Superfine denier nylon cotton-feeling fabric and preparation method thereof

Abstract

The invention discloses a superfine denier nylon cotton-feeling fabric and a preparation method thereof, and the preparation method sequentially comprises the following steps: yarn configuration and weaving: weaving is carried out by adopting warp yarns and weft yarns, the weft yarns are nylon air textured yarns (ATY), and the weft yarns are prepared by FDY filaments with the filament number of not more than 10D through air texturing processing; the dyed fabric is subjected to padding treatment, adopted finishing liquid contains waterborne polyurethane and a fluoride-free waterproof agent, baking shaping is conducted after padding, and the fabric is subjected to humidifying and moisture regaining treatment during fabric discharging. According to the superfine denier nylon cotton feeling fabric and the preparation method thereof, the touch feeling of the nylon fabric is improved through the specific yarn structure design and the synergistic after-finishing technology, so that the nylon fabric has the soft comfort close to that of a cotton fabric, and meanwhile, the characteristics of high wear resistance and high strength of nylon fibers and the effective fluoride-free waterproof performance are kept.

Description

Technical Field

[0001] This invention relates to the field of textile technology, specifically to an ultrafine denier nylon cotton-feel fabric and its preparation method. Background Technology

[0002] Traditional Taslan fabrics are mostly made of coarse nylon, which, while lightweight and durable, typically feels stiff and smooth, lacking the softness, fluffiness, and skin-friendly feel of natural cotton. To improve the feel of synthetic fabrics, current technologies usually employ mechanical softening or chemical finishing with silicone-based softeners. However, these methods often only affect the fiber surface and cannot fundamentally change the rigidity of the nylon fibers themselves, resulting in limited improvement in feel. Furthermore, excessive use of softeners may sacrifice the fabric's strength and abrasion resistance, and affect the effectiveness of subsequent functional finishing (such as waterproofing). In addition, to achieve waterproofing, traditional processes widely use fluorinated waterproofing agents. These substances persist in the environment, and their decomposition products pose a risk of bioaccumulation, which is inconsistent with increasingly stringent environmental regulations and market demands. Summary of the Invention

[0003] The purpose of this invention is to overcome the aforementioned defects or problems in the prior art and to provide an ultra-fine denier nylon cotton-feel fabric and its preparation method. This preparation method improves the tactile feel of nylon fabric through specific yarn structure design and synergistic finishing techniques, making it have a softness and comfort close to that of cotton fabric, while maintaining the high abrasion resistance, high strength, and effective fluorine-free waterproof properties of nylon fibers.

[0004] To achieve the above objectives, the various embodiments of the present invention employ the following technical solutions, but are not limited to the following solutions: The first technical solution relates to a method for preparing an ultra-fine denier nylon cotton-feel fabric, which includes the following steps: yarn configuration and weaving: weaving is performed using warp and weft yarns, wherein the weft yarn is nylon air-textured yarn (ATY), and the weft yarn is made from FDY filaments with a single filament fineness of no more than 10D through air texturing; finishing: the dyed fabric is subjected to padding treatment, and the finishing liquid used contains water-based polyurethane and fluorine-free waterproofing agent. After padding, the fabric is baked and shaped, and the fabric is humidified and rehydrated when it is produced.

[0005] The second technical solution is based on the first technical solution, wherein the warp yarn is nylon fully dull FDY or fully dull DTY filament, and the weft yarn is ATY yarn made by merging two fully dull FDY filaments with a single filament fineness of 10D / 12F and then using compressed air to perform jet deformation processing at a nozzle.

[0006] The third technical solution is based on the second technical solution, wherein the warp yarn is 20D / 24F fully dull FDY filament, and / or the weft yarn is 25D / 24F ATY yarn.

[0007] The fourth technical solution is based on the third technical solution. In the yarn configuration and weaving steps, the weaving adopts a plain weave structure, and the warp density of the resulting greige fabric is 200-240 threads / inch, and the weft density is 150-180 threads / inch.

[0008] The fifth technical solution is based on the second, third or fourth technical solutions, and includes the following pretreatment steps in sequence before the finishing step: desizing treatment: the woven fabric is impregnated with alkaline solution and then cold-piled, and then washed with tension-free water; dyeing: the desized fabric is dyed in an overflow dyeing machine; drying: the dyed fabric is dried using a tension-free drying device.

[0009] The sixth technical solution is based on the fifth technical solution, wherein in the deslurry treatment step, the concentration of the alkali solution is 20-30 g / L, and the cold pile time is 40-56 hours.

