Super-soft yarn-loosening-resistant nano-composite roller shutter fabric and manufacturing method thereof

Abstract

The invention relates to a super-soft yarn-loosening-resistant nano-composite roller shutter fabric and a manufacturing method thereof. The composite roller shutter fabric comprises a base cloth layer, a foaming coating, a PUR glue layer and a fabric layer which are sequentially compounded, the base cloth layer is made of polyester plain grey cloth, warp is made of composite yarn with fully-drawn yarn as a core layer and wrapped with draw-textured yarn, and weft is made of draw-textured yarn; the foaming coating is formed by coating water-based acrylate foaming glue containing nano TiO2 and nano carbon black and carrying out sectional foaming curing; the PUR glue layer is of a discrete point structure formed by low-modulus flexible PUR glue, and the projection width of glue points in the weft direction is smaller than the center distance of weft yarns of the base cloth; and the fabric layer is made of terylene sanded cloth. By means of the collaborative design of the structure and the technology, the interlayer bonding firmness is guaranteed, meanwhile, edge yarn scattering is effectively restrained, the rigidity of the composite fabric is remarkably reduced, and the composite fabric is suitable for large-width building roller shutter sunshade products.

Description

Technical Field

[0001] This invention relates to the field of composite roller blind fabric processing and production technology, and in particular to an ultra-soft, anti-fraying nanocomposite roller blind fabric and its manufacturing method. Background Technology

[0002] With the acceleration of urbanization and the booming development of the construction industry, blackout roller blind fabrics have been widely used in diverse scenarios such as homes, hotels, cinemas, and offices. Among them, the mainstream "base fabric + TPU film + base fabric" composite structure product, while achieving excellent anti-sticking effects through the intermediate TPU film layer, faces a core technological bottleneck that is difficult to overcome:

[0003] On the one hand, TPU film itself has a high modulus (generally ≥200MPa). The high temperature and pressure during the lamination process will intensify the cross-linking of its molecular chains or increase its crystallinity, causing the mechanical properties of the composite fabric to be dominated by the TPU film. This transforms the originally flexible fabric into a rigid "plate-like structure," resulting in a stiff feel. Tests show that its bending length is generally >15cm (far exceeding the industry reference standard of ≤8cm for soft fabrics), seriously affecting the user experience. On the other hand, this composite structure relies on the bonding effect between the film and the adhesive, lacking effective restraint of the edge yarns, making it prone to fraying. To solve the fraying problem, the industry commonly uses PA or PU adhesives to coat or impregnate the base fabric surface. However, these adhesives form a rigid film after curing (Shore hardness ≥D60), which further exacerbates the rigidity of the fabric, creating a vicious cycle of "fraying → hardening adhesive → even stiffer," which is the long-standing technical contradiction of "composite fabrics inevitably becoming stiff" that the industry has been unable to resolve.

[0004] Furthermore, while traditional foamed coated fabrics possess a certain degree of light-blocking ability, they suffer from problems such as stickiness, uneven light-blocking, and easy cracking of the coating. Existing technologies have consistently failed to provide a systematic solution that simultaneously addresses the core contradiction of "composite fabrics inevitably being stiff + edge fraying," while also ensuring anti-sticking properties and high uniformity of light blocking. Therefore, developing a composite roller blind fabric that is non-fraying, ultra-soft to the touch, and meets the requirements for light blocking and anti-sticking has become a pressing technical challenge for the industry. Summary of the Invention

[0005] The technical problem to be solved by this invention is that traditional "base fabric + TPU film + base fabric" composite fabrics have the core contradiction of "composite must be hard" because they have a hard feel and loose threads at the edges require additional PA / PU glue to be applied, which increases rigidity. At the same time, this invention solves the problems of traditional foamed coated fabrics being sticky, having uneven light blocking, and being prone to coating cracking.

[0006] The technical solution adopted by this invention to solve its technical problem is:

[0007] An ultra-soft, anti-fraying nanocomposite roller blind fabric comprises a base fabric layer, a foam coating, a PUR adhesive layer, and a fabric layer sequentially laminated together.

[0008] The base fabric layer is a plain polyester fabric, with its warp yarns being a composite yarn with fully drawn yarn as the core layer and wrapped with stretch textured yarn; its weft yarns are stretch textured yarns.

[0009] The foamed coating is formed by coating and curing a foaming adhesive. The foaming adhesive uses an aqueous acrylic emulsion with a solid content of 30%-35% as a base material and also includes 3.0%-5.0% modified nano-TiO2 and 2.0%-4.0% nano-carbon black relative to the wet weight of the base material.

[0010] The PUR adhesive layer is a low-modulus flexible PUR adhesive with a 100% tensile modulus ≤ 80MPa; the PUR adhesive layer is a discrete array of dots, and the projected width of the adhesive dots in the weft direction is smaller than the center spacing of the weft yarns of the base fabric layer, so that the weft yarns have unconstrained segments that can produce micro-displacement between adjacent adhesive dots.

[0011] The fabric layer is made of polyester brushed fabric.

[0012] As a preferred technical solution, the adhesive dots coverage of the PUR adhesive layer is 15%-20%.

[0013] As a preferred technical solution, the modified nano-TiO2 is anatase nano-TiO2 modified with silane coupling agent, with a particle size of 15nm-30nm and a purity of ≥99.5%; the nano-carbon black is high-pigment hydrophilic nano-carbon black, with a particle size of 20nm-40nm and an oil absorption value of 80-110mL / 100g.

