Innovative manufacturing process of high-elasticity crease-resistant polyester fabric

Abstract

The invention relates to the technical field of textile material preparation, and discloses a high-elasticity anti-wrinkle polyester fabric innovative manufacturing process which comprises the following steps: S1, fiber potential construction: firstly, preparing gradient crystallization polyester DTY yarns with cross section crystallinity difference, and reserving amorphous regions for storing stress-induced deformation potential in core parts of the gradient crystallization polyester DTY yarns; s2, fabric structure optimization: weaving the gradient crystallization polyester DTY yarns under a constant low-tension condition to form loose gray cloth with microstructure redundancy; and S3, molecular memory induction: padding the loose gray cloth into a working solution containing a eutectic auxiliary agent. The polyester DTY yarn with the gradient crystal morphology is constructed, the limitation that common polyester is high in rigidity and poor in elasticity is broken through from the double dimensions of raw materials and the structure, and on the premise that polyurethane elastic fibers (spandex) are not used, the all-polyester fabric is endowed with excellent mechanical stretching resilience.

Description

Technical Field

[0001] This invention relates to the field of textile material preparation technology, specifically to an innovative manufacturing process for high-elasticity, wrinkle-resistant polyester fabric. Background Technology

[0002] Polyethylene terephthalate (PET) fiber, commonly known as polyester, has long dominated the synthetic textile fiber market due to its excellent mechanical strength, abrasion resistance, and low cost. However, with the increasing demands for comfort in clothing from consumers, the inherent defects of traditional polyester fabrics, such as high rigidity, poor resilience, and susceptibility to wrinkling, have become increasingly prominent. To impart elasticity to the fabric, the most common solution in current technology is to incorporate polyurethane elastic fiber (i.e., spandex) during the weaving process. Although the introduction of spandex can significantly improve the tensile recovery performance of the fabric, it also introduces a series of unavoidable industrial challenges: On the one hand, spandex has significantly different heat resistance and dyeability compared to polyester, leading to problems such as color difference, elasticity damage, and dimensional instability during dyeing and finishing; on the other hand, the heterogeneous blended structure formed by spandex and polyester greatly increases the difficulty of recycling and separating waste textiles, making it difficult to recycle the blended fabric through simple melt spinning, which does not meet the urgent needs of the current textile industry for green and circular development.

[0003] To address the aforementioned environmental and processing challenges, the development of pure polyester high-elastic fabrics without spandex has become a hot research topic in the industry. Currently, while physical deformation processing or the use of new polyester chips can impart mechanical crimp elasticity to polyester yarns to a certain extent, subsequent fabric dyeing and finishing processes face an irreconcilable contradiction between "high elasticity" and "morphological stability." As a thermoplastic fiber, polyester typically requires high-temperature heat setting to eliminate internal stress in order to obtain good wrinkle resistance and dimensional stability. However, this high-temperature treatment can lead to excessive crystallization and hardening of polyester molecular chains, locking or even destroying the original crimp structure and microscopic movement ability of amorphous regions of the yarn, resulting in a stiffer fabric feel and a significant loss of elasticity.

[0004] In addition, to improve the wrinkle resistance of polyester fabrics, existing technologies often use resin finishing agents for chemical cross-linking treatment. Although this method can improve the wrinkle resistance level, it often sacrifices the softness of the fabric, making it feel rough. Furthermore, some finishing agents have problems such as formaldehyde release or poor wash resistance. At the same time, existing low-temperature setting technology lacks effective molecular chain activation methods, which cannot promote sufficient stress relaxation and orderly rearrangement of polyester molecular chains at low temperatures. As a result, the fabric is prone to severe dimensional shrinkage and surface wrinkling during subsequent washing. Therefore, this invention designs an innovative manufacturing process for high-elasticity wrinkle-resistant polyester fabric based on the above-mentioned problems. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an innovative manufacturing process for high-elasticity, wrinkle-resistant polyester fabric. This process solves the problems of existing technologies, such as the reliance on adding spandex to polyester fabrics to achieve elasticity, which leads to difficulties in recycling, and the tendency of pure polyester fabrics to suffer from fiber thermal embrittlement and severe loss of elasticity when using traditional high-temperature setting processes.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an innovative manufacturing process for high-elasticity, wrinkle-resistant polyester fabric, comprising the following steps:

[0007] S1. Fiber potential construction: First, a gradient crystallized polyester DTY yarn with different cross-sectional crystallinity is prepared. The core of the gradient crystallized polyester DTY yarn retains an amorphous region for storing stress-induced deformation potential.

