Wear-resistant fabric and preparation method thereof

Abstract

The invention discloses a wear-resistant woven fabric and a preparation method thereof, and relates to the technical field of silicon carbide fibers and fabrics thereof, the wear-resistant woven fabric sequentially comprises a functional protection layer, an energy dissipation middle layer and a flexible bearing substrate layer from outside to inside, by constructing a three-layer gradient structure, directional conduction and multi-stage dissipation of external mechanical energy are achieved, and the wear-resistant woven fabric has the advantages of being high in wear resistance, good in wear resistance and good in wear resistance. When the fabric is hooked or violently rubbed by a sharp object, the functional protection layer on the surface layer disperses concentrated point-shaped stress into planar stress by virtue of a compact and smooth low-surface-energy interface of the functional protection layer, initial puncture is resisted by virtue of high rigidity of the functional protection layer, the stress is transmitted to the energy dissipation layer in the middle, and the high-strength and high-modulus fiber skeleton conducts main load, so that the fabric is prevented from being damaged. The thermoplastic polyurethane elastic fibers wrapping the knitted base layer in a three-dimensional network shape are elastically deformed, mechanical energy is converted into friction heat energy in the material to be dissipated, instant fiber breakage caused by local stress gathering is avoided, and residual weak stress is absorbed by the knitted base layer with the soft bottom layer.

Description

Technical Field

[0001] This invention relates to the field of silicon carbide fiber and its fabric technology, specifically to a wear-resistant fabric and its preparation method. Background Technology

[0002] High-performance abrasion-resistant fabrics are indispensable basic materials in industrial protection, outdoor sports, and special transportation. With increasingly demanding application scenarios, the market's performance requirements for abrasion-resistant fabrics have evolved from simply abrasion resistance to simultaneously possessing excellent tear resistance, impact resistance, durability, and wearing comfort. Traditional technical approaches primarily improve durability by selecting high-strength fibers, increasing fabric density, or applying thick coatings. However, this often comes at the cost of sacrificing the material's flexibility, breathability, and lightweight properties. Therefore, how to innovate designs at multiple scales, including molecular structure, fiber morphology, and fabric configuration, to break through the traditional constraints between abrasion resistance and other key properties has become a research hotspot in the field of textile materials.

[0003] However, in terms of structural design, existing technologies for wear-resistant fabrics often employ a single homogeneous structure or simple double-layer bonding, lacking modulus and functional gradients from the surface to the interior. When subjected to friction or impact, stress cannot be effectively guided and dissipated step by step, easily leading to stress concentration at the point of impact and resulting in rapid localized damage. Secondly, regarding energy dissipation mechanisms, existing technologies either rely on the rigidity of the fiber itself or on the deformation of the elastomer, failing to achieve spatial network synergy between rigid and flexible components, resulting in low and uncontrollable energy dissipation efficiency. Simultaneously, in terms of functional composites and interfacial bonding, conventional coating or lamination processes often clog fabric pores, severely impairing air permeability and moisture permeability. Furthermore, interlayer bonding is mostly physical, making interfacial delamination prone to occur under dynamic fatigue loads, causing the composite structure to fail.

[0004] In summary, existing abrasion-resistant fabric technologies, limited by their homogeneous structure and single energy dissipation mode, struggle to achieve a balance between high strength, high durability, and high comfort. Therefore, there is an urgent need for a technology that fundamentally addresses these shortcomings through biomimetic gradient structure design and multi-scale energy dissipation mechanisms. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a wear-resistant fabric and its preparation method. This fabric achieves directional transmission and multi-level dissipation of external mechanical energy through a three-layer gradient structure. When the fabric is snagged by a sharp object or subjected to severe friction, the surface functional protective layer, with its dense and smooth low surface energy interface, disperses concentrated point stress into planar stress and resists initial puncture with its high rigidity. The stress is transferred to the middle energy dissipation layer, where a high-strength, high-modulus fiber skeleton conducts the main load. Meanwhile, the thermoplastic polyurethane elastic fibers covering it undergo elastic deformation, resulting in significant interfacial micro-slip between the rigid and elastic fiber networks. Simultaneously, the elastic fiber coils themselves are stretched and twisted, converting a large amount of mechanical energy into internal frictional heat dissipation. This synergistic mechanism of skeleton bearing and elastic body dissipation avoids instantaneous fiber breakage caused by localized stress accumulation. Residual weak stress is absorbed by the soft knitted base layer, ensuring comfortable wear. Thus, while maintaining a relatively thin and lightweight overall material, it achieves highly efficient resistance to damage.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: On the one hand, a wear-resistant fabric, which comprises a three-layer structure from the outside to the inside, namely a functional protective layer, an energy dissipation intermediate layer and a flexible load-bearing base layer; The functional protective layer is a fabric layer woven from a core-sheath composite filament. The sheath material of the core-sheath composite filament is either polytetrafluoroethylene or silicone-modified polyurethane, and the core material is either polyamide 6 or polyethylene terephthalate. The mass ratio of the sheath to the core is (10-30):(90-70). The outer surface of the functional protective layer is coated with a fluorocarbon polymer finishing agent and microcapsules; The energy dissipation intermediate layer is a three-dimensional mesh structure layer composed of high-modulus fibers and thermoplastic polyurethane elastic fibers through a warp knitting process. The high-modulus fiber is one of para-aramid fiber and ultra-high molecular weight polyethylene fiber; the monofilament fineness of the TPU elastic fiber is 20 denier to 40 denier. The mass ratio of the high modulus fiber to the TPU elastic fiber is (60-80):(40-20). The flexible load-bearing base layer is a weft-knitted fabric layer made of natural fibers and regenerated cellulose fibers; The functional protective layer, the energy dissipation intermediate layer, and the flexible load-bearing substrate are bonded together by a functional coating containing nanoparticles, which penetrates and solidifies between the interfaces of the three-layer structure.