[0014] As a preferred technical solution, the warp and weft yarns of the base fabric layer are both 300D, and the number of single filaments F is ≥144f; the warp and weft density of the base fabric layer is 70*50 threads / inch.

[0015] As a preferred technical solution, the foaming adhesive further includes compounding additives, which include a composite foam stabilizer, a polyacrylate leveling agent, and a hydroxyethyl cellulose thickener. The amount of the composite foam stabilizer added is 8% of the wet weight of the base material, the amount of the polyacrylate leveling agent added is 0.4%-0.6% of the wet weight of the base material, and the amount of the hydroxyethyl cellulose thickener added is 1.5%-2.5% of the wet weight of the base material. The viscosity of the foaming adhesive is 6000-8000 mPa·s.

[0016] As a preferred technical solution, the polyester brushed fabric has a specification of 75D*150D and a warp and weft density of 110*80 threads / inch.

[0017] A method for manufacturing an ultra-soft, anti-fraying nanocomposite roller blind fabric includes the following steps:

[0018] S1. Selection of base fabric: The base fabric is polyester plain weave fabric, with its warp yarns being a composite yarn with fully drawn yarn as the core layer and stretched textured yarn wrapped on the outside; its weft yarns are stretched textured yarns; its warp and weft density is 70*50 yarns / inch;

[0019] S2. Base fabric pretreatment: The base fabric is subjected to pre-setting, overflow washing and dyeing and re-setting in sequence; the pre-setting is carried out by hot air treatment at 130℃ and the re-setting temperature is 190℃.

[0020] S3. Preparation of foamed coating:

[0021] Modified nano-TiO2 and nano-carbon black were dispersed and then mixed with water-based acrylate base material and compounding additives to prepare foaming adhesive.

[0022] The foaming adhesive is applied to the pretreated base fabric surface, followed by segmented foaming and curing. After curing, it enters the cooling channel and is gradually cooled to room temperature.

[0023] S4. Composite Molding: Polyester brushed fabric is laminated onto a foamed coating using a PUR adhesive layer at a lamination temperature of 120-140℃ and a lamination pressure of 0.3-0.4MPa. The PUR adhesive layer is a low-modulus flexible PUR adhesive with a 100% tensile modulus ≤80MPa. The PUR adhesive layer has a discrete array of dots, and the projected width of the adhesive dots in the weft direction is smaller than the center spacing of the weft yarns of the base fabric layer, so that the weft yarns have unconstrained segments that can produce microscopic displacement between adjacent adhesive dots. After lamination, the fabric undergoes gradient cooling and curing treatment to obtain an ultra-soft, anti-fraying composite roller blind fabric.

[0024] As a preferred technical solution, in step S2, during the pre-forming process, the warp tension is controlled at 20% of the breaking strength of the base fabric, the weft tension is reduced to 15% of the breaking strength of the base fabric, the forming time is 30-40 seconds, the machine speed is 25-30 meters / minute, and the flatness of the base fabric is tested after pre-forming. Only when the wrinkle rate is ≤0.3% can the next process be carried out.

[0025] As a preferred technical solution, after overflow washing and dyeing in step S2, the base fabric is dehydrated using a centrifugal dewatering machine to control the moisture content of the base fabric to ≤20%, so as to avoid excessive dehydration and loss of elasticity of DTY weft yarn.

[0026] As a preferred technical solution, during the re-forming process in step S2, the warp tension is increased to 25% of the breaking strength of the base fabric, the weft tension is maintained at 20% of the breaking strength of the base fabric, and the vehicle speed is 20-25 meters per minute.

[0027] As a preferred technical solution, the specific preparation method of the foaming adhesive includes the following steps:

[0028] S31. Nanopowder pretreatment: Weigh 3.0-5.0 parts of modified nano-TiO2 and 2.0-4.0 parts of nano-carbon black, respectively, and place them in a dispersion medium for ultrasonic pretreatment to break up the initial agglomerates and obtain a uniformly dispersed nano-functional liquid; wherein, the modified nano-TiO2 is anatase nano-TiO2 modified with a silane coupling agent, with a particle size of 15-30 nm; the nano-carbon black is high-pigment hydrophilic nano-carbon black, with a particle size of 20-40 nm;

[0029] S32, Base material mixing: Weigh 100 parts of water-based acrylic emulsion as base material, with a solid content of 30%-35%; under stirring, slowly add the nano-functional liquid obtained in step (1) to the base material, and then add 8.0 parts of composite foam stabilizer, 0.4-0.6 parts of polyacrylate leveling agent and 1.5-2.5 parts of hydroxyethyl cellulose thickener in sequence, and mix evenly;

[0030] S33. Rheology and performance adjustment: The viscosity of the mixture is monitored in real time, and the overall viscosity of the coating adhesive is controlled at 6000-8000 mPa·s by adjusting the amount of the hydroxyethyl cellulose thickener.

[0031] S34. Mechanical foaming: The coating adhesive with adjusted viscosity is introduced into a foaming machine, and the foaming ratio is controlled at 2.5 for mechanical foaming. The bubble generation rate is adjusted by the composite foam stabilizer so that the bubbles are evenly distributed in the adhesive system, and finally the functional foaming adhesive is obtained.

