Chemical-physical synergistic interaction wool layer fabric and preparation method thereof

Abstract

The invention discloses a chemical-physical synergistic interaction wool layer fabric and a preparation method thereof, and belongs to the technical field of textile engineering.The fabric comprises a bottom layer and a surface layer, the bottom layer is formed by weaving and thermal shrinkage finishing of blended yarn formed by superfine fibers, wool fibers and high-shrinkage fibers, the surface layer is a pure wool layer, and the surface layer is a wool layer. The fiber surface of the pure wool layer is loaded with a silane-nano silver-tea saponin composite function network, and the bottom layer and the surface layer are integrally connected through a woven coil structure; the interior of the fabric comprises a plurality of integrally-formed three-dimensional hollow cavities, and the edges of the three-dimensional hollow cavities are subjected to three-dimensional locking through prestress generated by shrinkage of the high-shrinkage fibers. The wool layer fabric provided by the invention has the integrated performance of soft touch feeling, light weight, warm keeping and environmental protection.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of textile engineering, and particularly relates to a wool top fabric with chemical-physical synergistic effect and a preparation method thereof. BACKGROUND

[0002] Wool fabric is widely used in high-end clothing field due to its excellent warmth retention, moisture absorption and ventilation, and comfortable touch. However, in the process of pursuing higher performance, the existing technology faces difficult-to-reconcile technical contradictions and bottlenecks: 1) conflict between functionality and hand feeling: in order to give wool fabric persistent and efficient anti-fouling and antibacterial performance, a nano-silver finishing system is often used. At the same time, the silver ions in the traditional process are simply attached to the surface of the wool structure, and the silver ions gradually fall off with daily use and washing. Chemical treatment often damages the natural scale layer on the surface of wool fibers, resulting in stiff and rough fiber hand feeling, and loss of the original warm and soft touch of wool. 2) conflict between light weight and structural stability: in order to achieve light and thin warmth, the existing technology attempts to form a three-dimensional air layer (such as 3D knitting and quilting) inside the fabric. However, the "air pocket" formed by these structures can be warm in a static state, but it is easy to collapse irreversibly during wearing, friction or washing, resulting in the disappearance of the air layer and the rapid decay of the warmth retention performance. This "structural instability" greatly reduces the durability of light and thin warmth, and cannot meet the actual use requirements. 3) conflict between environmental protection and composite fastness: traditional wool composite fabric relies on glue to bond, which not only has environmental problems, but also the bonding layer is easy to age and crack in long-term use, resulting in delamination of the fabric and seriously affecting the service life.

[0003] Chinese Patent No. CN116676699A discloses a wool worsted fabric and a processing method. The wool fabric uses wool fibers with silver fibers and cross-shaped polyester fibers inside, and uses anti-yellowing solution and hydrogen peroxide bleaching in the processing process, combined with regenerated cellulose fibers to improve antibacterial, wrinkle-resistant and rapid moisture-wicking functions, and simplify the processing process. The wool worsted fabric realizes multifunctionality such as antibacterial, wrinkle-resistant, rapid moisture-wicking, avoids bending and yellowing, simplifies the processing process, and improves the quality of finished products and operation convenience. However, the fabric structure is single-layer mixed weaving without layered structure, the fabric structure is relatively simple, cannot realize integrated and firm connection, and only realizes antibacterial through weaving silver fibers, which is difficult to simultaneously have soft touch, light and warm, and environmentally friendly integrated performance. SUMMARY

[0004] In order to overcome the shortcomings of the above-mentioned prior art, the purpose of the present application is to provide a wool top fabric with chemical-physical synergistic effect and a preparation method thereof, to solve the technical problem that the existing wool fabric is difficult to simultaneously have soft touch, light and warm, and environmentally friendly integrated performance.

[0005] To achieve the above object, the present application adopts the following technical solutions: The present application provides a kind of chemical-physical synergistic wool layer fabric, the fabric includes bottom and surface layer, the bottom is formed by the blended yarn of superfine fiber, wool fiber and high shrinkage fiber warp knitting and heat shrinkage finishing, the surface layer is pure wool layer, the fiber surface of pure wool layer is loaded with silane-nano silver-tea saponin composite functional network, and the bottom and surface layer are integrally connected by the loop structure of weaving. The fabric contains a plurality of integrally formed three-dimensional hollow cavities, the edges of the three-dimensional hollow cavities are three-dimensionally locked by the prestress generated by the shrinkage of the high shrinkage fiber.