[0008] S2. Fabric structure optimization: The gradient crystallized polyester DTY yarn is woven under constant low tension conditions to form a loose fabric with microstructural redundancy.

[0009] S3, Molecular memory induction: The loose fabric is immersed in a working solution containing a eutectic agent, so that the eutectic agent penetrates into the amorphous region of the gradient crystallized polyester DTY yarn;

[0010] S4. Dynamic stress coupling setting: The loose fabric after impregnation is transported to a low-temperature setting environment. Under the action of the eutectic agent, a periodic longitudinal dynamic stress coupling field is applied to the loose fabric to induce the molecular chains of the gradient crystallized polyester DTY yarn to rearrange and be fixed into a eutectic memory structure. Then, it is cooled and solidified to obtain a semi-finished fabric.

[0011] S5. Performance Enhancement: Finally, the semi-finished fabric is subjected to instant swelling treatment using a washing liquid containing a bio-based swelling agent to eliminate residual stress, and then dried at low temperature to restore it, thus obtaining the high-elasticity wrinkle-resistant polyester fabric.

[0012] Preferably, the gradient crystallized polyester DTY yarn described in step S1 is prepared by controlling the temperature difference of the heating chamber in the texturing process, wherein the set value of the second heating chamber temperature in the texturing process is lower than the set value of the first heating chamber temperature, the first heating chamber temperature is 175℃-185℃, and the second heating chamber temperature is 155℃-165℃.

[0013] Preferably, the low tension condition specifically refers to: the warp yarn opening tension being controlled at 15-20 cN / end, and the weft yarn insertion tension being controlled at 10-15 cN; the density of the loosely woven fabric is 10%-15% lower than that of conventional polyester fabrics of the same specification.

[0014] Preferably, the eutectic aids in the working fluid described in step S3 include aromatic ester eutectic inducers, aliphatic diol penetrants, nonionic surfactants, and water.

[0015] Preferably, the eutectic agent comprises, by weight percentage: 40%-50% aromatic ester eutectic inducer, 20%-30% aliphatic diol penetrant, 10%-15% nonionic surfactant, and the balance being deionized water; the aromatic ester eutectic inducer is selected from low molecular weight derivatives of benzyl benzoate or dimethyl terephthalate.

[0016] Preferably, the temperature of the low-temperature setting environment in step S5 is 120℃-140℃; the periodic longitudinal dynamic stress coupling field is applied by the variable overfeed system of the tenter frame, and its control parameters include the reference overfeed rate and the overfeed fluctuation amplitude.

[0017] Preferably, the reference overfeed rate is +20% to +30%, the overfeed fluctuation range is ±5% to ±10%, and the fluctuation frequency is 0.5 to 1.5 Hz, so that the loose fabric changes in the form of a sine wave or trapezoidal wave when subjected to force in the warp direction.

[0018] Preferably, the bio-based swelling agent in step S5 is selected from ethyl lactate or butyl carbitol, the concentration of the bio-based swelling agent in the washing solution is 2.0-5.0 g / L, and the washing temperature is 50℃-60℃.

[0019] Preferably, the low-temperature drying recovery in step S5 is carried out in a tensionless loose dryer at a drying temperature of 100℃-110℃ until the moisture content of the high-elasticity wrinkle-resistant polyester fabric is less than 3%.

[0020] Preferably, the innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric is characterized by the high-elasticity wrinkle-resistant polyester fabric being composed of pure polyester fibers and containing no polyurethane elastic fibers; during the manufacturing process, the loose fabric is treated with a working solution containing a eutectic agent, which, by weight percentage, includes: 40%-50% aromatic ester eutectic inducer, 20%-30% aliphatic diol penetrant, and 10%-15% nonionic surfactant.