[0032] The beneficial effects of this invention are:

[0033] 1. A breakthrough solution to the core contradiction of "composite materials must be rigid + loose fibers at the edges":

[0034] This invention utilizes a composite structure design of "customized base fabric + flexible foam coating + low-modulus PUR adhesive layer + polyester brushed fabric," combined with a CNC dot-matrix adhesive application process (avoiding the elastic zone of the weft yarn). This fundamentally avoids the drawbacks of traditional composite fabrics that rely on high-modulus TPU film and rigid PA / PU adhesive. After the PUR adhesive layer cures, it can wrap and bind the edge yarns, completely solving the problem of loose threads without the need for additional hard adhesive. At the same time, the low-modulus PUR adhesive (modulus ≤ 80MPa) can deform synchronously with the expansion and contraction of the base fabric. Combined with the high elasticity design of the base fabric weft yarn and the porous and flexible structure of the foam coating, the composite fabric achieves a warp bending length ≤ 4.8cm and a weft bending length ≤ 3.7cm, reaching an ultra-soft level. This completely breaks the industry curse of "composite fabrics must be rigid." The technical effect far exceeds the expectations of those skilled in the art and is an unexpected technical achievement.

[0035] 2. Excellent interlayer bonding stability:

[0036] Through the "anchoring effect" of PUR adhesive, the precise positioning of CNC dot-matrix coating (focusing on the warp support area), and gradient cooling and constant temperature curing processes, the average peel strength between fabric layers reaches 25±1.2N, far exceeding the industry standard requirement of ≥12N. This effectively avoids delamination and curling problems during long-term rolling and hanging, and the structural stability is significantly better than that of traditional composite fabrics.

[0037] 3. Simultaneously achieve multiple superior performance characteristics:

[0038] While resolving the core contradiction, the technical solution of this invention simultaneously achieves multiple superior performance characteristics: ① Anti-adhesion performance: the adhesion force at room temperature is only 0.6±0.1N, and 2.1±0.3N under high temperature and high humidity (60℃, 90%RH), demonstrating significant anti-adhesion effect; ② Light-blocking performance: light-blocking rate ≥97% (Level 1 high light-blocking), with a light-blocking rate variation coefficient ≤0.15%, solving the problem of uneven light-blocking in traditional fabrics; ③ Structural stability: the coating has no risk of cracking or peeling, meeting the needs of long-term use. These synergistic improvements in performance are not the sum of the effects of a single technical means, but rather an unexpected comprehensive benefit brought about by a systematic technical solution.

[0039] 4. Strong process compatibility, facilitating industrial production:

[0040] The pretreatment, coating, and lamination process parameters of this invention are precisely controllable. The pneumatic adjustable doctor blade coating machine, CNC dot coating machine, and dual-axis synchronous unwinding system used are all mature equipment in the industry. Mass production can be achieved without the need for additional special equipment development, and it has significant industrial application value. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the cross-sectional structure of the ultra-soft anti-fragment composite roller blind fabric of the present invention.

[0042] Figure 2 This is a schematic diagram of the manufacturing process of the ultra-soft anti-fraying composite roller blind fabric of the present invention.

[0043] In the diagram: 1-base fabric layer, 2-foam coating, 3-PUR adhesive layer, 4-fabric layer. Detailed Implementation

[0044] Example 1 (Core Example)

[0045] like Figure 1 As shown, this embodiment provides an ultra-soft, anti-fragmentation nanocomposite roller blind fabric, the structure of which, from bottom to top, includes: a base fabric layer 1, a foam coating layer 2, a PUR adhesive layer 3, and a fabric layer 4.

[0046] like Figure 2As shown, this embodiment systematically solves the technical problems of traditional composite fabrics, such as "stiffness after composite, loose threads at the edges, and easy stickiness, uneven light blocking, and easy cracking of the foam coating", through the synergistic effect of customized base fabric structure design, nanocomposite foam coating design, and low modulus dotted PUR composite process.

[0047] I. Structural Design and Pretreatment of Base Fabric Layer

[0048] (I) Base Fabric Layer Structure Design

[0049] The base fabric layer is made of plain polyester fabric, with a differentiated structural design for its warp and weft yarns:

[0050] Warp yarn: A composite yarn with a core of fully drawn yarn (FDY) and an outer layer of stretched textured yarn (DTY), with a specification of 300D and a single filament count of ≥144f;

[0051] Weft yarn: DTY (dithered textured yarn) is used, with a specification of 300D and a single filament count of ≥144f;

[0052] Warp density × weft density: 70 × 50 threads / inch.

[0053] In the above structure, the FDY core warp yarns provide stable longitudinal rigid support, ensuring that the base fabric does not collapse longitudinally during the foaming coating and lamination process; while the outer DTY and weft DTY yarns give the base fabric high weft elasticity and recovery ability, providing a structural basis for releasing weft micro-displacement through the dotted PUR adhesive layer.

[0054] (II) Base Fabric Pretreatment Process (One of the Key Processes)

[0055] The base fabric undergoes a series of processes: pre-setting, overflow washing and dyeing, and re-setting.

[0056] 1. Pre-order type

[0057] The greige fabric is fed into a hot air setting machine for pre-setting treatment:

[0058] · Setting temperature: 130℃;

[0059] · Warp tension: controlled at 20% of the breaking strength of the base fabric;

[0060] · Weft tension: Reduced to 15% of the base fabric's breaking strength;

[0061] · Setting time: 30–40 seconds;

[0062] · Vehicle speed: 25–30 m / min.

[0063] By pre-setting at a relatively low temperature, the residual stress inside the FDY / DTY composite warp and DTY weft yarns can be fully released, avoiding fabric structural imbalance caused by differences in heat shrinkage during subsequent high-temperature processes. After pre-setting, the flatness of the base fabric is checked, and the next process can only proceed if the wrinkle rate is ≤0.3%.