[0010] The seventh technical solution is based on the fifth technical solution, wherein in the dyeing step, the dyeing temperature is 95-102℃, and the temperature is maintained at this temperature for 20-40 minutes.

[0011] The eighth technical solution is based on the seventh technical solution, wherein the dyeing temperature is 102℃.

[0012] The ninth technical solution is based on the first technical solution, wherein, in the post-finishing step, the concentration of waterborne polyurethane in the finishing liquid is 15-25 g / L, and the concentration of fluorine-free waterproofing agent is 40-60 g / L; the baking and setting temperature is 155-165℃, and the time is 60-90 seconds.

[0013] The tenth technical solution is based on any one of the first to ninth technical solutions, wherein an ultrafine denier nylon cotton-feel fabric is prepared by the above-mentioned method for preparing an ultrafine denier nylon cotton-feel fabric.

[0014] As can be seen from the above description of the various embodiments of the present invention, compared with the prior art, the various embodiments of the present invention have the following beneficial effects: In the first technical solution and related embodiments, the contradiction of simultaneously achieving cotton feel, abrasion resistance, and environmental protection and waterproofing in the prior art is resolved through the synergistic effect of yarn structure design and finishing system. In the yarn structure design, the weft yarn is made from FDY filaments with a single filament fineness of no more than 10D through air deformation processing. This is the physical basis for achieving cotton feel. Using extremely fine 10D-level FDY filaments as raw materials, the air deformation process is used to form ATY yarn with a loose structure and a surface covered with tiny loops and hairs, which highly simulates the structure of natural cotton fibers from a microscopic perspective, providing the fundamental premise for obtaining cotton feel. Through a synergistic finishing system, waterborne polyurethane, fluorine-free waterproofing agent, and humidification and rehydration treatment are combined into a complete finishing process. Specifically, waterborne polyurethane can effectively penetrate into the interior of the fiber and between fiber bundles, and through its flexible molecular chains, it wraps and connects the fibers, chemically removing the rigidity of nylon fibers, making the fiber bundles soft and compliant. The fluorine-free waterproofing agent constructs an environmentally friendly water-repellent barrier on the fiber surface, achieving a high level of water-repellent function and avoiding the environmental problems associated with fluorine-containing substances. The humidification and rehydration treatment is carried out immediately after high-temperature baking, similar to quenching in metal heat treatment. High temperature activates the fiber and auxiliary agent molecules, and the subsequent humidification treatment utilizes the inherent hygroscopic properties of nylon fibers, allowing the fibers and the internal water-based PU film to quickly and evenly absorb moisture. This promotes the relaxation of molecular chains, releasing and solidifying the softening effect brought by the water-based PU, effectively resolving the hardening sensation that may result from high-temperature setting, preventing the formation of "chicken claw" creases, and ultimately locking the cotton-like feel into the fabric. These three sub-steps are not simply superimposed. Water-based PU provides the inherent softening potential, the fluorine-free waterproofing agent imparts surface functionality without affecting the inherent softening, and humidification and rehydration is the physical switch that activates and fixes the inherent softening. The three elements work together to achieve a soft, cotton-like feel in the fabric while ensuring the durability of its environmentally friendly and waterproof properties, and maintaining the high strength of the nylon substrate. This solves the problem of mutual constraints between soft finishing and functionality and durability in traditional technologies.

[0015] In the second technical solution and related embodiments, fully dull nylon FDY or fully dull DTY is used as the warp yarn, which is combined with ultra-fine ATY weft yarn to jointly construct a fluffy fabric base. The weft yarn is formed by two 10D / 12F FDY yarns through high-pressure jet air deformation to ensure a fluffy cotton-like structure.

[0016] In the third technical solution and related embodiments, the yarn specifications are 20D / 24F DTY warp yarn and 25D / 24F ATY weft yarn. This combination achieves a balance between bulkiness, strength and cost, and is a specific embodiment of combining cotton feel and durability.

[0017] In the fourth technical solution and related embodiments, the plain weave provides a dense and abrasion-resistant fabric structure, ensuring the fabric's high strength and abrasion resistance. Combined with soft yarns, it achieves an effect of being soft on the outside and strong on the inside.

[0018] In the fifth technical solution and related embodiments, pretreatments include desizing, dyeing, and drying. Plain weave combined with BO tension-free desizing fully releases the internal stress of the fibers during weaving, making the fabric structure fluffy and soft. The gentle circulation of the dye bath during overflow dyeing allows the ATY yarn to be further untwisted and relaxed in a humid and hot environment, fully unfolding its fluffy structure and enhancing the cotton-like feel of the yarn itself. Tension-free desizing and overflow dyeing fully release the internal stress generated in the fibers during weaving, and the ATY yarn is further untwisted and relaxed in the dye bath, creating a relaxed fabric state for subsequent finishing processes, which is a preliminary step in forming a cotton-like feel.