[0006] Preferably, the superfine fiber is any one of polyester, nylon and acrylic, and the single filament fineness of the superfine fiber is less than 1.0 dtex.

[0007] Preferably, the average fineness of the wool fiber is 16 μm -21 μm.

[0008] Preferably, the high shrinkage fiber is any one of modified polyester, modified nylon and modified acrylic.

[0009] Preferably, the silane-nano silver-tea saponin composite functional network is formed by immersing the surface layer in a silane-nano silver-tea saponin composite finishing liquid, and the components of the silane-nano silver-tea saponin composite finishing liquid include, by weight percentage, 1.0%-5.0% silane coupling agent, 0.5%-3.0% silver (provided by nano silver sol), 1.0%-4.0% tea saponin, 40%-60% ethanol, and the balance water, and the pH value of the silane-nano silver-tea saponin composite finishing liquid is 4.5-5.5.

[0010] Preferably, acetic acid is used to adjust the pH value of the silane-nano silver-tea saponin composite finishing liquid to 4.5-5.5.

[0011] Preferably, the silane-nano silver-tea saponin composite functional network is formed by immersing the surface layer in a silane-nano silver-tea saponin composite finishing liquid, and the components of the silane-nano silver-tea saponin composite finishing liquid include, by weight percentage, 2% silane coupling agent, 1% silver (provided by nano silver sol), 2% tea saponin, 50% ethanol, and 45% water.

[0012] Preferably, the mass ratio of the superfine fiber, wool fiber and high shrinkage fiber is 3:16:1.

[0013] This invention also provides a method for preparing the above-mentioned chemical-physical synergistic wool layer fabric, comprising the following steps: Step 1) Prepare a silane-nano silver-tea saponin composite finishing solution according to the proportion, immerse the combed pure wool tops in the silane-nano silver-tea saponin composite finishing solution, and then perform padding, drying and baking treatments to load the surface of the wool fibers with a composite functional network to obtain modified wool tops. Step 2) The blended yarn formed by microfiber, wool fiber and high shrinkage fiber is simultaneously woven with the modified wool tops, wherein the blended yarn constitutes the bottom layer of the fabric and the modified wool tops constitute the top layer of the fabric, and the bottom layer and the top layer are integrally connected by a woven loop structure to form an integral greige fabric. During the weaving process, air is sprayed in a preset weaving area corresponding to the three-dimensional hollow cavity through a pre-set airflow nozzle array, so that the top layer and the bottom layer are separated in the preset weaving area, thereby simultaneously forming the three-dimensional hollow cavity; Step 3) The fabric is subjected to a combined heat-shearing process, which causes the high-shrinkage fibers in the bottom layer to shrink under heat and generate prestress, thereby locking the edge of the three-dimensional hollow cavity in three dimensions, thus obtaining a wool layer fabric with chemical-physical synergistic effect.