[0064] 2. Overflow washing, dyeing, and dehydration

[0065] An overflow washing dyeing method is used to keep the base fabric in a relaxed, cyclical state during the dyeing process, avoiding uneven stress. After dyeing, a centrifugal dehydrator is used for dehydration to control the moisture content of the base fabric to ≤20%, preventing loss of weft elasticity due to sudden evaporation of moisture during subsequent setting.

[0066] 3. Re-fixing

[0067] The dehydrated base fabric is then reshaped.

[0068] · Setting temperature: 190℃;

[0069] · Warp tension: Increased to 25% of the base fabric's breaking strength;

[0070] · Weft tension: maintained at 20% of the base fabric's breaking strength;

[0071] · Vehicle speed: 20–25 m / min.

[0072] The re-setting process stabilizes and fixes the width, warp and weft density, and structural shape of the base fabric, providing a dimensionally stable and uniformly stressed substrate for subsequent foaming coating.

[0073] II. Preparation and Formation Mechanism of Foamed Coatings

[0074] (I) Composition Design of Expanding Foam Adhesive

[0075] In this embodiment, the foamed coating is formed by coating, foaming, and curing a foaming adhesive. The foaming adhesive uses a water-based acrylic emulsion as its base material, has a solid content of 32%, and further incorporates nano-scale light-shielding fillers and functional additives.

[0076] · Modified nano-TiO2: accounting for 4.0% of the wet weight of the base material, it is anatase nano-TiO2 modified with silane coupling agent, with a particle size of about 20nm;

[0077] · Nano carbon black: accounting for 3.0% of the wet weight of the base material, it is a hydrophilic nano carbon black with a particle size of about 30nm and an oil absorption value of about 95mL / 100g;

[0078] · Compound foam stabilizer: 8.0%;

[0079] · Polyacrylate leveling agent: 0.5%;

[0080] · Hydroxyethyl cellulose thickener: 2.0%.

[0081] By adjusting the amount of thickener, the viscosity of the foaming adhesive was stably controlled at 7000 mPa·s, and a mechanical foaming method was adopted to achieve a foaming ratio of 2.5.

[0082] The key to the above formula design lies in:

[0083] After silane coupling modification and ultrasonic dispersion, nano-sized TiO2 and carbon black can be uniformly distributed in the water-based acrylate matrix, forming a stable and uniform porous structure during the foaming process, avoiding the problems of local embrittlement and uneven light shading caused by the agglomeration of traditional micron-sized fillers.

[0084] (II) Foaming Coating and Segmented Curing Process (Core Innovation)

[0085] The expanding adhesive is applied to the pretreated base fabric surface using a pneumatically adjustable doctor blade applicator, and then enters a segmented foaming and curing channel, specifically including:

[0086] 1. Preheating zone (70-90℃)

[0087] Slowly release the residual internal stress of the DTY weft yarn to avoid uneven weft shrinkage during the subsequent high-temperature stage.

[0088] 2. Foaming start-up zone (110-120℃)

[0089] Trigger the foaming reaction to start generating bubbles, ensuring that the foaming reaction matches the warp and weft thermal stability of the base fabric.

[0090] 3. Bubble stability zone (130-140℃)

[0091] Controlling the bubble growth rate ensures that the bubbles are evenly distributed in the FDY warp support area and the DTY weft elastic area, avoiding localized bubble collapse or excessive expansion.

[0092] 4. Curing zone (150-160℃)

[0093] It promotes the full cross-linking of water-based acrylic ester materials to form a stable foamed coating structure.

[0094] After curing, the coating enters the cooling channel and is gradually cooled to room temperature (25°C) using a gradual cooling method to avoid stress concentration between the DTY weft yarn and the foam structure due to the difference in cooling rate, thereby preventing the coating from cracking or peeling.

[0095] III. PUR Adhesive Layer and Composite Structure Design (Key Innovations)

[0096] (I) PUR Adhesive Layer Design

[0097] Low-modulus flexible PUR adhesive was selected as the composite adhesive, with a 100% elongation modulus of 65 MPa.

[0098] The PUR adhesive layer is formed by a CNC dot-matrix coating method to create a discrete array of adhesive dots:

[0099] · Adhesive dot coverage: 18%;

[0100] · The projection width of the adhesive dots in the weft direction is smaller than the center spacing of the weft yarns of the base fabric.

[0101] Through the above design, the PUR adhesive can effectively wrap and bind the warp and edge yarns after curing, suppressing the fraying phenomenon. At the same time, it retains unconstrained segments between adjacent adhesive dots for the weft yarn that can produce micro-displacement, thereby significantly reducing the restriction of the composite structure on the weft elasticity.

[0102] (II) Composite Process

[0103] Polyester brushed fabric is laminated onto a foamed coating as the fabric layer:

[0104] · Fabric layer specifications: 75D×150D;

[0105] · Warp and weft density: 110 x 80 threads / inch;

[0106] · Composite temperature: 130℃;

[0107] · Composite pressure: 0.35MPa.

[0108] After lamination, the fabric undergoes gradient cooling and constant temperature and humidity curing treatments to ensure that the PUR adhesive layer is fully cross-linked and stably cured, ultimately resulting in an ultra-soft, anti-fragmentation composite roller blind fabric.

[0109] The constant temperature and humidity curing treatment is carried out in a constant temperature and humidity curing room (25±2℃, humidity 60±5%) for 72 hours to ensure that the dotted adhesive layer is fully cross-linked. During the curing period, the adhesive is turned over once every 12 hours to avoid local pressure that could cause deformation of the adhesive dots.