[0007] Furthermore, the woven structure of the functional protective layer is 2 / 2 twill, 3 / 1 twill, or 5-end satin; The core-sheath composite filament has a single filament fineness of 20 denier to 70 denier and a single filament count of 24f to 96f.

[0008] Furthermore, the microcapsules on the outer surface of the functional protective layer include self-healing microcapsules and phase change material microcapsules; The wall material of the self-healing microcapsule is urea-formaldehyde resin, and the core material is hydrogen-terminated polydimethylsiloxane. The wall material of the phase change material microcapsules is melamine resin, and the core material is either n-octadecane or n-eicosane.

[0009] Furthermore, the warp-knitted structure of the energy dissipation intermediate layer is a weft-backed warp-knitted structure, wherein the high-modulus fiber is laid out in a straight line as the weft yarn, and the TPU elastic fiber is woven into a loop structure as the chain yarn and binds and covers the weft yarn inside.

[0010] Furthermore, the fiber of the flexible load-bearing base layer is one of combed cotton, flame-retardant viscose, and lyocell fiber, and the weft-knitted fabric structure is one of plain weft knit and 1+1 rib knit.

[0011] Furthermore, the functional coating is formed by curing an aqueous slurry prepared from the following components by weight percentage: Waterborne polyurethane resin dispersion: 40%-50%; Epoxysilane coupling agent: 1%-3%; Nano-silica particles: 3%-5%; Silicon carbide whiskers: 2%-4%; Leveling agent: 0.3%-0.8%; The remainder is deionized water; The nano-silica particles have a diameter of 10nm-30nm, and the silicon carbide whiskers have a length of 5μm-20μm.

[0012] On the other hand, a method for preparing abrasion-resistant fabric includes the following specific steps: S100, Layered preparation of base fabric: separately weave to prepare functional protective layer base fabric, warp knit to prepare energy dissipation intermediate layer base fabric, and weft knit to prepare flexible load-bearing base layer base fabric; S200, Lamination and Surface Activation: The three base fabrics are laminated in sequence and preliminarily sewn and fixed. The laminate is then surface-treated with low-temperature plasma. The treatment gas is a mixture of argon and oxygen, with oxygen accounting for 10%-30% of the volume. The treatment pressure is 30Pa-50Pa, the treatment power is 200W-300W, and the treatment time is 2-5 minutes. S300. Applying and curing the interface functional coating: Prepare the functional coating slurry and apply it in two coats. Apply part of the slurry to the back of the functional protective layer base fabric and bond it to the energy dissipation intermediate layer base fabric. Apply the remaining slurry to the back of the energy dissipation intermediate layer base fabric and bond it to the flexible load-bearing base layer base fabric. Pre-bake at 95℃-105℃ for 1-3 minutes and then cure at 125℃-135℃ for 2-4 minutes to obtain the composite fabric. S400, Low surface energy finishing: The composite fabric is immersed in a working solution containing a fluorocarbon finishing agent, wherein the concentration of the fluorocarbon finishing agent in the working solution is 20g / L-40g / L, and then baked at 150℃-160℃ for 1-3 minutes. S500, Microcapsule Finishing: Self-healing microcapsules and phase change material microcapsules are dispersed in an aqueous adhesive at a mass ratio of (1:1) to (1:3). The surface of the functional protective layer of the composite fabric is impregnated and treated. After drying and curing at 85℃-100℃ for 3-8 minutes, mechanical pre-shrinking finishing is performed, and the wear-resistant fabric is obtained by winding.