[0014] Preferably, in step 3), the temperature of the combined hot-cutting process is 80-90℃.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention provides a chemically-physically synergistic wool layer fabric. The fabric is an integrated structure prepared using chemically-physically synergistic technology, comprising a bottom layer and a top layer. The bottom layer is formed by weaving and heat-shrinking finishing of a blended yarn of microfiber, wool, and high-shrinkage fiber. After shrinkage, the high-shrinkage fiber shrinks, causing the bottom layer yarn network to form a dense and pre-stressed stable structure, giving the fabric crispness, abrasion resistance, and windproof properties. The top layer is a pure wool layer, with its fiber surface loaded with a "silane-nano silver-tea saponin" composite functional network. This network not only provides long-lasting stain resistance and antibacterial properties but also retains the original soft and warm feel of wool. Through the synergistic effect of tea saponin, this composite functional network achieves, for the first time, the ability of wool fabric to maintain its original soft and warm feel under a strong silane-silver chemical finishing system. Tests showed that the bending stiffness of the fabric of this invention was reduced by 40% compared to fabrics treated only with silane-silver, while the bonding strength of the antibacterial finishing agent was increased by more than 30%, achieving a perfect balance between functionality and comfort. The silane "molecular bridge" and the synergistic effect of tea saponin jointly ensured the durability of the fabric's function. After 100 standard washes, the antibacterial rate remained above 95%. At the same time, the shrinkage effect of the high-shrinkage fibers strengthened the entanglement between the wool fibers and the underlying layer, significantly improving the shedding phenomenon. Specifically, the "molecular bridging" effect of silane coupling agents: After hydrolysis, the silanol groups of the silane coupling agent undergo dehydration condensation reactions with the hydroxyl and amino functional groups on the surface of wool fibers, forming stable Si-OC or Si-NC covalent bonds. Simultaneously, its amino terminus coordinates and chelates with silver ions in the nano-silver sol, thus firmly "anchoring" the nano-silver particles to the surface of the wool fibers. This treatment process does not cover or replace the natural bioactivity of wool, but rather constructs a functionally enhanced layer on its fiber surface, synergizing with the antibacterial properties of wool itself to form a stronger protective barrier. The unreacted alkyl chains face outwards, forming a low-surface-energy hydrophobic layer, achieving anti-fouling functionality.

[0016] At the same time, tea saponins played a key role in "enhancing efficacy and reducing side effects": In terms of synergistic effects: Tea saponin, as a natural dispersant and penetrant, prevents the aggregation of nano-silver particles in the finishing solution, ensuring their antibacterial activity. On the other hand, it promotes the penetration of the entire finishing system into the wool fiber, significantly improving the chemical bonding efficiency between the silane coupling agent and the fiber functional groups. This results in a more robust and uniformly distributed composite functional network compared to the traditional silane-silver system.

[0017] In terms of reducing side effects: Tea saponin molecules bind to wool keratin through hydrogen bonds, forming a "molecular lubricating film" on the fiber surface, which precisely counteracts the stiffness caused by silane cross-linking, achieving a synergistic unity of "powerful function" and "original feel".

[0018] The fabric contains multiple integrally molded three-dimensional hollow cavities, the edges of which are three-dimensionally locked by the pre-stress generated by the shrinkage of the high-shrinkage fibers in the bottom layer. This gives the fabric excellent resistance to compression fatigue and shape memory function, ensuring the long-lasting and stable lightweight warmth retention. After being subjected to 5 kPa pressure for one hour, the thickness recovery rate of the three-dimensional hollow cavity structure of this invention is over 95%, while that of traditional 3D woven air-layer fabrics is only about 60%, ensuring the long-lasting and stable warmth retention. The stable three-dimensional hollow cavity structure, combined with the fluffy bottom layer, increases the warmth retention rate by approximately 30% compared to ordinary wool fabric of the same thickness. The bottom layer and the top layer are interwoven and connected as a whole through a braided coil structure, without any adhesive layer, which completely eliminates the risk of delamination, is highly environmentally friendly, and has a long service life.

[0019] Furthermore, the microfiber monofilament fineness is <1.0dtex, forming a denser and softer yarn network. Combined with high-shrinkage fibers, the bottom layer has a more delicate feel and better windproof performance after heat shrinkage, supporting the surface wool and enhancing the overall fabric comfort.

[0020] Furthermore, the average fineness of wool fibers is 16μm-21μm, giving the wool fibers themselves a soft and smooth feel like cashmere, providing a natural soft foundation for the surface layer.

[0021] Furthermore, the high-shrinkage fiber is any one of modified polyester, nylon, and polypropylene, attributed to the specific heat-shrinkage properties of these modified synthetic fibers. Upon heating, they shrink significantly, creating pre-stress in the underlying yarn network, thus endowing the fabric with excellent compression recovery and shape memory properties.

[0022] Furthermore, a silane-nano silver-tea saponin composite finishing solution was prepared using appropriate weight percentages of silane coupling agent, silver, tea saponin, ethanol, and water to ensure a balance in silver dispersion, binding strength, and hand feel. Tea saponin, as a natural surfactant, promoted dispersion and penetration and improved hand feel. Weakly acidic conditions (pH=4.5-5.5) were conducive to the hydrolysis of silane coupling agent and its binding with wool fibers.