[0110] Example 2 (Lower limit of adhesive dot coverage)

[0111] The PUR adhesive dot coverage in Example 1 was adjusted to 15%, while other conditions remained unchanged. Test results showed that the fabric could still effectively suppress edge fraying, with a warp bending length of 5.0 cm and a weft bending length of 3.9 cm, verifying the rationality of the lower limit of adhesive dot coverage in the claims.

[0112] Example 3 (Upper Limit of Adhesive Dot Coverage)

[0113] The PUR adhesive dot coverage in Example 1 was adjusted to 20%. The peel strength increased to 26 N, but the woven bending length increased to 4.1 cm, indicating that exceeding this range would begin to have an adverse effect on flexibility, thus verifying the technical criticality of the range.

[0114] Technical effect testing and comparative experiments:

[0115] I. Test on the anti-sticking properties of foamed coated fabrics

[0116] Test Objective: To verify the anti-sticking properties of the soft roller blind fabric based on nanocomposite technology of this invention, and to evaluate its anti-sticking effect under normal temperature, high temperature and humidity, and long-term rolling and stacking conditions, ensuring that the fabric will not experience coating adhesion, peeling, or other problems, and meeting the storage and use needs of homes, hotels, cinemas, and other scenarios. Each group of tests was conducted 15 times, and the average value was taken.

[0117] Test sample:

[0118] Sample type describe This invention relates to foamed composite roller blind fabric. Foamed coated base fabric + PUR + brushed fabric double-sided composite process Commercially available standard fabrics (comparison) Traditional base fabric + ordinary foam coating structure, without special anti-sticking treatment.

[0119] Test conditions and equipment:

[0120] (1) Environmental simulation equipment:

[0121] • Constant temperature and humidity chamber (temperature range: -40℃~120℃, humidity range: 30%~95%RH);

[0122] • Universal testing machine (simulating mechanical stress, tensile rate 50 mm / min);

[0123] • Fabric roll-up simulation device (can apply a constant pressure of 500Pa to simulate the roll-up state of curtains);

[0124] (2) Measuring tools:

[0125] • High-precision digital caliper (resolution 0.01mm);

[0126] • Laser rangefinder (accuracy ±0.05mm);

[0127] (3) Testing standards:

[0128] • Refer to FZ / T 64045-2019 "Determination of Anti-blocking Properties of Coated Fabrics";

[0129] • Select test methods comprehensively based on ISO 18792-2:2016 "Textiles - Coated fabrics - Part 2: Determination of blocking resistance";

[0130] • Adhesion strength requirements: ≤1N at room temperature (25±2℃, 60±5%RH); ≤3N at high temperature and high humidity (60℃, 90%RH); ≤1.5N after long-term winding;

[0131] Test items and steps:

[0132] (1) Steps for room temperature static anti-adhesion test:

[0133] • Cut 15 pieces of each of the two types of samples, each measuring 200mm × 200mm. Attach the foamed coating surface of each sample to the foamed coating surface and to the fabric surface, applying a pressure of 500Pa as required.

[0134] • Allow the sample to stand for 72 hours in a standard environment (25±2℃, 60±5%RH). Then, take out the sample and test the peel adhesion force using an electronic tensile testing machine at a rate of 50mm / min as specified in GB / T 2660. At the same time, observe the condition of the coating and the fabric surface.

[0135] (2) High temperature and high humidity static anti-adhesion test procedure:

[0136] • Take 15 sets of double samples of the same specifications, and place each sample with the foamed coating surface attached to the foamed coating surface and the foamed coating surface attached to the fabric surface. Then place them in a constant temperature and humidity chamber with the following environmental parameters: set temperature 60℃, humidity 90%RH, apply 500Pa pressure, and leave for 48 hours.

[0137] • Referring to the recovery requirements of ISO 18792-2, after removal, allow to recover for 2 hours in a standard environment, then test the peel adhesion force, observe whether the coating has fallen off, whether the fabric has been bonded and deformed, and record the location and extent of damage.

[0138] (3) Long-term winding and static anti-adhesion test procedure:

[0139] • According to the industry's technical specifications for blackout fabrics, the sample was cut into 1m×0.5m sizes, and wound onto a 5cm diameter roller in a manner that simulates the rolling up of a curtain. A constant tension was applied, and the sample was placed in a constant temperature and humidity chamber (25℃, 60%RH) and left to stand for 10 days.

[0140] • Test the interlayer adhesion and observe the surface smoothness and integrity of the coating using a digital microscope.

[0141] Data recording and analysis:

[0142] The anti-adhesion test data comparison is as follows:

[0143]

[0144] Conclusion: Under different test conditions, the ultra-soft roller blind fabric of this invention exhibits adhesion strength far lower than the comprehensive judgment standard and commercially available conventional fabrics, and shows no issues such as coating peeling or fabric damage throughout the testing process, demonstrating excellent anti-sticking performance. Its anti-sticking effect is attributed to the isolation and protection provided by the composite brushed fabric on the foamed coating surface, solving the stickiness problem of traditional foamed coated fabrics and meeting the storage and usage needs of various scenarios.

[0145] II. Softness Performance Test of Composite Curtain Fabrics

[0146] Test Objective: To evaluate the softness of the ultra-soft roller blind fabric based on nanocomposite technology of this invention, quantify its bending stiffness and bending length, and verify the smoothness and conformability of the fabric during rolling, unfolding, and daily use, ensuring that it meets the core requirements of "soft and easy to operate" for curtains in home, hotel, and other scenarios. By comparing with commercially available conventional fabrics, the technical advantages of nanocomposite technology in improving fabric softness are highlighted. Each test was conducted 15 times, and the average value was taken as the final result.