[0013] Furthermore, in S300, the wet film thickness of the two coatings is controlled as follows: the wet film thickness on the back of the functional protective layer base fabric during the first coating is 0.12mm-0.18mm, and the wet film thickness on the back of the energy dissipation intermediate layer base fabric during the second coating is 0.08mm-0.15mm.

[0014] Furthermore, in the S500 microcapsule finishing solution, the total mass of the microcapsules accounts for 10%-20% of the mass of the finishing solution, the mass of the aqueous adhesive accounts for 5%-10% of the mass of the finishing solution, and the roll residue of the padding treatment is 35%-45%.

[0015] Compared with existing technologies, this wear-resistant fabric and its preparation method have the following advantages: This invention achieves directional transmission and multi-level dissipation of external mechanical energy by constructing a three-layer gradient structure. When the fabric is snagged by a sharp object or subjected to severe friction, the surface functional protective layer, with its dense and smooth low surface energy interface, disperses concentrated point stress into planar stress and resists initial puncture with its high rigidity. The stress is transferred to the middle energy dissipation layer, where the high-strength, high-modulus fiber skeleton conducts the main load, while the thermoplastic polyurethane elastic fibers covering it undergo elastic deformation. Significant microscopic slippage occurs between the rigid fibers and the elastic fiber network, and the elastic fiber coils themselves are stretched and twisted, converting a large amount of mechanical energy into internal frictional heat dissipation. This synergistic mechanism of skeleton bearing and elastic body dissipation avoids the instantaneous fiber breakage caused by local stress accumulation. The residual weak stress is absorbed by the soft knitted base layer at the bottom, ensuring a comfortable wearing experience. Thus, while maintaining a relatively thin and lightweight overall material, it achieves highly efficient material resistance to damage.

[0016] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0018] Figure 1 This is a flowchart of a method for preparing abrasion-resistant fabric. Detailed Implementation

[0019] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0020] To address the problems of existing technologies, this invention first describes the application scenarios of the abrasion-resistant fabric involved in this invention. This invention is mainly applied to equipment manufacturing in industries such as industrial protection, outdoor sports, and special transportation, where stringent requirements for abrasion resistance of the fabric are necessary, while also considering tear resistance, impact resistance, durability, and wearing comfort. In these scenarios, the single homogeneous structure or simple double-layer bonding design of traditional abrasion-resistant fabrics results in the inability to effectively guide and dissipate stress step by step, easily leading to localized stress concentration. Simultaneously, conventional coating processes easily clog fabric pores, impair breathability and moisture permeability, and exhibit poor interlayer bonding stability, making it difficult to balance abrasion resistance with other key properties. This invention, through a three-layer gradient structure biomimetic design, the construction of a multi-scale energy dissipation mechanism, and an interface-enhanced composite process, aims to achieve a unity of high strength, high abrasion resistance, high durability, and high comfort.

[0021] This invention provides a wear-resistant fabric and its preparation method. The fabric consists of a functional protective layer, an energy dissipation intermediate layer, and a flexible load-bearing base layer, arranged sequentially from the outside to the inside. The functional protective layer is woven from core-sheath composite filaments, with a fluorocarbon polymer finishing agent and microcapsules attached to the outer surface to achieve surface wear resistance and functional repair. The energy dissipation intermediate layer is formed by warp knitting high-modulus fibers and TPU elastic fibers to create a three-dimensional mesh structure, constructing a rigid-flexible energy dissipation system. The flexible load-bearing base layer is weft-knitted from natural or regenerated cellulose fibers to ensure wearing comfort. The three-layer structure is bonded together by a functional coating containing nanoparticles and silicon carbide whiskers to enhance interfacial bonding stability. The preparation process is as follows: Figure 1 As shown, the specific steps are as follows: S100, Layered preparation of base fabric: separately weave to prepare functional protective layer base fabric, warp knit to prepare energy dissipation intermediate layer base fabric, and weft knit to prepare flexible load-bearing base layer base fabric; S200, Lamination and Surface Activation: The three base fabrics are laminated in sequence and preliminarily sewn and fixed. The laminate is then surface-treated with low-temperature plasma. The treatment gas is a mixture of argon and oxygen, with oxygen accounting for 10%-30% of the volume. The treatment pressure is 30Pa-50Pa, the treatment power is 200W-300W, and the treatment time is 2-5 minutes. S300. Applying and curing the interface functional coating: Prepare the functional coating slurry and apply it in two coats. Apply part of the slurry to the back of the functional protective layer base fabric and bond it to the energy dissipation intermediate layer base fabric. Apply the remaining slurry to the back of the energy dissipation intermediate layer base fabric and bond it to the flexible load-bearing base layer base fabric. Pre-bake at 95℃-105℃ for 1-3 minutes and then cure at 125℃-135℃ for 2-4 minutes to obtain the composite fabric. S400, Low surface energy finishing: The composite fabric is immersed in a working solution containing a fluorocarbon finishing agent, wherein the concentration of the fluorocarbon finishing agent in the working solution is 20g / L-40g / L, and then baked at 150℃-160℃ for 1-3 minutes. S500, Microcapsule Finishing: Self-healing microcapsules and phase change material microcapsules are dispersed in an aqueous adhesive at a mass ratio of (1:1) to (1:3). The surface of the functional protective layer of the composite fabric is impregnated and treated. After drying and curing at 85℃-100℃ for 3-8 minutes, mechanical pre-shrinking finishing is performed, and the wear-resistant fabric is obtained by winding.