[0019] In the sixth technical solution and related embodiments, the key parameters of the desizing process (alkali concentration 20-30g / L, cold stacking 40-56 hours) ensure thorough removal of slurry and clean fibers, which is beneficial for subsequent uniform coloring and penetration of finishing agents.

[0020] In the seventh technical solution and related embodiments, the temperature range of the dyeing process (95-102℃) can ensure that dark-colored dyes are fully applied and reduce residual liquid discharge. Its heat effect can also promote further relaxation of ATY yarn and enhance the cotton style.

[0021] In the eighth technical solution and related embodiments, the dyeing temperature of 102°C is optimized for dark colors and takes into account both dyeing rate and cotton feel improvement.

[0022] In the ninth technical solution and related embodiments, the specific formulation concentration of the finishing liquid and the baking process parameters are specified. This parameter range ensures that the water-based PU and the fluorine-free waterproofing agent can crosslink and form a film on the fiber in an optimal ratio, achieving sufficient flexibility and waterproofing while avoiding the sticky feel or performance degradation that may result from excessive additives.

[0023] In the tenth technical solution and related embodiments, the fabric produced by this method has the soft touch of cotton, the high abrasion resistance of nylon (Martindale abrasion resistance ≥50,000 times), and the environmentally friendly high water repellency (AATCC 22 standard ≥4 level), and does not contain PFOA / PFOS, thus meeting the market demand for high-end functional and environmentally friendly fabrics. Detailed Implementation

[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are preferred embodiments of the present invention and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] Unless otherwise expressly defined, the claims and description of this invention use terms such as "first," "second," or "third" to distinguish different objects, rather than to describe a specific order.

[0027] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims and description of this invention should be interpreted broadly, that is, any connection in which there is no displacement relationship or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection, and fixed connection by other means or components.

[0028] In the claims and description of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."

[0029] A method for preparing an ultrafine denier nylon cotton-like fabric includes the following processes in sequence: yarn configuration and weaving, pretreatment, and finishing. This method, through specific yarn design, pretreatment processes, and finishing techniques, enables the 100% nylon fabric to achieve a distinct cotton-like feel, effective fluorine-free water resistance, and good durability.

[0030] Yarn configuration and weaving form the physical basis for the cotton-like feel and durability of the fabric. Specifically, the warp yarn is made of fully dull nylon FDY or DTY filaments, preferably with a fineness of 15D-30D, such as 20D / 24F. The weft yarn is made of fully dull FDY filaments with a single filament fineness of no more than 10D (preferably 10D / 12F), which are processed into nylon air-textured yarn (ATY) by jet deformation using high-pressure compressed air at a special nozzle. Preferably, two 10D / 12F FDY filaments are combined to process them into ATY yarn with a final fineness of 20D-30D (e.g., 25D / 24F). Subsequently, the warp and weft yarns are interwoven on a water-jet loom in a plain weave, controlling the warp density of the greige fabric at 200-240 ends / inch and the weft density at 150-180 ends / inch.

[0031] In this embodiment, the weft yarn is made from FDY filaments with a single filament fineness of no more than 10D through air texturing. This is the physical basis for achieving a cotton feel. Using extremely fine 10D-level FDY filaments as raw materials, the air texturing process is used to form ATY yarns with a loose structure and a surface covered with tiny loops and hairs, which highly simulates the structure of natural cotton fibers in terms of microscopic morphology, providing the foundation for obtaining a cotton feel.

[0032] Pretreatment includes desizing, dyeing, and drying processes. The purpose of this stage is to release weaving stress, purify fibers, and create an ideal state for subsequent finishing. Specifically, the above-mentioned greige fabric is desized. First, at room temperature, the greige fabric is impregnated with a liquid alkali (such as caustic soda) at a concentration of 20-30 g / L, with the pick-up rate controlled at approximately 60%. Subsequently, the impregnated greige fabric is rolled up and wrapped with plastic film, and stacked at room temperature (cold stack) for 40-56 hours (preferably 48 hours). After the cold stack, a high-temperature water wash is performed using a BO tensionless desizing machine to thoroughly remove the swollen sizing and impurities. The desized clean fabric is placed in an overflow dyeing machine, where acidic dyes and auxiliaries are added, and the temperature is raised to 95-102°C (preferably 102°C for dark colors) at a rate of 1-2°C / min, and maintained at this temperature for 20-40 minutes, followed by cooling and water washing.