[0147] Test sample:

[0148]

[0149] Test conditions and equipment

[0150] (1) Environmental simulation equipment:

[0151] • Fabric stiffness tester (using cantilever beam method, test range 0-200mN, accuracy ±0.1mN, can automatically record bending length and stiffness value, used to directly determine the bending stiffness and bending length of fabric).

[0152] • Standard sample cutter (can accurately cut 250mm×50mm samples) to ensure that the sample size meets the stiffness test requirements.

[0153] • Electronic balance (accuracy 0.001g), used to measure the mass per unit area of ​​a sample.

[0154] • Fabric thickness gauge (accuracy 0.01mm), used to measure sample thickness.

[0155] (2) Measurement indicators:

[0156] Bending length (cm); Specification requirements: Bending length in both the warp and weft directions ≤ 5cm is considered ultra-soft; 5cm < warp and weft bending length ≤ 10cm is considered soft; 10cm < warp and weft bending length ≤ 15cm is considered general; warp and weft bending length > 15cm is considered hard.

[0157] (3) Testing standards:

[0158] • GB / T 18318.1-2009 "Determination of bending properties of textiles - Part 1: Cantilever beam method";

[0159] • FZ / T 01045-2008 "Determination of softness of textile fabrics".

[0160] Test steps:

[0161] (1) Sample pretreatment: The two fabric samples were placed in a standard environment (25±2℃, 60±5%RH) for 24 hours. During this period, direct sunlight and external pressure were avoided to ensure that the moisture content of the fabric was stable and to eliminate the influence of environmental factors on the test results.

[0162] (2) Sample preparation: According to the requirements of GB / T 18318.1-2009, the fabric of the present invention and the control fabric were cut with a standard sample cutter, 15 pieces each in the warp and weft directions, with a uniform size of 250mm×50mm. The cut edges should be flat without burrs or stretching deformation. Each sample should be clearly marked with direction, number and coating surface.

[0163] (3) Equipment calibration: Start the fabric stiffness tester, preheat for 30 minutes and then calibrate. Place the standard stiffness sample (known stiffness value 5mN·cm) into the test fixture and verify that the instrument reading error is ≤0.1mN·cm. At the same time, confirm that the test angle is 41°30′.

[0164] (4) Stiffness test: Fix the sample flat on the tester's sample stage, ensuring that the sample length direction is consistent with the cantilever beam extension direction, the coated surface is facing upward and there are no wrinkles. After starting the instrument, the cantilever beam slowly descends. When the free end of the sample bends to 41°30′, the instrument automatically records the stiffness value and bending length. Each sample is tested 15 times, and the average value is taken as the final data.

[0165] Test Results and Analysis:

[0166] Sample type Meridional bending length (cm) Weft bending resistance length (cm) Overall level This invention relates to roller blind fabric. 4.8±0.5 3.7±0.4 Super soft Commercially available standard fabrics (comparison) 15.6±0.8 14.8±0.7 Level 3 (General)

[0167] Conclusion: The warp and weft bending lengths of the ultra-soft roller blind fabric of this invention are 4.8cm and 3.7cm, respectively, both significantly lower than those of commercially available conventional fabrics, achieving the standard of ultra-soft hand feel. The core reasons for its superior softness are: firstly, the modified nanoparticles added to the nano-composite foam coating optimize the porous structure inside the coating, reducing its rigidity and improving its flexibility; secondly, the PUR double-sided composite process uses a low-modulus flexible adhesive, which, while achieving a strong bond between the base fabric and the coating, maximizes the preservation of the base fabric's inherent softness, avoiding the fabric stiffening problem caused by adhesive curing in traditional composite processes.

[0168] III. Peel strength test of composite curtains

[0169] Test objective: To verify the peel strength of the composite curtain fabric of this invention, ensuring no separation or curling between layers, and meeting the structural stability requirements during long-term use. Based on the FZ / T 60011 standard, determine whether the peel strength of the fabric of this invention is ≥12N. Each group is tested 15 times, and the average value is taken.

[0170] Test sample:

[0171] Sample type describe This invention relates to foamed composite roller blind fabric. Foamed coated base fabric + PUR + brushed fabric double-sided composite process Commercially available standard fabrics (comparison) Traditional base fabric + TPU film + traditional base fabric

[0172] Test conditions and equipment:

[0173] (1) Environmental simulation equipment:

[0174] • Constant temperature and humidity chamber (temperature 25℃±2℃, humidity 65%±5%);

[0175] • Peel strength tester (range 0-50N, accuracy ±0.01N), peel clamp (compatible with 180° peel method), cutter (accuracy ±0.5mm);

[0176] • Measurement index: Average peel strength (N);

[0177] • Test standard: FZ / T 60011-2016 Determination of peel strength of nonwoven and textile composite products.

[0178] Test items and steps:

[0179] Peel strength test procedure:

[0180] (1) Cut 15 samples with a size of 200mm×50mm, and pre-peel 50mm along the interface of the composite layer to ensure that the peeling start end is undamaged.

[0181] (2) Environmental pretreatment: Equilibrate for 24 hours under standard environment (25℃±2℃, humidity 65%±5%RH).

[0182] (3) Use 180° peeling method, peeling rate 100mm / min, record the average force (peeling strength) during the peeling process. If the film breaks instead of the interlayer separation occurs, record the valid data.