[0022] Example 1 This embodiment details the implementation of the present invention, demonstrating the preparation of a gradient structure fabric with breathability and self-healing / temperature control functions using optimized materials and process parameters. The functional protective layer is a PTFE / PA6 core-sheath composite fiber twill woven fabric; the energy dissipation intermediate layer is a warp-knitted mesh structure composed of para-aramid and TPU elastic fibers; and the flexible load-bearing base layer is a combed cotton weft-knitted fabric. The three layers are firmly bonded by a nanocomposite coating with a specific formulation, and then sequentially undergo fluorine-containing finishing and microencapsulation finishing.

[0023] In the specific implementation of this embodiment, the specific steps of a method for preparing abrasion-resistant fabric are as follows: (1) Layered preparation of the base fabric: Functional protective layer base fabric (A): The core-sheath composite filament is selected with a single filament fineness of 30 denier / 48 single filaments (30D / 48f), wherein the sheath is polytetrafluoroethylene (PTFE) and the core is polyamide 6 (PA6). The mass ratio of the sheath to the core is 20:80. It is woven on a rapier loom with a 2 / 2 twill weave, with a warp density of 420 threads / 10 cm and a weft density of 320 threads / 10 cm, resulting in a base fabric A with an areal density of approximately 68 g / m².

[0024] Energy dissipation intermediate layer base fabric (B): 1000 denier para-aramid filament is selected as the weft yarn, and 40 denier TPU elastic filament is selected as the chain yarn. The weft-backed warp knitting structure is woven on a double needle bed warp knitting machine. The mass ratio of para-aramid to TPU is 70:30. The knitting density is controlled to obtain base fabric B with an areal density of about 82 g / m² and a distinct three-dimensional mesh structure.

[0025] Flexible load-bearing base layer fabric (C): 40-count combed cotton yarn is selected and knitted on a single-sided circular knitting machine with a weft plain knit structure. The horizontal density is 65 loops / 5 cm and the vertical density is 85 loops / 5 cm, resulting in a base fabric C with an areal density of approximately 115 g / m².

[0026] (2) Layering and surface activation: The base fabrics A, B, and C are precisely stacked in sequence, and sparse quilting is performed using long polyester thread with a stitch spacing of 5 cm to achieve initial fixation. The fixed stack is then placed in a low-temperature plasma treatment device, and a mixture of argon and oxygen is introduced, with oxygen accounting for 20% of the volume. The pressure inside the chamber is maintained at 40 Pa, and the process is carried out for 3 minutes at a power of 250 W.

[0027] (3) Apply an interface functional coating and cure it: The functional coating slurry is prepared according to the following mass percentages: 45% waterborne polyurethane resin dispersion, 2% epoxy silane coupling agent, 4% nano-silica particles, 3% silicon carbide whiskers, 0.5% leveling agent, and the balance being deionized water. A scraping coating process is used. First, a layer of slurry is scraped onto the back of base fabric A, with a wet film thickness controlled at 0.15 mm. Then, it is bonded to base fabric B and lightly pressed. Next, a second layer of slurry is scraped onto the back of base fabric B, with a wet film thickness of 0.10 mm, and then bonded to base fabric C. The composite preform is placed in a hot air oven and pre-dried at 100℃ for 2 minutes, then cured at 130℃ for 3 minutes to obtain a preliminary composite fabric.

[0028] (4) Post-processing: Low surface energy finishing: Prepare a fluorocarbon finishing agent working solution with a concentration of 30 g / L, immerse the composite fabric in the working solution, adopt a two-dip two-ply process, control the ply rate at 65%, and then treat it in a baking oven at 155℃ for 1.5 minutes.

[0029] Microcapsule finishing: Self-healing microcapsules with urea-formaldehyde resin as the wall material and terminal hydrogen-based polydimethylsiloxane as the core material are mixed with phase change material microcapsules with melamine resin as the wall material and n-octadecane as the core material at a mass ratio of 1:2. The mixed microcapsules are dispersed at a mass fraction of 15% in a finishing solution containing 5% polyacrylate aqueous adhesive. The fabric functional protective layer is then subjected to single-sided padding with a padding rate controlled at 40%, followed by drying and curing at 95°C for 5 minutes.