[0033] In this embodiment, the alkaline cold piling process fully swells impurities on the sizing and fibers, while tension-free desizing thoroughly removes impurities without mechanical stretching. The combination of these two processes releases the internal stress generated in the warp and weft yarns during weaving, resulting in a looser and more fluffy fabric. The plain weave combined with BO tension-free desizing further releases the internal stress of the fibers during weaving, making the fabric fluffy and soft. The gentle circulation of the dyeing solution during overflow dyeing allows the ATY yarn to be further untwisted and relaxed in a humid and hot environment, fully unfolding its fluffy structure and enhancing the cotton-like quality of the yarn itself. After this stage of treatment, the fabric reaches a clean, fluffy, and fully relaxed state, with high fiber surface activity, which is beneficial for the uniform adsorption and penetration of subsequent finishing agents.

[0034] The finishing process includes padding, baking, and humidification. This stage is the key chemical and physical treatment step to achieve fabric functionalization (softness, water resistance) and final hand feel shaping. Specifically, firstly, the dyed and dried fabric is passed through a padding tank and a finishing solution is applied. The finishing solution formula is: 15-25 g / L (preferably 20 g / L) of waterborne polyurethane (e.g., a product from Ruifeng Technology Co., Ltd.), 40-60 g / L (preferably 50 g / L) of fluorine-free water-repellent agent (e.g., Huntsman R3 model), with the padding rate controlled at around 60%. Then, the padded fabric is sent to a setting machine and baked at a temperature of 155-165℃ (preferably 160℃) for 60-90 seconds (preferably 90 seconds). After baking and the fabric exiting the oven, it is immediately humidified at the end of the machine, for example, by spraying water mist onto the fabric through a spray device or passing it through a humidity-controlled channel to rapidly increase the fabric's moisture regain, followed by unloading into a box.

[0035] In this embodiment, waterborne polyurethane can effectively penetrate into the interior of the fiber and between the fiber bundles. Its soft molecular chains act as lubricants and binders, reducing the rigidity of the fiber and making the fiber bundles soft and compliant, which is a chemical means of achieving a cotton-like feel. A fluorine-free waterproofing agent forms a water-repellent film on the fiber surface, achieving a water-repellent effect of level 4 (AATCC 22 standard) or higher, and is completely free of restricted substances such as PFOA and PFOS, meeting green environmental protection requirements. Humidification and rehydration serve as physical quenching and hand-feel setting. After high-temperature baking, the fiber and auxiliary film are in a heat-set state. The immediate humidification treatment utilizes the strong hygroscopic properties of nylon fibers, allowing the fibers and the internal PU film to quickly and evenly absorb moisture, producing an effect similar to "quenching." This effectively resolves the fiber rigidity rebound caused by high temperature, preventing permanent creases (chicken claw marks), and allows the soft PU film to complete its final relaxation and setting in a moist state, locking the soft, fluffy cotton feel into the fabric without a stiff hand feel. Water-based PU and fluorine-free waterproofing agents work synergistically in the formula to achieve a unified function of softness and waterproofing; while the sequential combination of humidification and baking creates a physical synergy of shaping and softening, ensuring the full and lasting expression of the chemical finishing effect. All three are indispensable, working together to resolve the contradiction in traditional processes where it is difficult to balance feel, function, and durability.

[0036] In this embodiment, the contradiction of not being able to simultaneously achieve cotton feel, abrasion resistance, and environmental protection and waterproofing in the prior art is resolved through the synergistic effect of yarn structure design, pretreatment and finishing system.

[0037] A superfine denier nylon cotton-like fabric is prepared using the aforementioned method. The fabric composition is 100% nylon. The fabric produced by this method combines the soft touch of cotton, the high abrasion resistance of nylon (Martindale abrasion resistance ≥50,000 cycles), and environmentally friendly high water repellency (AATCC 22 standard ≥4 level), and is free of PFOA / PFOS, meeting the market demand for high-end functional and environmentally friendly fabrics.

[0038] Example 1 The present invention will be further described below through a preferred embodiment, but this application is not limited to this embodiment.

[0039] The preparation of an ultrafine denier nylon cotton-like fabric is carried out according to the following steps: Yarn configuration and weaving: The warp yarn is 20D / 24F fully dull nylon DTY filament. The weft yarn is 25D / 24F fully dull nylon ATY yarn. This ATY yarn is produced using a Japanese AIKI air-jet loom, where two 10D / 12F fully dull FDY filaments are fed in and intertwined by a high-pressure air jet. The fabric is woven on a water-jet loom in a plain weave, with a warp density of 220 ends / inch and a weft density of 160 ends / inch to obtain the greige fabric.