[0183] Data recording and analysis:

[0184]

[0185] Conclusion: The average peel strength of the composite curtain fabric of the present invention reaches 25N. Whether it is the peel strength between the foam coating and the base fabric or the peel strength between the brushed fabric layer and the foam coating, it far exceeds the index of ≥12N. Although it is slightly lower than the conventional fabrics on the market, its peel strength can fully meet the needs of daily roller blind use and can avoid delamination and curling problems during long-term rolling and hanging.

[0186] IV. Fabric light-blocking performance test

[0187] Test Objective: To evaluate the light-blocking performance and uniformity of the ultra-soft roller blind fabric based on nanocomposite technology of this invention, quantify the core indicator of light-blocking rate, verify the light-blocking effect of the fabric under different light intensities, and ensure that it meets the usage requirements of scenarios with high light-blocking requirements such as cinemas, bedrooms, and conference rooms. By comparing with commercially available conventional fabrics, each group was tested 15 times, and the average value and coefficient of variation were used as the judgment criteria.

[0188] Test sample:

[0189]

[0190] Testing standards and equipment:

[0191] (1) Equipment:

[0192] • Full-spectrum light box (adjustable from 0-200,000 lux).

[0193] • Fabric shading rate tester (measurement range 0-100%, accuracy ±0.1%, can simulate D65 and A light sources, supports multi-point testing function) is used to determine the shading rate and uniformity of fabrics.

[0194] • Standard sample cutter (can accurately cut 300mm×300mm samples, ensuring clean cut edges).

[0195] • High-definition CCD camera (≥12 million pixels, used with image analysis software for visual analysis of fabric coating distribution and light-blocking uniformity).

[0196] (2) Standard:

[0197] • EN14501 "Performance Classification of Blackout Curtains";

[0198] • GB / T 24250-2023 Determination of light-blocking properties of textiles.

[0199] Test items and steps:

[0200] Initial shading performance comparison steps:

[0201] (1) Cut 15 pieces of each of the two types of samples using a standard sample cutter. The size of each sample is 300mm×300mm. The cut edges are flat and free of burrs and stretching deformation. Mark the front and back sides and 5 test points on each sample (1 point in the center and 1 point at each of the four corners). Equilibrate for 24 hours in a standard environment (25℃±2℃, 65%±5%RH).

[0202] (2) Opacity test: Place the sample flat on the test window of the tester, ensuring that the sample is completely in contact with the window and there are no gaps for light leakage. Test 5 points of each sample in sequence according to the marked points, record the occupancy value of each point, and take the average value for each point 3 times.

[0203] (3) Uniformity analysis: The sample surface was photographed with a high-definition CCD camera and the coating distribution was observed in combination with image analysis software; the shading rate difference of 5 points of each sample and the overall coefficient of variation of 15 samples were calculated to complete the uniformity assessment.

[0204] Data recording and analysis:

[0205] Sample type Light blocking rate (%) Light blocking level Coefficient of variation of shading rate (%) This invention relates to foamed composite roller blind fabric. 97±1 Level 1 (High shading) 0.15±0.04 Commercially available standard fabrics (comparison) 78±2 Level 3 (Standard shading) 1.2±0.15

[0206] Conclusion: The light-blocking rate of the foamed composite roller blind fabric of this invention reaches 97%, belonging to the Class 1 high light-blocking level, far exceeding the 78% of commercially available conventional fabrics. The core reason lies in the light-blocking modified nanoparticles added to the nano-composite foaming coating. These nanoparticles have uniform particle size and good dispersion, enabling them to efficiently absorb and scatter incident light. Simultaneously, the dense structure formed by the PUR double-sided composite process further blocks the light penetration path, achieving highly efficient light blocking. Moreover, the light-blocking rate variation coefficient is only 0.15%, achieving excellent uniformity. This is attributed to the precise coating process used in the nano-composite coating, ensuring uniform coating thickness and component distribution. In contrast, the maximum difference in point values ​​for commercially available conventional fabrics reaches 1.2%, indicating poor uniformity, mainly due to insufficient precision in traditional coating processes, resulting in uneven coating density.

Claims

1. A super-soft, anti-fraying nanocomposite roller blind fabric, characterized in that, It includes a base fabric layer, a foam coating, a PUR adhesive layer, and a fabric layer that are laminated sequentially; The base fabric layer is a plain polyester fabric, and its warp yarns are composite yarns with fully drawn yarn as the core layer and stretched textured yarn wrapped on the outside. Its weft yarn is made of stretch textured yarn; The foamed coating is formed by coating and curing a foaming adhesive. The foaming adhesive uses an aqueous acrylic emulsion with a solid content of 30%-35% as a base material and also includes 3.0%-5.0% modified nano-TiO2 and 2.0%-4.0% nano-carbon black relative to the wet weight of the base material. The PUR adhesive layer is a low-modulus flexible PUR adhesive with a 100% tensile modulus ≤ 80MPa; the PUR adhesive layer is a discrete array of dots, and the projected width of the adhesive dots in the weft direction is smaller than the center spacing of the weft yarns of the base fabric layer, so that the weft yarns have unconstrained segments that can produce micro-displacement between adjacent adhesive dots. The fabric layer is made of polyester brushed fabric.

2. The ultra-soft, anti-fraying nanocomposite roller blind fabric as described in claim 1, characterized in that, The PUR adhesive layer has an adhesive dot coverage of 15%-20%.