[0021] This invention provides an innovative manufacturing process for highly elastic, wrinkle-resistant polyester fabric. It offers the following advantages:

[0022] 1. This invention constructs polyester DTY yarn with a gradient crystallization morphology, which utilizes the high-orientation amorphous region retained in its core to store huge stress-induced deformation potential, and combines it with a constant tension low-density weaving process to reserve microstructural redundancy for yarn shrinkage. From the dual dimensions of raw materials and structure, it breaks through the limitations of ordinary polyester's strong rigidity and poor elasticity, and endows all polyester fabrics with excellent mechanical tensile resilience without using polyurethane elastic fibers (spandex).

[0023] 2. This invention combines aromatic ester eutectic inducers with a low-temperature setting process, using eutectic agents to reduce the kinetic energy barrier of polyester molecular chains. This allows polyester molecular chains to be activated and rearranged at temperatures significantly lower than those of traditional heat setting. This significantly reduces energy consumption during production and effectively avoids damage to fiber strength and surface "thermal embrittlement" caused by traditional high-temperature setting, while perfectly preserving the excellent flexibility and abrasion resistance of polyester fibers.

[0024] 3. This invention introduces a periodic longitudinal dynamic stress coupling field during the low-temperature setting stage, and uses dynamic mechanical energy in conjunction with thermal energy and chemical induction to drive the molecular chains in the amorphous region inside the fiber to undergo deep and orderly adjustment, and fix them into a thermodynamically metastable eutectic molecular memory structure. This special microstructure endows the fabric with a strong shape memory function, significantly improving the smoothness and wrinkle resistance of the fabric after washing, and solving the technical problem of poor dimensional stability that usually exists in low-temperature setting.

[0025] 4. This invention utilizes the selective penetration of bio-based swelling agents into the amorphous regions of fibers through instantaneous swelling-recovery treatment after shaping. This eliminates the forced internal stress generated during processing at the molecular scale. Combined with tension-free low-temperature drying, the fiber structure remains microscopically relaxed while shrinking and densifying. This gives the finished fabric a fluffy, soft, and lively feel, effectively overcoming the shortcomings of traditional polyester fabrics, such as stiffness and lack of drape.

[0026] 5. This invention completely eliminates the heterogeneous components that are difficult to recycle and separate in traditional elastic fabrics through a high-performance modification path of all-polyester single components. This makes the final product maintain a high degree of purity and uniformity of chemical composition, greatly reduces the difficulty of recycling waste textiles, and facilitates melt regeneration or chemical recycling. It is in line with the development trend of green manufacturing and circular economy and has significant environmental benefits. Attached Figure Description

[0027] Figure 1 This is one of the schematic diagrams of the manufacturing process of the present invention;

[0028] Figure 2 This is a second schematic diagram of the manufacturing process of the present invention;

[0029] Figure 3 This is the third schematic diagram of the manufacturing process of the present invention;

[0030] Figure 4 This is the fourth schematic diagram of the manufacturing process of the present invention;

[0031] Figure 5 This is the fifth schematic diagram of the manufacturing process of the present invention;

[0032] Figure 6 This is the sixth schematic diagram of the manufacturing process of the present invention. Detailed Implementation

[0033] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Please see the appendix Figure 1 - Appendix Figure 6 This invention provides an innovative manufacturing process for high-elasticity, wrinkle-resistant polyester fabric, comprising the following steps:

[0035] S1. Fiber potential construction: First, gradient crystallized polyester DTY yarn with different cross-sectional crystallinity is prepared. The core of the gradient crystallized polyester DTY yarn retains an amorphous region for storing stress-induced deformation potential. The gradient crystallized polyester DTY yarn is prepared by controlling the temperature difference of the hot box in the texturing process. The temperature setting of the second hot box in the texturing process is lower than that of the first hot box. The temperature of the first hot box is 175℃-185℃, and the temperature of the second hot box is 155℃-165℃.