[0023] Furthermore, acetic acid is mild and does not damage the fibers, so acetic acid is used to adjust the pH of the silane-nano silver-tea saponin composite finishing solution to 4.5-5.5.

[0024] Furthermore, the mass ratio of microfiber, wool fiber, and high-shrinkage fiber is 3:16:1. This ratio ensures that the high proportion of wool guarantees the natural comfort and warmth of the base layer, the microfiber enhances the fineness and strength, and the appropriate amount of high-shrinkage fiber ensures that sufficient prestress is generated to stabilize the structure and avoids excessive amount leading to a stiff feel.

[0025] The present invention also provides a method for preparing the above-mentioned chemical-physical synergistic wool layer fabric. During weaving, a pre-set airflow nozzle array is used to perform air jet action in a preset weaving area corresponding to the three-dimensional hollow cavity, so that the surface layer and the bottom layer are separated in the preset weaving area, thereby simultaneously forming the three-dimensional hollow cavity. The process is efficient and the structure is uniform.

[0026] Furthermore, the heat treatment temperature (80-90℃) causes the high-shrinkage fibers to shrink in a predetermined manner, creating a pre-stressed locking structure without damaging the wool fibers. During this process, the high-shrinkage fibers in the blended yarn begin to shrink, and the resulting shrinkage tension not only densifies the underlying yarn network, but more importantly, this tension is precisely transmitted to the coil interlacing points at the edges of each three-dimensional hollow cavity. Like tightening a belt, this applies three-dimensional pre-stress to the three-dimensional hollow cavity, permanently and firmly locking its structure. This step achieves interlocking reinforcement of physical structure and chemical composition. The shrinkage process of the high-shrinkage fibers and the locking process of the three-dimensional hollow cavity occur simultaneously, giving the three-dimensional hollow cavity excellent resistance to compression fatigue. Even under long-term pressure, it can quickly rebound, completely solving the problem of easy collapse of traditional air-layer structures. Detailed Implementation

[0027] To enable those skilled in the art to understand the features and effects of the present invention, the following descriptions and definitions are only general descriptions of the terms and expressions mentioned in the specification and claims. Unless otherwise specified, all technical and scientific terms used herein have the ordinary meaning understood by those skilled in the art regarding the present invention, and in the event of any conflict, the definitions in this specification shall prevail.

[0028] The theories or mechanisms described and disclosed herein, whether right or wrong, should not in any way limit the scope of the invention, that is, the contents of the invention can be implemented without being limited by any particular theory or mechanism.

[0029] In this document, all features defined by numerical ranges or percentage ranges, such as numerical values, quantities, contents, and concentrations, are for the sake of brevity and convenience only. Accordingly, descriptions of numerical ranges or percentage ranges should be considered as covering and specifically disclosing all possible sub-ranges and individual numerical values ​​(including integers and fractions) within those ranges.

[0030] In this article, unless otherwise specified, “contains,” “includes,” “containing,” “has,” or similar terms cover the meanings of “composed of” and “mainly composed of,” for example, “A contains a” covers the meanings of “A contains a and others” and “A contains only a.”

[0031] For the sake of brevity, not all possible combinations of the technical features in each implementation scheme or embodiment are described herein. Therefore, as long as there is no contradiction in the combination of these technical features, the technical features in each implementation scheme or embodiment can be combined arbitrarily, and all possible combinations should be considered within the scope of this specification.

[0032] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0033] The following examples use instruments and equipment conventional in the art. Experimental methods in the following examples, unless otherwise specified, are generally performed under conventional conditions or as recommended by the manufacturer. All raw materials used in the following examples are conventional commercially available products with specifications conventional in the art. In this specification and the following examples, unless otherwise specified, "%" represents weight percentage, "parts" represents parts by weight, and "ratio" represents weight proportion.

[0034] Example 1 Raw material preparation: Blended yarn: The yarn is made by blending 15% polyester microfiber, 80% wool fiber, and 5% high-shrinkage polyester fiber by mass. The polyester microfiber has a single filament fineness of 0.8 dtex, the wool fiber has an average fineness of 19 μm, and the high-shrinkage polyester fiber has a shrinkage rate of 35% in boiling water.