3. The ultra-soft, anti-fraying nanocomposite roller blind fabric as described in claim 1, characterized in that, The modified nano-TiO2 is anatase nano-TiO2 modified with silane coupling agent, with a particle size of 15nm-30nm and a purity of ≥99.5%; the nano-carbon black is high-pigment hydrophilic nano-carbon black, with a particle size of 20nm-40nm and an oil absorption value of 80-110mL / 100g.

4. The ultra-soft, anti-fraying nanocomposite roller blind fabric as described in claim 1, characterized in that, The warp and weft yarns of the base fabric layer are both 300D, and the number of single filaments F is ≥144f; the warp and weft density of the base fabric layer is 70*50 threads / inch.

5. The ultra-soft, anti-fraying nanocomposite roller blind fabric as described in claim 1, characterized in that, The foaming adhesive further includes compounding additives, which include a composite foam stabilizer, a polyacrylate leveling agent, and a hydroxyethyl cellulose thickener. The composite foam stabilizer is added at 8% of the wet weight of the base material, the polyacrylate leveling agent is added at 0.4%-0.6% of the wet weight of the base material, and the hydroxyethyl cellulose thickener is added at 1.5%-2.5% of the wet weight of the base material. The viscosity of the foaming adhesive is 6000-8000 mPa·s.

6. The ultra-soft, anti-fraying nanocomposite roller blind fabric as described in claim 1, characterized in that, The polyester brushed fabric has a specification of 75D*150D and a warp and weft density of 110*80 threads / inch.

7. A method for manufacturing an ultra-soft, anti-fraying nanocomposite roller blind fabric, characterized in that, Includes the following steps: S1. Selection of base fabric: The base fabric is polyester plain weave fabric, with its warp yarns being a composite yarn with fully drawn yarn as the core layer and stretched textured yarn wrapped on the outside; its weft yarns are stretched textured yarns; its warp and weft density is 70*50 yarns / inch; S2. Base fabric pretreatment: The base fabric is subjected to pre-setting, overflow washing and dyeing and re-setting in sequence; the pre-setting is carried out by hot air treatment at 130℃ and the re-setting temperature is 190℃. S3. Preparation of foamed coating: Modified nano-TiO2 and nano-carbon black were dispersed and then mixed with water-based acrylate base material and compounding additives to prepare foaming adhesive. The foaming adhesive is applied to the pretreated base fabric surface, followed by segmented foaming and curing. After curing, it enters the cooling channel and is gradually cooled to room temperature. S4. Composite Molding: Polyester brushed fabric is laminated onto a foamed coating using a PUR adhesive layer at a lamination temperature of 120-140℃ and a lamination pressure of 0.3-0.4MPa. The PUR adhesive layer is a low-modulus flexible PUR adhesive with a 100% tensile modulus ≤80MPa. The PUR adhesive layer has a discrete array of dots, and the projected width of the adhesive dots in the weft direction is smaller than the center spacing of the weft yarns of the base fabric layer, so that the weft yarns have unconstrained segments that can produce microscopic displacement between adjacent adhesive dots. After lamination, the fabric undergoes gradient cooling and curing treatment to obtain an ultra-soft, anti-fraying composite roller blind fabric.

8. The manufacturing method as described in claim 7, characterized in that, In step S2, during pre-setting, the warp tension is controlled at 20% of the base fabric's breaking strength, and the weft tension is reduced to 15% of the base fabric's breaking strength. The setting time is 30-40 seconds, and the machine speed is 25-30 meters per minute. After pre-setting, the flatness of the base fabric is checked. Only when the wrinkle rate is ≤0.3% can it proceed to the next process. After overflow washing and dyeing, the base fabric is dehydrated using a centrifugal dewatering machine to control the moisture content of the base fabric to ≤20%. During re-setting, the warp tension is increased to 25% of the base fabric's breaking strength, and the weft tension is maintained at 20% of the base fabric's breaking strength. The machine speed is 20-25 meters per minute.

9. The manufacturing method as described in claim 7, characterized in that, The specific preparation method of the foaming adhesive includes the following steps: S31. Nanopowder pretreatment: Weigh 3.0-5.0 parts of modified nano-TiO2 and 2.0-4.0 parts of nano-carbon black, respectively, and place them in a dispersion medium for ultrasonic pretreatment to break up the initial agglomerates and obtain a uniformly dispersed nano-functional liquid; wherein, the modified nano-TiO2 is anatase nano-TiO2 modified with a silane coupling agent, with a particle size of 15-30 nm; the nano-carbon black is high-pigment hydrophilic nano-carbon black, with a particle size of 20-40 nm; S32. Base material mixing: Weigh 100 parts of water-based acrylic emulsion as the base material, with a solid content of 30%-35%; under stirring, slowly add the obtained nano-functional liquid to the base material, and then add 8.0 parts of composite foam stabilizer, 0.4-0.6 parts of polyacrylate leveling agent and 1.5-2.5 parts of hydroxyethyl cellulose thickener in sequence, and mix evenly; S33. Rheology and Performance Adjustment: The viscosity of the mixture is monitored in real time, and the overall viscosity of the coating adhesive is controlled at 6000-8000 mPa·s by adjusting the amount of the hydroxyethyl cellulose thickener. S34. Mechanical foaming: The coating adhesive with adjusted viscosity is introduced into a foaming machine, and the foaming ratio is controlled at 2.5 for mechanical foaming. The bubble generation rate is adjusted by the composite foam stabilizer so that the bubbles are evenly distributed in the adhesive system, and finally the functional foaming adhesive is obtained.

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