[0040] Preprocessing: Desizing: The fabric is impregnated with 25g / L of liquid alkali, with a roll-up rate of 60%, and then rolled up and cold-batched for 48 hours. Subsequently, it is washed at a high temperature of above 95℃ in a BO tensionless desizing machine to fully desizing.

[0041] Dyeing: Place the desizing equipment in an overflow dyeing machine, add black acid dye, heat to 102℃ at 1.5℃ / min, keep dyeing for 30 minutes, then cool, soap, and wash with water.

[0042] Drying: The dyed fabric is fed into a tensionless conveyor belt dryer, where hot steam at 130-145℃ is used to allow the fabric to shrink freely and dry in a relaxed state.

[0043] Post-editing: Preparation of finishing solution: Water-based PU (Rueying Technology) 20 g / L, Fluorine-free waterproofing agent (Hunsmay R3) 50 g / L.

[0044] Padding: The dried fabric is passed through a padding tank, with the liquid content controlled at 60%.

[0045] Baking: Baking at 160°C for 90 seconds in a setting machine.

[0046] Humidification and moisture regain: A spray device is used at the fabric exit point to humidify the baked fabric, increasing its moisture regain rate to about 8%, and then the fabric is dropped.

[0047] Performance testing: Feel: As rated by multiple people, it has a significant cotton-like softness and fluffiness, and is comfortable against the skin.

[0048] Water repellency: Tested according to AATCC 22 standard, initial rating of 90 points (level 4).

[0049] Abrasion resistance: Tested according to the Martindale method of ISO 12947-2, abrasion resistance > 50,000 cycles.

[0050] Anti-pilling: According to GB / T 4802.1-2008 test, it reaches level 4 (≥300 times).

[0051] Environmental friendliness: Tested by EN17681-1:2025 alkaline hydrolysis method, it does not contain restricted substances such as PFOA and PFOS, and meets the requirements of OEKO-TEX100 standard.

[0052] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.

Claims

1. A method for preparing superfine denier nylon cotton touch fabric, characterized in that, Comprise the following steps in sequence: Yarn configuration and weaving: weaving with warp and weft, wherein the weft is nylon air texturing yarn (ATY) made by air texturing processing of FDY filament with a single filament fineness of no more than 10D; Post-finishing: dip treating the dyed fabric, the finishing liquid used contains water-based polyurethane and fluorine-free waterproof agent, dip treated fabric is then baked and set, and the fabric is humidified and treated for moisture regain when it is taken out.

2. The method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 1, characterized in that, The warp is nylon full-dull FDY or full-dull DTY filament, and the weft is ATY yarn made by jet texturing processing of two full-dull FDY filaments with a single filament fineness of 10D / 12F at the nozzle using compressed air.

3. The method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 2, characterized in that, The warp is full-dull FDY filament with a fineness of 20D / 24F, and / or the weft is ATY yarn with a fineness of 25D / 24F.

4. The method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 3, characterized in that, in In the yarn configuration and weaving step, the weaving uses plain weave, and the obtained grey fabric has a warp density of 200-240 threads / inch and a weft density of 150-180 threads / inch.

5. A method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 2, 3, or 4, characterized in that, Before the post-finishing step, the following pretreatment steps are further included in sequence: Desizing treatment: dip treating the obtained grey fabric with alkali solution, then cold piling, and then tensionless washing; Dyeing: dyeing the desized grey fabric in an overflow dyeing machine; Drying: drying the dyed fabric using a tensionless drying device.

6. The method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 5, characterized in that, In the desizing treatment step, the concentration of the alkali solution is 20-30 g / L, and the time of cold piling is 40-56 hours.

7. The method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 5, characterized in that, In the dyeing step, the temperature of dyeing treatment is 95-102℃, and the holding time is 20-40 minutes.

8. The method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 7, characterized in that, The temperature of dyeing treatment is 102℃.

9. The method for preparing an ultrafine denier nylon cotton-feel fabric as described in claim 1, characterized in that, In the post-finishing step, in the finishing liquid, the concentration of water-based polyurethane is 15-25 g / L, and the concentration of fluorine-free waterproof agent is 40-60 g / L; the temperature of baking and setting is 155-165℃, and the time is 60-90 seconds.

10. An ultra-fine denier nylon cotton touch fabric, characterized in that, Prepared by the method of claim 1-9. Prepared by the method of claim 1-9.