[0030] Finishing: Finally, the fabric is loosely pre-shrinked using a mechanical pre-shrinking machine to stabilize the fabric dimensions and obtain the finished woven fabric.

[0031] The finished woven fabric obtained from the above process was tested, including abrasion resistance, tear strength, impact resistance, air permeability, and tensile strength. The test results are as follows: Abrasion resistance: Martindale abrasion test was conducted using wool abrasive under 12 kPa pressure. The test results showed that the fabric did not break after 65,000 abrasions, demonstrating extremely high resistance to planar abrasion.

[0032] Mechanical strength: The radial trapezoidal tear strength was tested, and the results showed that the tear strength reached 480N, indicating that the gradient structure can effectively prevent crack propagation and has excellent tear resistance.

[0033] Comfort and breathability: The breathability was tested and found to be 158 mm / s, proving that despite being a three-layer composite structure, the fabric maintains good airflow due to the unique coating process and mesh interlayer design.

[0034] Structural durability: The interlayer peel strength was tested by simulating repeated bending in actual use. The results showed that the peel strength reached 25 N / cm. After 100,000 bidirectional bending tests, the fabric was cut and inspected. No interlayer peeling, bubbling or interface cracking was observed, which proved that the interlayer bonding was extremely strong.

[0035] Surface functional properties: The static water contact angle was measured using a contact angle meter, and the result was 148°, confirming that the low surface energy finishing imparts excellent hydrophobicity. Furthermore, after micro-scratches were created on the surface and left at room temperature for 24 hours, the hydrophobic properties of the scratched areas were largely restored, verifying the self-healing function.

[0036] Example 2 This embodiment demonstrates the flexibility of the technical solution of the present invention, focusing on industrial protection applications. The functional protective layer uses silicone-modified polyurethane / PET core fiber satin fabric, the energy dissipation intermediate layer uses ultra-high molecular weight polyethylene fiber instead of aramid, the flexible load-bearing base layer uses flame-retardant viscose fiber, and focuses on flame-retardant finishing. Microcapsule finishing is only selected for repair functions. The specific implementation method is as follows: (1) Layered preparation of the base fabric: Functional protective layer base fabric (A): 50D / 72f core-sheath composite filament is selected, the sheath is silicone-modified polyurethane, the core is PET, the sheath-core mass ratio is 15:85, it is woven with a 5-end satin weave, and the areal density is 95g / m².

[0037] Energy dissipation intermediate layer base fabric (B): 1200D UHMWPE filament is used as the weft yarn and 30D TPU filament is used as the chain yarn to weave a weft-weft warp-knitted structure with a mass ratio of 75:25 and a surface density of 118g / m².

[0038] Flexible load-bearing base layer fabric (C): 1+1 rib weave made of flame-retardant viscose fiber yarn with a surface density of 125g / m².

[0039] (2) Layering and surface activation: The lamination and plasma treatment processes are the same as in Example 1, but the processing power is adjusted to 280W and the time is 4 minutes.

[0040] (3) Apply an interface functional coating and cure it: The preparation of the coating slurry and the coating process are the same as in Example 1.

[0041] (4) Post-processing: Low surface energy finishing: The process is the same as in Example 1.

[0042] Flame retardant finishing: Impregnate with phosphorus and nitrogen-based flame retardant working liquid, with a roll-off rate of 70%, and bake at 170℃ for 2 minutes.

[0043] Microcapsule finishing: Only self-healing microcapsules were used for padding finishing, accounting for 12% of the finishing solution mass, and the process parameters were the same as in Example 1.

[0044] Finalization: Same as Example 1.

[0045] The finished woven fabric obtained in this embodiment was subjected to the same performance tests as in Example 1, and the results are as follows: Abrasion resistance: Martindale abrasion resistance exceeds 50,000 cycles.

[0046] Mechanical strength: The warp trapezoidal tear strength is 520N. Due to the use of UHMWPE fiber and high-density structure, the tear resistance is better than that of Example 1, demonstrating the high strength characteristics after material replacement.

[0047] Comfort and breathability: The breathability is 85 mm / s. Due to the use of a denser satin weave and flame-retardant finishing, the breathability is lower than that of Example 1, but it is not completely sealed due to the coating.

[0048] Structural durability: Its interlayer peel strength is 24 N / cm. After 100,000 bending tests, the interlayer bonding is intact and there is no peeling. At the same time, its limiting oxygen index test result is greater than 32%. It has passed the vertical burning test and shows excellent flame retardant durability.