[0036] Specifically, polyethylene terephthalate (PET) chips with an intrinsic viscosity (IV) of 0.64-0.68 dL / g were selected as the substrate, and additives were added. (by weight) titanium dioxide To improve the frictional properties and gloss of the fiber surface;

[0037] POY spinning basics: First, pre-oriented yarn (POY) is prepared. To facilitate subsequent gradient processing, the spinning process needs to ensure that the fiber has a moderate degree of orientation but low crystallinity. Specific process settings are: screw extrusion temperature 285℃-295℃, winding speed controlled at 3000-3300m / min, producing POY precursor yarn with a single filament fineness of 2.0-2.5dtex. Gradient crystallization texturing process: Stretching and deformation processing is performed on a texturing machine. This invention employs a differentiated hot box temperature control strategy, utilizing the time difference and temperature gradient of heat conduction to create a crystallinity gradient in the fiber cross-section. First hot box (deformation hot box): temperature set at 175℃-185℃. At this high temperature, the fiber… The surface layer of the fiber rapidly heats up and crystallizes, forming a "hard shell" microcrystalline region with high modulus and shape retention. The second heating box (setting heating box) is set at 155℃-165℃, which is significantly lower than the first heating box. The lower temperature of the second heating box is insufficient to completely thermally crystallize the fiber core, thus retaining amorphous regions with high orientation in the core. The molecular chains of these amorphous regions are in a high-energy state, like compressed springs, storing huge stress-induced deformation potential. Draw ratio and false twist: In conjunction with the above temperature difference, the draw ratio is controlled at 1.65-1.75, and the false twist is controlled at 3200-3600T / m to ensure that the fiber obtains bulkiness while its core molecular chains are fully stretched and oriented.

[0038] S2. Fabric Structure Optimization: Gradient-crystallized polyester DTY yarn is woven under constant low tension conditions to form a loosely structured fabric with redundant microstructure. The low tension conditions are specifically: warp yarn opening tension is controlled at 15-20 cN / end, and weft yarn insertion tension is controlled at 10-15 cN. The density of the resulting loosely woven fabric is 10%-15% lower than that of conventional polyester fabrics of the same specifications.

[0039] Specifically, in order to convert the fiber potential stored in step S1 into macroscopic fabric elasticity in subsequent processes, sufficient physical space, i.e., "structural redundancy," must be reserved during the weaving stage. The fabric structure uses a 2 / 1 twill or 2 / 2 twill weave, utilizing the longer float length to reduce interlacing resistance between yarns. Constant low tension control is also crucial: the high tension of traditional high-density weaving locks the yarns in place, limiting their shrinkage, while this invention implements strict low tension control.

[0040] Warp yarn shedding tension: controlled at 15-20 cN / end (significantly lower than conventional processes);

[0041] Weft tension: Controlled at 10-15 cN;

[0042] Loose density setting: The woven loose fabric has a warp density controlled at 380-420 threads / 10cm and a weft density controlled at 280-320 threads / 10cm. This density setting is lower than that of conventional polyester fabrics of the same specification. This loose microstructure provides freedom for the subsequent contraction and rearrangement of molecular chains.

[0043] S3, Molecular Memory Induction: The loosely packed fabric is impregnated into a working solution containing a eutectic agent, allowing the eutectic agent to penetrate into the amorphous region of the gradient-crystallized polyester DTY yarn. The eutectic agent in the working solution in step S3 includes an aromatic ester eutectic inducer, an aliphatic glycol penetrant, a nonionic surfactant, and water. The eutectic agent, by weight percentage, consists of: 40%-50% aromatic ester eutectic inducer, 20%-30% aliphatic glycol penetrant, 10%-15% nonionic surfactant, and the remainder is deionized water. The aromatic ester eutectic inducer is selected from low molecular weight derivatives of benzyl benzoate or dimethyl terephthalate.

[0044] Specifically, this step involves introducing a eutectic agent through chemical means, aiming to lower the kinetic energy barrier of the polyester molecular chains so that they can be activated at low temperatures.