[0035] Wool tops: Selected fine wool combed tops with an average fineness of 18μm.

[0036] 1) Synergistic modification treatment of wool tops: Preparation of silane-nano silver-tea saponin composite finishing solution: Weigh 2 kg of silane coupling agent KH-550, 1 kg of nano silver sol (solid content 10%), 2 kg of tea saponin, 50 kg of ethanol, and 45 kg of deionized water. Adjust the pH of the solution to 5.0 with acetic acid.

[0037] 100 kg of wool tops were immersed in the above-mentioned silane-nano silver-tea saponin finishing solution for 5 minutes, and the liquid removal rate was 30% after being removed by a water spinner.

[0038] The modified wool tops were dried in an oven at 90℃ for 5 minutes. This process benefited from the penetration and dispersion effect of tea saponin, resulting in uniform penetration of the finishing solution and no aggregation of nano-silver.

[0039] 2) Integrated weaving and airbag molding: On a jacquard loom equipped with a micro airflow nozzle array, blended yarns are woven as warp and weft yarns to form the bottom layer.

[0040] Modified wool slivers are introduced during weaving using a specialized feeding device and interwoven with warp and weft yarns to form the surface layer. The blended yarns and the modified wool slivers are integrally connected through a woven loop structure to form a single, integrated fabric.

[0041] The airflow nozzle array of the loom is preset. During the weaving process, when the loom runs to the preset weaving area of ​​the three-dimensional hollow cavity, the control system activates the airflow nozzles. Through the preset airflow nozzle array integrated on the loom, air is sprayed in the preset weaving area corresponding to the three-dimensional hollow cavity, so that the surface layer and the bottom layer are separated in the preset weaving area, thereby forming the three-dimensional hollow cavity simultaneously.

[0042] 3) Structural locking and collaborative modeling: The resulting greige fabric is fed into a combined heat-shearing machine, set to a temperature of 85℃, and subjected to 7 heat-shearing cycles to obtain a wool layer fabric with synergistic chemical-physical effects.

[0043] During this process, the high-shrinkage fibers shrink, which not only reinforces the bottom layer, but the tension they generate also tightens the interlacing points at the edges of the three-dimensional hollow cavity, achieving three-dimensional locking. At the same time, loose fibers are trimmed to make the fiber layer smooth.

[0044] The obtained chemical-physical synergistic effect wool layer fabric was tested, and the results showed that: Synergistic effect verification (chemical): After 100 standard washes, the antibacterial rate against Staphylococcus aureus remained at 96.5%. The feel rating is 5 (highest), soft and smooth, without any stiffness. This demonstrates the achievement of synergy between function and feel.

[0045] Synergistic Lock-in Validation (Physical): After 1 hour of pressure at 5 kPa, the fabric thickness recovery rate was 96%. The warmth retention rate was improved by 32% compared to the control group (without air pocket structure). This demonstrates the achievement of a synergistic effect between lightweight and stability.

[0046] Other properties: The fabric shows no signs of delamination, and shedding is reduced by 85%.

[0047] Example 2 Unlike Example 1, the wool fibers used had an average fineness of 16 μm.

[0048] Example 3 Unlike Example 1, the wool fibers used had an average fineness of 21 μm.

[0049] Example 4 Unlike Example 1, when preparing the silane-nano silver-tea saponin composite finishing solution, the mass of the nano silver sol (solid content 10%) used was 5 kg, so that the silver content in the final finishing solution was 0.5%.

[0050] Example 5 Unlike Example 1, when preparing the silane-nano silver-tea saponin composite finishing solution, the mass of the nano silver sol (solid content 10%) used was 30 kg, so that the silver content in the final finishing solution was 3.0%.

[0051] Example 6 Unlike Example 1, the temperature of the combined hot-cutting process in step 3) is set to 80°C.

[0052] Example 7 Unlike Example 1, the temperature of the combined hot-cutting process in step 3) is set to 90°C.

