Preparation method of three-dimensional fabric

Abstract

The invention discloses a preparation method of a three-dimensional fabric, and the preparation method of the three-dimensional fabric comprises the following steps: feeding yarns according to a preset yarn feeding speed to form a pretreated three-dimensional fabric; carrying out setting treatment on the pretreated three-dimensional fabric through a setting machine; wherein when yarns are fed, waterproof and oil-proof treatment is carried out on the yarns by using a waterproof and oil-proof functional yarn waterproof and oil-proof auxiliary agent on the three-dimensional fabric, or when the three-dimensional fabric is shaped, waterproof and oil-proof treatment is carried out on the pretreated three-dimensional fabric by using the waterproof and oil-proof auxiliary agent on the pretreated three-dimensional fabric; and cleaning the pretreated three-dimensional fabric through high-temperature pre-washing and deoiling.

Description

Technical Field

[0001] This invention relates to a fabric, and more particularly to a method for preparing a three-dimensional fabric that can be used with roller coating or spray coating adhesives. Background Technology

[0002] With the rapid development of the automotive industry, the market's requirements for the texture, durability, and environmental friendliness of automotive interiors and upholstery components are increasing. Three-dimensional fabrics, due to their excellent bulk, breathability, and three-dimensionality, are widely used in interior components such as automotive headliners, door panel upholstery, and seat fabrics.

[0003] In the processing of 3D fabrics, the combined use of roller coating and spray coating is a key process for achieving bonding between the fabric and the substrate and imparting specific functions to the fabric. However, in existing technologies, 3D fabrics have problems such as high porosity and low surface energy. When directly applying roller coating or spray coating, defects such as insufficient adhesion strength between the adhesive layer and the fabric substrate, uneven adhesive layer distribution, and the formation of bubbles or pinholes after curing are prone to occur. At the same time, traditional processing techniques do not specifically modify the surface of 3D fabrics, resulting in a narrow coating process window. Clients typically use spray coating, which is coordinated with the fabric's waterproof rating and surface morphology. Recently, the automotive industry has adopted roller coating technology to reduce costs. It has been found that roller coating has strict requirements on fabric waterproofing, surface morphology, fabric surface roughness, waterproof uniformity, waterproof rating, oil stain removal, and fabric thickness tolerance accuracy, making it difficult to balance production efficiency and product quality.

[0004] Therefore, it is necessary to develop a three-dimensional fabric processing method that can be used in conjunction with roller coating and spray coating. By optimizing key processes such as pretreatment, surface modification, post-treatment and weaving, the bonding performance with the three-dimensional fabric can be improved, that is, the required peel force can be increased and the uniformity of adhesive distribution on the fabric surface can be improved, so as to ensure product quality stability and meet the needs of large-scale production of automotive interior and overlay parts.

[0005] Automobiles, especially family cars, have become integrated vehicles with multiple functions, and consumers have increasingly strong demands for personalized, functional, and diversified car interiors. Fabrics, due to their wear resistance, durability, strong anti-aging properties, good breathability, and stable chemical properties, as well as their ability to be flexibly designed and developed through various methods, are widely used in automotive interior components.

[0006] With the development of technology, new textile technologies are constantly emerging. For example, the three-dimensional integrated molding process of flat knitting technology makes it possible to weave and wrap automotive interior leather materials. Warp-knitted spacer fabric composite fabric developed by double needle bed warp knitting technology can replace polyurethane foam and has a variety of excellent properties such as resilience and compression resistance.

[0007] Furthermore, users are increasingly concerned about environmental protection and health. Traditional automotive interior composite materials, such as polyurethane foam, contain irritating odors and volatile harmful substances, while new materials such as 3D cotton are more environmentally friendly in their production process, creating a healthier driving environment in the car. For example, 3D cotton, made from recycled materials such as mineral water bottles, clothing scraps, and discarded fishing nets, saves resources and reduces pollution.