[0045] Cocrystallization aid component: Aromatic ester eucrystallization inducer (40%-50%): selected from low molecular weight derivatives of benzyl benzoate or dimethyl terephthalate. This component has an aromatic ring structure similar to PET and can pass through... The stacking effect embeds itself between PET molecular chains, inducing the orderly arrangement of molecular chains;

[0046] Aliphatic diol penetrant (20%-30%): Selected from 1,4-butanediol or hexanediol. Small molecule diols can quickly carry the inducing agent to penetrate into the interior of the highly dense amorphous region of polyester.

[0047] Nonionic surfactant (10%-15%): preferably isotridecyl alcohol polyoxyethylene ether, to ensure the emulsification stability and wettability of the system;

[0048] Deionized water: Balance;

[0049] Padding process: Prepare a working solution with a concentration of 30-50 g / L, and use a one-dip-one-padding or two-dip-two-padding process to bring the loose fabric into contact with the solution, controlling the residual rate. This ensures that the additives fully penetrate into the amorphous region of the core of the gradient crystallized yarn.

[0050] S4. Dynamic stress coupling setting: The loose fabric after impregnation is transported to a low temperature setting environment. Under the action of the eutectic agent, a periodic longitudinal dynamic stress coupling field is applied to the loose fabric at the same time, which induces the molecular chains of gradient crystallized polyester DTY yarn to rearrange and be fixed into a eutectic memory structure. Then, it is cooled and solidified to obtain a semi-finished fabric.

[0051] Specifically, the temperature of the tenter frame oven is first set to 120℃-140℃. This temperature range is far below the melting point of polyester and only slightly above its glass transition temperature, which is sufficient to protect the microcrystalline structure of the fiber surface from melting and sticking together. However, with the assistance of the eutectic agent, it is sufficient to make the molecular chains in the amorphous region move.

[0052] Periodic longitudinal dynamic stress coupling field: During the setting process, the fabric is not in a static or constant tension state, but rather experiences a dynamic mechanical wave. This is achieved through the variable overfeed system of the setting machine: Reference overfeed rate: set to High overfeed rate allows the fabric to shrink significantly in the warp direction, which is the source of its high elasticity;

[0053] Dynamic fluctuation parameter: Based on the benchmark overfeed, a parameter with an amplitude of [value missing] is superimposed. Periodic fluctuations with a frequency of 0.5-1.5Hz, for example, if the reference is... Fluctuation is The actual overfeeding rate is to They change rapidly in a cyclical manner in the form of sine waves or trapezoidal waves;

[0054] Working principle: Dynamic tension changes generate mechanical vibration energy, which is transferred to the microscopic molecular chains to help the eutectic agent overcome intermolecular forces. During the relaxation phase of the fluctuating tension, the molecular chains curl and shrink; during the stretching phase, the molecular chains are oriented and adjusted. After a dwell time of 45-60 seconds, the amorphous molecular chains in the core of the gradient crystallized yarn are induced to form a thermodynamically metastable eutectic structure and are cooled and solidified, thereby giving the fabric a strong shape memory function.

[0055] S5. Performance Enhancement: Finally, the semi-finished fabric is subjected to instantaneous swelling treatment using a washing liquid containing a bio-based swelling agent to eliminate residual stress. It is then restored through low-temperature drying to obtain a high-elasticity, wrinkle-resistant polyester fabric. The low-temperature setting environment is 120℃-140℃. The periodic longitudinal dynamic stress coupling field is applied through the variable overfeed system of the tenter frame. Its control parameters include the reference overfeed rate and the overfeed fluctuation amplitude. The reference overfeed rate is +20% to +30%, and the overfeed fluctuation amplitude... The degree of change is ±5%-±10%, and the fluctuation frequency is 0.5-1.5Hz, so that the loose fabric changes in the form of a sine wave or trapezoidal wave under warp stress. The bio-based swelling agent is selected from ethyl lactate or butyl carbitol. The concentration of the bio-based swelling agent in the washing solution is 2.0-5.0g / L. The washing temperature is 50℃-60℃. Low-temperature drying and recovery are carried out in a tensionless loose dryer at a drying temperature of 100℃-110℃ until the moisture content of the high-elasticity wrinkle-resistant polyester fabric is less than 3%.

[0056] Specifically, although the shaped fabric has a structural basis, there is still internal stress between the molecular chains, and the residual additives need to be removed. At this time, the structure can be further improved through the solvent effect.