[0053] The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solution based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. A chemically-physically synergistic wool top fabric, characterized in that, The fabric comprises a bottom layer and a surface layer, the bottom layer is formed by the warp knitting of blended yarns of superfine fibers, wool fibers and high shrinkage fibers and heat shrinkage finishing, the surface layer is pure wool layer, the fiber surface of the pure wool layer is loaded with silane-nano silver-tea saponin composite functional network, and the bottom layer and the surface layer are integrally connected through the loop structure of knitting. The fabric contains a plurality of integrally formed three-dimensional hollow cavities, the edges of the three-dimensional hollow cavities are three-dimensionally locked by the prestress generated by the shrinkage of the high shrinkage fibers.

2. A chemo-physically synergistic wool top fabric according to claim 1, characterized in that, The superfine fiber is any one of polyester, nylon and acrylic, and the fineness of the superfine fiber is less than 1.0 dtex.

3. A chemically-physically synergistic wool top fabric according to claim 1, characterized in that, The average fineness of the wool fiber is 16-21 μm.

4. A chemo-physically synergistic wool top fabric as claimed in claim 1, wherein, The high shrinkage fiber is any one of modified polyester, modified nylon and modified acrylic.

5. A chemically-physically synergistic wool top fabric according to claim 1, characterized in that, The silane-nano silver-tea saponin composite functional network is formed by immersing the surface layer in a silane-nano silver-tea saponin composite finishing liquor, the components of the silane-nano silver-tea saponin composite finishing liquor include, by weight percentage, silane coupling agent: 1.0%-5.0%, silver: 0.5%-3.0%, wherein the silver is provided by nano silver sol, tea saponin: 1.0%-4.0%, ethanol: 40%-60%, water: balance, and the pH value of the silane-nano silver-tea saponin composite finishing liquor is 4.5-5.

5.

6. A chemo-physically synergistic wool top fabric according to claim 5, characterised in that, The pH value of the silane-nano silver-tea saponin composite finishing liquor is adjusted to 4.5-5.5 by acetic acid.

7. A chemo-physically synergistic wool top fabric according to claim 1, characterized in that, The silane-nano silver-tea saponin composite functional network is formed by immersing the surface layer in a silane-nano silver-tea saponin composite finishing liquor, the components of the silane-nano silver-tea saponin composite finishing liquor include, by weight percentage, silane coupling agent: 2%, silver: 1%, wherein the silver is provided by nano silver sol, tea saponin: 2%, ethanol: 50%, and water: 45%.

8. A chemo-physically synergistic wool top fabric according to claim 1, characterized in that, The mass ratio of the superfine fiber, the wool fiber and the high shrinkage fiber is 3:16:

1.

9. The method for the production of a chemically-physically synergistic wool top fabric according to any one of claims 1 to 8, characterized in that, The method comprises the following steps: Step 1) proportionally preparing a silane-nano silver-tea saponin composite finishing liquor, immersing the combed pure wool sliver in the silane-nano silver-tea saponin composite finishing liquor, and performing liquid rolling, drying and baking treatment to load the composite functional network on the surface of the wool fiber, thereby obtaining a modified wool sliver; Step 2) synchronously knitting the blended yarns of superfine fibers, wool fibers and high shrinkage fibers with the modified wool sliver, wherein the blended yarns constitute the bottom layer of the fabric, the modified wool sliver constitutes the surface layer of the fabric, and the bottom layer and the surface layer are integrally connected through the loop structure of knitting to form an integrated gray fabric, and in the knitting process, the corresponding preset knitting area of the three-dimensional hollow cavity is subjected to air jet action through a pre-set air jet nozzle array, so that the surface layer and the bottom layer are separated in the preset knitting area, thereby synchronously forming the three-dimensional hollow cavity. Step 3) the base cloth is subjected to combined scalding and shearing treatment, the high-shrinkage fibers in the bottom layer are heated to shrink and generate pre-stress, so as to three-dimensionally lock the edges of the hollow cavity, thereby obtaining the wool surface fabric with synergistic effect of chemical and physical.

10. The method for preparing a chemically-physically synergistic wool fleece fabric according to claim 9, characterized in that, In the step 3), the temperature of the combined scalding and shearing treatment is 80-90℃.