[0008] Three-dimensional fabric is a new type of environmentally friendly woven three-dimensional material with a sponge-like three-dimensional structure, such as a vertical fiber web structure or a honeycomb fiber web structure, which differs from the parallel fiber web structure of traditional nonwoven materials. It boasts numerous advantages, including recyclability, resistance to decomposition and yellowing, non-toxicity, strong flame retardancy, high resilience, high compressive strength, lightweight feel, high breathability, and easy cleaning. It is highly suitable for automotive upholstery components, enhancing the quality and comfort of automotive interiors.

[0009] The development from traditional two-dimensional planar fabrics to three-dimensional fabrics involves the addition of a longitudinal warp system, with yarns interwoven and distributed in three-dimensional space. As a type of three-dimensional fabric, three-dimensional spacer fabric typically consists of two independent surface layers and an intermediate spacer layer, forming a unique sandwich structure.

[0010] Three-dimensional spacer fabrics possess numerous superior properties. Their unique structure allows for the retention of a large amount of still air within the spacer layers, resulting in excellent thermal insulation. Simultaneously, they are lightweight, exhibit excellent moisture absorption and breathability, are compression resistant, possess high strength, and have good resilience, providing users with a comfortable experience. They can be widely used in clothing, furniture, sporting goods, and other fields.

[0011] Furthermore, in other civilian sectors, people are increasingly demanding higher performance from textiles. For example, in the clothing industry, consumers expect garments to not only be aesthetically pleasing but also possess excellent breathability, warmth, and comfort. Three-dimensional interlocking fabrics can also be used to create functional clothing to meet these needs.

[0012] In the furniture industry, three-dimensional spacer fabrics can be used in the production of mattresses and cushions, providing excellent breathability and elasticity. In the sporting goods sector, three-dimensional spacer fabrics can be used to make uppers and insoles for high-end athletic shoes, enhancing breathability and providing cushioning protection. Summary of the Invention

[0013] To solve the above technical problems, the present invention provides a method for preparing a three-dimensional fabric, the method comprising the following steps:

[0014] S1001, feed yarn at a predetermined yarn feeding speed to form a pre-treated three-dimensional fabric, and dynamically feed tension of 2cN-20cN according to the tension reflected by the predetermined yarn feeding speed when weaving loops, so as to complete the adjustment of fabric surface roughness.

[0015] S1002, the pre-treated three-dimensional fabric is set by a setting machine; the yarn used in the three-dimensional fabric weaving has waterproof and oil-proof functions, or the pre-treated three-dimensional fabric is waterproofed and oil-proofed by a waterproof and oil-proof auxiliary agent when setting the three-dimensional fabric.

[0016] S1003, the pre-treated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing.

[0017] According to one embodiment of this application, the fiber yarn raw material is selected from at least one of the following: polyethylene terephthalate fiber, polypropylene terephthalate fiber, polybutylene terephthalate fiber, polyvinyl chloride fiber, polypropylene fiber, polyamide fiber, polyacrylonitrile fiber, acetate fiber, or polyvinyl alcohol formal fiber.

[0018] According to one embodiment of this application, the drying temperature is 120~200℃, and the hot air and exhaust air velocity is ≥500r / min.

[0019] According to one embodiment of this application, the surface fiber roughness Ra of the fabric is 0.3μm-1.5μm.

[0020] According to one embodiment of this application, it satisfies at least one of the following conditions:

[0021] When the fabric is laid flat, the lateral distance between the surface loops is 0.3mm-2.2mm;

[0022] When the fabric is laid flat, the distance between the vertical height of the coil body and the extension line is 0.03mm-2mm.

[0023] The tension reflected by the yarn feeding speed during loop weaving is dynamic feeding tension of 2cN-20cN.

