obtain a milky white mixed liquid B; Step S13, pause stirring, add 5-10 parts of nano-silicon dioxide and 3-8 parts of nano-zinc oxide to mixed liquid B in sequence, then transfer the three-necked flask to an ultrasonic cell disruptor, ultrasonic dispersion for 25-30 minutes at a power of 300-350 W, break the nano-particle agglomerates, obtain a suspension C; Step S14, put suspension C back into the constant temperature water bath, restore the temperature to 30-35℃ and the stirring speed to 300-400 r / min, add 1-3 parts of ultraviolet absorber UV-531 and 1-4 parts of epoxy soybean oil, stir for 20-25 minutes, then add 0.1-0.3 parts of silicone defoaming agent dropwise, continue stirring for 10-15 minutes, obtain a uniform anti-fading coating solution.

4. The process as claimed in claim 1, wherein the nylon fabric is prevented from discoloration due to pattern bleeding and the process for manufacturing sports cap using the fabric is provided. The anti-fading modification treatment of nylon fabric in step S2 further comprises the following steps: Step S21, take 100 parts of nylon 66 fabric substrate, soak in 50-55℃ deionized water for 20-25 minutes, add 0.5% neutral detergent, gently stir to remove oil dirt and dust on the surface of the fabric, complete the pretreatment; Step S22, the pretreated fabric is placed in a hot air circulating oven, dried at 80-85℃ for 30-35 minutes, until the moisture content of the fabric is ≤5%, then cooled to room temperature, and laid on the workbench of the coating machine; Step S23, the dried fabric is coated on one side using a doctor blade coating machine, the gap of the doctor blade is adjusted to 80-100μm, and the running speed of the coating machine is controlled at 1.5-2m / min to ensure uniform coverage of the coating liquid on the surface of the fabric; Step S24, the coated fabric is immediately sent to a pre-drying oven, pre-dried at 60-65℃ for 40-45 minutes to volatilize most of the deionized water in the coating and form a semi-cured coating; Step S25, after pre-drying, the fabric is transferred to a curing oven, cured at 120-125℃ for 60-70 minutes to fully crosslink the water-based polyurethane and firmly bond the nanoparticles with the fabric, obtaining the anti-discoloration modified nylon fabric.

5. The process as claimed in claim 1, wherein the nylon fabric is prevented from discoloration due to pattern bleeding and the process for manufacturing sports cap using the fabric is provided. In step S3, the anti-discoloration modified nylon fabric is used to manufacture sports hats, which further includes the following steps: Step S31, according to the designed sports hat paper pattern, the anti-discoloration modified nylon fabric is cut using a numerical control cutting machine to ensure that the cutting edges are smooth with an error ≤0.5cm, obtaining various component pieces; Step S32, the printed area of the hat body piece is pretreated: the printed area is wiped with alcohol to remove surface dust, then an environmentally friendly water-based printing ink is printed on the specified position of the piece using a screen printing machine, the printing pressure is controlled at 0.3-0.4MPa, and after printing, the piece is placed in a low-temperature oven at 40-45℃ and dried for 25-30 minutes to complete pattern setting; Step S33, the hat body is sewn using an industrial flat sewing machine: the side edges of the two hat body pieces are aligned, and the edges are sewn with polyester thread, the sewing width is 1.2-1.5cm, and the sewing speed is controlled at 2500-2800 stitches / minute to form a hollow hat body main body; Step S34, the brim is sewn: the brim piece is aligned with the bottom edge of the hat body main body, 3-4 positioning points are fixed manually, then the brim is sewn using a flat sewing machine, the sewing width is 0.8-1cm to ensure that the brim is firmly connected with the hat body without wrinkles; Step S35, the sweatband is installed: the raw edges of the sweatband piece are folded inward by 0.5cm, then the sweatband is pressed and shaped using an iron, and then the sweatband is attached to the forehead position inside the hat body and sewn using a blind stitch process; Step S36, the adjusting buckle is installed: the adjusting buckle patch is sewn at the opening at the back of the hat body, the patch edge is aligned with the sewing width of the hat body, 2-3 reinforcing lines are sewn, then the plastic adjusting buckle is fixed on the patch to ensure smooth opening and closing of the adjusting buckle and adaptation to different head circumferences; Step S37, the finished sports hat is placed in a steam ironing machine, ironed at a steam pressure of 0.2-0.3MPa and a temperature of 95-100℃ for 10-15 seconds, focusing on ironing the brim and the joint between the hat body to make the hat shape crisp, then naturally cooled to room temperature to complete the preparation of the sports hat.

6. The process as claimed in claim 1, wherein the nylon fabric is prevented from discoloration due to pattern bleeding and the process for manufacturing sports cap using the fabric is provided. In the step S1, the rotation speed of the electric mixer is stably controlled at 300-400 r / min, with no fluctuation above ±5 r / min; the power output deviation of the ultrasonic cell disrupter is ≤10 W, ensuring that the uniformity of nanoparticle dispersion is ≥95%.

7. The process as claimed in claim 1, wherein the nylon fabric is used for manufacturing sports cap. In the step S2, the plain weave density of the nylon 66 fabric substrate is 30-35 ends / cm in the warp direction and 28-32 ends / cm in the weft direction; the temperature uniformity error of the hot air circulation oven is ≤±2℃, avoiding excessive or insufficient drying of the fabric in some areas; the blade edge flatness deviation of the doctor blade coating machine is ≤0.02 mm, ensuring the uniformity of the coating thickness.

8. The process as claimed in claim 1, wherein the nylon fabric is prevented from discoloration due to pattern bleeding and the process for manufacturing sports cap using the fabric is provided. In the step S3, the cutting accuracy error of the numerical control cutting machine is ≤0.3 cm, and the cutting speed can be adjusted between 0.8-1.2 m / min according to the fabric thickness; the printing pressure stability deviation of the screen printing machine is ≤±0.02 MPa, ensuring that the edge definition of the printed pattern is ≥98%; the needle spacing of the industrial flat bed sewing machine can be adjusted in the range of 2-3 mm, adapting to different fabric splicing requirements.

9. The process as claimed in claim 8, wherein the nylon fabric is prevented from discoloration due to pattern bleeding and the process for manufacturing the sports cap using the fabric is characterized by, The hydrophilic modification degree of the nano-silicon dioxide is detected by a contact angle measuring instrument, with a contact angle ≤30°; the gel content of the water-based polyurethane emulsion is ≥90%, ensuring the water washing resistance of the cured coating.

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