[0057] Instant swelling treatment: Add a bio-based swelling agent (ethyl lactate or butyl carbitol) at a concentration of 2.0-5.0 g / L to the washing solution. Control the washing temperature at 50℃-60℃ and the time... Bio-based swelling agents can selectively penetrate amorphous regions, causing them to swell microscopically, giving the molecular chains a final opportunity for fine-tuning and eliminating the forced internal stress generated during the shaping process.

[0058] Low-temperature drying recovery: Subsequently, the fabric enters a loose-feed dryer (without tension) and is dried at 100℃-110℃. As the solvent evaporates, the swollen amorphous regions rapidly shrink and densify, not only locking in the elastic structure but also giving the fabric excellent wrinkle resistance, resilience, and a soft feel. Finally, it is dried until the moisture content is below [a certain level]. The finished product can then be obtained after removing it from the machine.

[0059] The innovative manufacturing process of high-elasticity wrinkle-resistant polyester fabric is made of pure polyester fiber and does not contain polyurethane elastic fiber. During the manufacturing process, the loose fabric is treated with a working solution containing eutectic agents. The eutectic agents include, by weight percentage: 40%-50% aromatic ester eutectic inducer, 20%-30% aliphatic glycol penetrant, and 10%-15% nonionic surfactant.

[0060] To verify the advantages of the wrinkle-resistant polyester fabric prepared by this method in terms of elasticity, the following comparative test experiment was designed, and the experimental procedure is as follows:

[0061] Test subject:

[0062] Example 1: The wrinkle-resistant polyester fabric prepared in the above steps;

[0063] Comparative Example 1: Compared with Example 1, the difference is that in the gradient crystallization DTY texturing process, the temperature of the second hot box (setting hot box) is set to 180°C (the same as the temperature of the first hot box) to obtain a conventional polyester DTY yarn with uniform internal and external crystallinity, and the high amorphous region in the core is no longer retained. The remaining steps and parameters are the same as in Example 1.

[0064] Comparative Example 2: Compared with Example 1, the difference is that: in the weaving process, a conventional high-tension compact weaving process is adopted, wherein the warp opening tension is set to 35cN / end, the weft insertion tension is set to 25cN, and the warp and weft density of the fabric is increased by 15% compared with Example 1. The remaining steps and parameters are the same as those in Example 1.

[0065] Comparative Example 3: Compared with Example 1, the difference is that: during the setting process, no periodic longitudinal dynamic stress coupling field was applied, but a constant reference overfeed rate (+25%) was maintained, that is, the overfeed fluctuation amplitude was 0%, so that the fabric was set at low temperature under constant tension. The remaining steps and parameters were the same as in Example 1.

[0066] Comparative Example 4: Compared with Example 1, the difference is that: in the shaping process, the traditional high-temperature shaping process is used, the shaping temperature is set to 190°C, and no dynamic stress coupling field is applied (maintaining conventional constant tension). The remaining steps and parameters are the same as in Example 1.

[0067] Sample preparation and pretreatment

[0068] Sample cutting: According to the requirements of ASTM D3107 standard, cut rectangular samples in the warp and weft directions from each group of fabrics, with at least 5 valid samples in each direction for each group;

[0069] Marking: Clearly mark the initial gauge length on the specimen;

[0070] Conditioning: Place all samples in a standard constant temperature and humidity environment for conditioning to ensure that the samples reach equilibrium humidity during testing;

[0071] Elongation test under constant load

[0072] Clamping: Clamp the conditioned sample in the upper and lower clamps of the tensile testing machine, ensuring moderate clamping force to avoid slippage or damage. Set the initial gauge length to L0.

[0073] Apply load: Stretch at a preset constant rate until the specimen is subjected to a preset constant load, then stop immediately;

[0074] Measure elongation: Record the specimen length Lmax when the constant load is reached;

[0075] Calculation: Calculate the elongation at constant load E according to the following formula:

[0076]

[0077] Relaxation: Relax the sample to a tension-free state in preparation for the next test.