[0049] Surface functional properties: The water contact angle is 142°, maintaining good hydrophobicity. The self-healing function test is the same as in Example 1, with obvious results. No phase change microcapsules were introduced, so the temperature control performance was not tested.

[0050] Example 3 This embodiment aims to investigate the effect of changes in the content of nano-reinforcing components in interfacial functional coatings. Two sets of samples were prepared, with the content of nano-silica and silicon carbide whiskers in their coating formulations set at the lower and upper limits, respectively. The remaining materials and processes were the same as in Example 1.

[0051] The preparation process in this embodiment is exactly the same as in Example 1, except that the formulation of the functional coating slurry in step (3) of coating the interface functional coating and curing it is changed: Sample T1 (lower limit group): The content of nano-silica particles is 3%, and the content of silicon carbide whiskers is 2%.

[0052] Sample T2 (Upper Limit Group): 5% content of nano-silica particles and 4% content of silicon carbide whiskers.

[0053] The T1 and T2 samples prepared in this embodiment were tested, and the test results are as follows: Abrasion resistance: The Martindale abrasion resistance of samples T1 and T2 were >52,000 and >60,000 cycles, respectively.

[0054] Mechanical strength: The radial trapezoidal tear strengths of T1 and T2 are 460N and 500N respectively, both remaining at a high level, indicating that the coatings within the parameter range can effectively transfer stress.

[0055] Comfort and breathability: The breathability of T1 and T2 is 165mm / s and 140mm / s, respectively.

[0056] Structural durability: The interlaminar peel strength test results show that the peel strengths of T1 and T2 are 18 N / cm and 22 N / cm, respectively.

[0057] Surface functional characteristics: The water contact angle is above 145°, the self-healing function is intact, and it is not closely related to the coating formulation, but mainly depends on the finishing process.

[0058] To systematically evaluate the effectiveness of the technical solution of this invention, parallel performance tests were conducted on the fabrics prepared in the three embodiments. Quantitative test results for abrasion resistance, mechanical strength, air permeability, structural durability, and surface function of Embodiments 1, 2, and 3 were summarized. The data show that all embodiments exhibited superior comprehensive performance compared to conventional fabrics. Embodiment 1 achieved the best balance across all indicators, Embodiment 2 demonstrated excellent strength and flame retardancy for special applications, and Embodiment 3 verified the effectiveness of the formulation parameters within their required range, particularly maintaining a high level of interlayer peel strength above 18 N / cm. Specific results are shown in Table 1 below. Table 1 Comparative Example 1 This comparative example aims to demonstrate the role of the energy dissipation intermediate layer in the three-layer gradient structure. It uses the same functional protective layer base fabric (A) and flexible load-bearing base layer base fabric (C) as in Example 1, but omits the energy dissipation intermediate layer (B) and directly composites A and C through the same interface functional coating.

[0059] Use the same base fabric A and base fabric C as in Example 1.

[0060] A and C are superimposed and subjected to the same low-temperature plasma treatment.

[0061] The functional coating slurry prepared in Example 1 was applied to the back of the base fabric A in one go, and then bonded to the base fabric C. The curing process was the same as in Example 1.

[0062] Perform the same low surface energy finishing and microcapsule finishing as in Example 1.

[0063] A comparison sample was obtained.

[0064] The performance test results of the comparative sample are as follows: Abrasion resistance: Martindale's abrasion resistance drops significantly to about 12,000 cycles. The main wear failure mode is that the functional protective layer is quickly worn through, and the bottom layer is directly exposed and cracked, with no intermediate buffer layer to dissipate energy.

[0065] Mechanical strength: The radial trapezoidal tear strength is only 150N. During tearing, the stress cannot be dispersed through the intermediate mesh structure, and the crack propagates rapidly in a straight line at the hard interface between the two layers.

[0066] Comfort and breathability: The breathability is 205mm / s. Due to the reduction of one layer and the use of a thicker coating, the porosity changes in complexity. Although the breathability value is high, the overall mechanical properties have been compromised.

[0067] Structural durability: Its interlayer peel strength is only 10 N / cm. After 20,000 bending tests, obvious local peeling and blistering can be observed. The shear stress generated by bending directly acts on the fragile interface between the two AC layers, leading to adhesive failure.

[0068] Surface functional characteristics: The initial water contact angle is 145°, but after wear or bending causes interface damage, the hydrophobic properties drop sharply and cannot be fully restored through self-healing because the underlying damage cannot be repaired.

[0069] Comparative Example 2 This comparative example aims to demonstrate the importance of the functional coating of the present invention in maintaining the long-term stability of the gradient structure. It uses the same three-layer base fabric as in Example 1, but uses a common commercial waterborne polyurethane adhesive instead of the functional coating slurry of the present invention during lamination.