[0078] Elastic recovery rate test

[0079] Stretch to a fixed elongation: Stretch the new or relaxed specimen to a preset fixed elongation and maintain it. time;

[0080] Unloading and Recovery: Quickly unload the load to return the specimen to a tension-free state, and record the specimen's recovery under no-load conditions. Length after time ;

[0081] Calculate: Elastic recovery rate Calculate according to the following formula:

[0082]

[0083] 4. Repetition: The tests were repeated for each group of samples, and the average value was taken as the final result. The test data is shown in the table below:

[0084] Sample number Testing direction Elongation at constant load E (%) Elastic recovery rate R (%) Example 1 via 34.5 93.1 Example 1 Latitudinal 38.9 90.5 Comparative Example 1 via 28.1 85.6 Comparative Example 1 Latitudinal 29.5 84.2 Comparative Example 2 via 30.8 87.9 Comparative Example 2 Latitudinal 33.4 86.1 Comparative Example 3 via 32.2 88.5 Comparative Example 3 Latitudinal 36.0 85.0 Comparative Example 4 via 25.9 79.8 Comparative Example 4 Latitudinal 27.3 78.1

[0085] The results of this experiment clearly reflect the key influence of fiber internal structure and finishing process on the elastic properties of pure polyester fabric. Fabrics made by conventional DTY (Comparative Example 1) and high temperature setting (Comparative Example 4) processes have low levels of elongation and elastic recovery under constant load. This is mainly because conventional DTY lacks amorphous regions that store high potential energy, and high temperature setting easily leads to excessive crystallization and cross-linking of molecular chains, causing the fiber to lose its flexibility, thereby limiting macroscopic elongation and recovery.

[0086] This invention first ensures that the fiber core has a highly oriented amorphous region through the preparation of gradient crystalline polyester DTY yarn, storing the maximum stress-induced deformation potential. This is the inherent spring that enables high elongation. However, yarn potential alone is insufficient to translate into high fabric elasticity; optimization of the weaving structure is equally important. Compared with Comparative Example 2, it can be seen that the constant low-tension weaving strategy of Example 1 reserves microscopic redundant space in the fabric, preventing excessive binding of the warp and weft yarns when the fiber contracts under stress. This provides physical freedom for the full contraction and rearrangement of molecular chains in the subsequent finishing stage, ensuring that the elastic potential can be effectively released and transformed. Compared with Comparative Example 3, it can be found that the low-temperature eutectic and periodic dynamic stress coupling field used in Example 1 exhibits a superior elastic recovery rate. This confirms the ternary synergistic mechanism of the present invention: low temperature protects the stability of the gradient crystal structure; the eutectic agent lowers the energy barrier of molecular chain rearrangement; and the periodic dynamic stress coupling field acts as a mechanical catalyst, providing additional and efficient mechanical energy for molecular chain rearrangement. This dynamic drive allows the potential elongation of the fiber core to be fully released (shrink) at low temperature and efficiently fixed by the formed eutectic molecular memory structure, thereby maximizing the elastic recovery rate and shaping stability of the fabric.

[0087] In summary, this invention provides an innovative manufacturing process for high-elasticity, wrinkle-resistant polyester fabric. By constructing polyester DTY yarn with a gradient crystalline morphology, it breaks through the limitations of ordinary polyester's high rigidity and poor elasticity from both raw material and structural dimensions. Without using polyurethane elastic fibers (spandex), it endows the all-polyester fabric with excellent mechanical tensile resilience. Furthermore, by combining aromatic ester eutectic inducing agents with low-temperature setting processes, and utilizing eutectic auxiliaries to reduce the kinetic energy barrier of polyester molecular chains, the polyester molecular chains can be activated and rearranged at temperatures significantly lower than those of traditional heat setting. This significantly reduces energy consumption during production and effectively avoids the damage to fiber strength and surface "thermal embrittlement" caused by traditional high-temperature setting, perfectly preserving the excellent flexibility and abrasion resistance of polyester fibers.