[0070] Use the same base fabrics A, B, and C as in Example 1.

[0071] After the three layers of base fabric are stacked, they undergo the same low-temperature plasma treatment.

[0072] Ordinary water-based polyurethane coating adhesive with a solid content of 40% was used. It does not contain nano-reinforcing particles or coupling agents. Interlayer lamination was carried out using the same two-coat process as in Example 1, with the same curing temperature and time.

[0073] Perform the same finishing process as in Example 1.

[0074] A comparison sample was obtained.

[0075] The test results for the second comparative sample are as follows: Abrasion resistance: Martindale has an abrasion resistance of approximately 20,000 cycles. The damage is not caused by fiber breakage, but rather by large-scale delamination between layers after the wear reaches a certain level, leading to premature termination of the test.

[0076] Mechanical strength: The initial trapezoidal tear strength was 300N, but during the test, it was found that the tearing process was accompanied by obvious interlayer slippage and debonding sound, and the strength value fluctuated greatly.

[0077] Comfort and breathability: Breathability is 130mm / s.

[0078] Structural durability: Its interlayer peel strength is only 8N / cm, which is far lower than that of the example. After 5 standard washes, obvious delamination appeared on the edge of the fabric, and the interlayer bonding was severely deteriorated, proving that the ordinary coating has extremely poor fatigue resistance and water washing ability.

[0079] Surface functional characteristics: The initial water contact angle is similar to that of the embodiment, approximately 140°. However, after washing or rubbing, the overall functional reliability is significantly reduced due to water ingress between layers or interface damage.

[0080] To highlight the necessity of the gradient structure and functional coating of this invention, two comparative examples were set up and subjected to the same performance tests. The test results of Comparative Example 1, which lacked an energy dissipation intermediate layer, and Comparative Example 2, which used a common adhesive coating, were compared to verify the importance of the three-layer gradient structure and dedicated functional coating of this invention. The specific test results are shown in the table below: Table 2 This invention successfully prepared a multifunctional abrasion-resistant fabric by constructing a gradient composite structure consisting of a functional protective layer, an energy dissipation intermediate layer, and a flexible load-bearing substrate layer, combined with a specialized functional coating and finishing process. As shown in Table 1, the fabric of Example 1 demonstrated the optimal effect of the overall technical solution in terms of abrasion resistance (>65,000 cycles), tear resistance (480N), interlayer bonding strength (25N / cm), and surface hydrophobicity (148°). Example 2, using different material combinations (UHMWPE, flame-retardant adhesive), still maintained high strength and high peel strength, and achieved flame-retardant function, verifying the universality and customizability of the technical solution. Example 3 confirmed that even at the lower limit (T1) or upper limit (T2) of the key coating components (nano-SiO2 and SiC whiskers), the fabric could still maintain effective interlayer bonding and high abrasion resistance. In contrast, the comparative examples in Table 2 show that Comparative Example 1 lacks an energy dissipation interlayer, resulting in stress that cannot be dissipated. Its abrasion resistance and tear strength drop sharply, and its interlayer peel strength is only 40% of that of Example 1. Moreover, it delaminates rapidly after bending. Comparative Example 2 uses a common adhesive coating, which has a weak interfacial bond, causing the fabric to delaminate prematurely during washing and abrasion, thus failing to maintain the integrity of the overall structure.

[0081] In summary, the test data fully demonstrates that the gradient dissipation structure design and functional coating of this invention are the key to obtaining high strength, high wear resistance and multifunctionality, and have good process reproducibility and material compatibility, fundamentally solving the problem that traditional wear-resistant fabrics cannot balance protection, durability and comfort.

[0082] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A wear-resistant fabric, characterized in that, The fabric consists of three layers from the outside in: a functional protective layer, an energy dissipation intermediate layer, and a flexible load-bearing base layer. The functional protective layer is a fabric layer woven from a core-sheath composite filament. The sheath material of the core-sheath composite filament is either polytetrafluoroethylene or silicone-modified polyurethane, and the core material is either polyamide 6 or polyethylene terephthalate. The mass ratio of the sheath to the core is (10-30):(90-70). The outer surface of the functional protective layer is coated with a fluorocarbon polymer finishing agent and microcapsules; The energy dissipation intermediate layer is a three-dimensional mesh structure layer composed of high-modulus fibers and thermoplastic polyurethane elastic fibers through a warp knitting process. The high-modulus fiber is one of para-aramid fiber and ultra-high molecular weight polyethylene fiber; the monofilament fineness of the TPU elastic fiber is 20 denier to 40 denier. The mass ratio of the high modulus fiber to the TPU elastic fiber is (60-80):(40-20). The flexible load-bearing base layer is a weft-knitted fabric layer made of natural fibers and regenerated cellulose fibers; The functional protective layer, the energy dissipation intermediate layer, and the flexible load-bearing substrate are bonded together by a functional coating containing nanoparticles, which penetrates and solidifies between the interfaces of the three-layer structure.