[0088] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An innovative manufacturing process for high-elasticity, wrinkle-resistant polyester fabric, characterized by: Includes the following steps: S1. Fiber potential construction: First, a gradient crystallized polyester DTY yarn with different cross-sectional crystallinity is prepared. The core of the gradient crystallized polyester DTY yarn retains an amorphous region for storing stress-induced deformation potential. S2. Fabric structure optimization: The gradient crystallized polyester DTY yarn is woven under constant low tension conditions to form a loose fabric with microstructural redundancy. S3, Molecular memory induction: The loose fabric is immersed in a working solution containing a eutectic agent, so that the eutectic agent penetrates into the amorphous region of the gradient crystallized polyester DTY yarn; S4. Dynamic stress coupling setting: The loose fabric after impregnation is transported to a low-temperature setting environment. Under the action of the eutectic agent, a periodic longitudinal dynamic stress coupling field is applied to the loose fabric to induce the molecular chains of the gradient crystallized polyester DTY yarn to rearrange and be fixed into a eutectic memory structure. Then, it is cooled and solidified to obtain a semi-finished fabric. S5. Performance Enhancement: Finally, the semi-finished fabric is subjected to instant swelling treatment using a washing liquid containing a bio-based swelling agent to eliminate residual stress, and then dried at low temperature to restore it, thus obtaining the high-elasticity wrinkle-resistant polyester fabric.

2. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 1, characterized in that, The gradient crystallized polyester DTY yarn described in step S1 is prepared by controlling the temperature difference of the hot box in the texturing process. The temperature setting value of the second hot box in the texturing process is lower than that of the first hot box. The temperature of the first hot box is 175℃-185℃, and the temperature of the second hot box is 155℃-165℃.

3. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 1, characterized in that, The low tension conditions are specifically: the warp opening tension is controlled at 15-20 cN / end, and the weft insertion tension is controlled at 10-15 cN; the density of the loose fabric formed by the weaving is 10%-15% lower than that of conventional polyester fabric of the same specification.

4. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 1, characterized in that, The eutectic aids in the working solution described in step S3 include aromatic ester eutectic inducers, aliphatic diol penetrants, nonionic surfactants, and water.

5. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 4, characterized in that, The eutectic agent, by weight percentage, comprises: 40%-50% aromatic ester eutectic inducer, 20%-30% aliphatic diol penetrant, 10%-15% nonionic surfactant, and the balance being deionized water; the aromatic ester eutectic inducer is selected from low molecular weight derivatives of benzyl benzoate or dimethyl terephthalate.

6. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 1, characterized in that, The temperature of the low-temperature setting environment mentioned in step S5 is 120℃-140℃; the periodic longitudinal dynamic stress coupling field is applied by the variable overfeed system of the tenter frame, and its control parameters include the reference overfeed rate and the overfeed fluctuation amplitude.

7. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 6, characterized in that, The reference overfeed rate is +20% to +30%, the overfeed fluctuation range is ±5% to ±10%, and the fluctuation frequency is 0.5 to 1.5 Hz, so that the loose fabric changes in the form of a sine wave or trapezoidal wave when subjected to force in the warp direction.

8. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 1, characterized in that, The bio-based swelling agent mentioned in step S5 is selected from ethyl lactate or butyl carbitol, and the concentration of the bio-based swelling agent in the washing solution is 2.0-5.0 g / L, and the washing temperature is 50℃-60℃.

9. The innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to claim 1, characterized in that, The low-temperature drying recovery described in step S5 is carried out in a tensionless loose dryer at a drying temperature of 100℃-110℃ until the moisture content of the high-elasticity wrinkle-resistant polyester fabric is less than 3%.

10. An innovative manufacturing process for high-elasticity, wrinkle-resistant polyester fabric, characterized in that... According to the innovative manufacturing process of the high-elasticity wrinkle-resistant polyester fabric according to any one of claims 1-9, the high-elasticity wrinkle-resistant polyester fabric is composed of pure polyester fibers and does not contain polyurethane elastic fibers; in the manufacturing process, the loose fabric is treated with a working solution containing a eutectic agent, the eutectic agent comprising, by weight percentage: 40%-50% aromatic ester eutectic inducer, 20%-30% aliphatic diol penetrant, and 10%-15% nonionic surfactant.

Images