2. The wear-resistant fabric according to claim 1, characterized in that, The woven structure of the functional protective layer is 2 / 2 twill, 3 / 1 twill, or 5-end satin. The core-sheath composite filament has a single filament fineness of 20 denier to 70 denier and a single filament count of 24f to 96f.

3. The wear-resistant fabric according to claim 1, characterized in that, The microcapsules on the outer surface of the functional protective layer include self-healing microcapsules and phase change material microcapsules; The wall material of the self-healing microcapsule is urea-formaldehyde resin, and the core material is hydrogen-terminated polydimethylsiloxane. The wall material of the phase change material microcapsules is melamine resin, and the core material is either n-octadecane or n-eicosane.

4. The wear-resistant fabric according to claim 1, characterized in that, The energy dissipation intermediate layer has a warp-knitted structure with weft yarns, wherein the high-modulus fibers are laid out in a straight line as weft yarns, and the TPU elastic fibers are woven into a loop structure as chain yarns and bind and cover the weft yarns inside.

5. The wear-resistant fabric according to claim 1, characterized in that, The flexible load-bearing base layer is made of one of combed cotton, flame-retardant viscose, and lyocell fiber, and the weft-knitted fabric is one of plain weft knit and 1+1 rib knit.

6. The wear-resistant fabric according to claim 1, characterized in that, The functional coating is formed by curing an aqueous slurry prepared from the following components by weight percentage: Waterborne polyurethane resin dispersion: 40%-50%; Epoxysilane coupling agent: 1%-3%; Nano-silica particles: 3%-5%; Silicon carbide whiskers: 2%-4%; Leveling agent: 0.3%-0.8%; The remainder is deionized water; The nano-silica particles have a diameter of 10nm-30nm, and the silicon carbide whiskers have a length of 5μm-20μm.

7. A method for preparing abrasion-resistant fabric, applicable to the abrasion-resistant fabric described in any one of claims 1-6, characterized in that, The specific steps of this method are as follows: S100, Layered preparation of base fabric: separately weave to prepare functional protective layer base fabric, warp knit to prepare energy dissipation intermediate layer base fabric, and weft knit to prepare flexible load-bearing base layer base fabric; S200, Lamination and Surface Activation: The three base fabrics are laminated in sequence and preliminarily sewn and fixed. The laminate is then surface-treated with low-temperature plasma. The treatment gas is a mixture of argon and oxygen, with oxygen accounting for 10%-30% of the volume. The treatment pressure is 30Pa-50Pa, the treatment power is 200W-300W, and the treatment time is 2-5 minutes. S300. Applying and curing the interface functional coating: Prepare the functional coating slurry and apply it in two coats. Apply part of the slurry to the back of the functional protective layer base fabric and bond it to the energy dissipation intermediate layer base fabric. Apply the remaining slurry to the back of the energy dissipation intermediate layer base fabric and bond it to the flexible load-bearing base layer base fabric. Pre-bake at 95℃-105℃ for 1-3 minutes and then cure at 125℃-135℃ for 2-4 minutes to obtain the composite fabric. S400, Low surface energy finishing: The composite fabric is immersed in a working solution containing a fluorocarbon finishing agent, wherein the concentration of the fluorocarbon finishing agent in the working solution is 20g / L-40g / L, and then baked at 150℃-160℃ for 1-3 minutes. S500, Microcapsule Finishing: Self-healing microcapsules and phase change material microcapsules are dispersed in an aqueous adhesive at a mass ratio of (1:1) to (1:3). The surface of the functional protective layer of the composite fabric is impregnated and treated. After drying and curing at 85℃-100℃ for 3-8 minutes, mechanical pre-shrinking finishing is performed, and the wear-resistant fabric is obtained by winding.

8. The method for preparing abrasion-resistant fabric according to claim 7, characterized in that, In S300, the wet film thickness of the two coatings is controlled as follows: the wet film thickness on the back of the functional protective layer base fabric during the first coating is 0.12mm-0.18mm, and the wet film thickness on the back of the energy dissipation intermediate layer base fabric during the second coating is 0.08mm-0.15mm.

9. The method for preparing abrasion-resistant fabric according to claim 7, characterized in that, In the S500 microcapsule finishing solution, the total mass of the microcapsules accounts for 10%-20% of the mass of the finishing solution, the mass of the aqueous adhesive accounts for 5%-10% of the mass of the finishing solution, and the roll residue of the padding treatment is 35%-45%.

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