[0024] According to one embodiment of this application, when the pre-treated three-dimensional fabric is shaped using a sizing machine, 3g to 50g of waterproof and oil-repellent additive is added per liter of water, and 0.2g to 1.5g of citric acid is added per liter of water. The fabric spray water repellency level is 1.5 to 4, water droplets stay on the fabric surface for ≥2 minutes, and the fabric surface pH is 3 to 7.

[0025] According to one embodiment of this application, the pre-treated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing, which includes:

[0026] The temperature of the first washing tank is controlled at 70~95℃. Add 0.3~1.5g / L of nonionic surfactant, pH=7~9, and 0.2~0.6g / L of weak alkaline detergent. The washing speed is controlled at 6~12m / min to ensure that the contact time between the fabric and the washing solution is ≥1.5min.

[0027] According to one embodiment of this application, the pre-treated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing, which includes:

[0028] The temperature of the second and third water washing tanks for deep cleaning with neutral warm water is reduced to 60~70℃. A neutral cleaning agent with pH=6~7.5 is used, along with ultrasonic cleaning with a frequency of 28~40kHz. The cavitation effect is used to remove trace amounts of silicone oil and impurities from the fiber gaps.

[0029] According to one embodiment of this application, the method for preparing the three-dimensional fabric further includes:

[0030] After washing with water, it needs to be rinsed with a spray at a pressure of 0.2~0.3MPa to prevent impurities from adhering again;

[0031] High-temperature drying is used to control the moisture content to below 40%.

[0032] According to one embodiment of this application, the surface wetting tension of the three-dimensional fabric is ≥38 mN / m, and the fabric moisture content is 0.5%~5.0%. Detailed Implementation

[0033] The preferred embodiments described below are merely examples, and other obvious variations will be apparent to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0034] According to the present application, a method for preparing a three-dimensional fabric includes the following steps:

[0035] S1001, yarn is fed in at a predetermined yarn feeding speed to form a pre-treated three-dimensional fabric.

[0036] It is worth mentioning that, in one embodiment, when the fabric is laid flat, the lateral distance between the surface loops is 0.3mm-2.2mm;

[0037] It is worth mentioning that, in one embodiment, when the fabric is laid flat, the coil body protrudes from the extension line by a distance of 0.03mm-2mm from the vertical height of the coil body;

[0038] It is worth mentioning that, in one embodiment, the dynamic feeding tension, reflected by the yarn feeding speed during coil weaving, is 2cN-20cN. It is also worth noting that the dynamic feeding tension, reflected by the yarn feeding speed during coil weaving, affects the roughness, tightness, and coil density of the final three-dimensional fabric, and consequently affects the spread of the adhesive.

[0039] It is worth mentioning that the raw material of the fiber yarn is selected from at least one of the following: polyethylene terephthalate fiber, polypropylene terephthalate fiber, polybutylene terephthalate fiber, polyvinyl chloride fiber, polypropylene fiber, polyamide fiber, polyacrylonitrile fiber, acetate fiber or polyvinyl alcohol formal fiber.

[0040] The method for preparing the three-dimensional fabric includes the following steps:

[0041] S1002A, the pre-treated three-dimensional fabric is shaped by a setting machine; wherein the yarn used in the three-dimensional fabric weaving has waterproof and oil-proof functions.

[0042] Those skilled in the art will understand that by applying a waterproof and oil-repellent yarn auxiliary to the yarn during the feeding process, the yarn can be made waterproof and oil-repellent, thereby enabling the fabric formed from the yarn to have waterproof and oil-repellent properties.

[0043] It is particularly worth mentioning that, in this embodiment, when the yarn is treated with a waterproof and oil-resistant yarn waterproof and oil-resistant additive during the feeding of the three-dimensional fabric, the formation of a large amount of wastewater and waste liquid can be effectively avoided.

[0044] In another embodiment, the method for preparing the three-dimensional fabric includes the following steps:

[0045] S1002B, when setting the three-dimensional fabric, the pre-treated three-dimensional fabric is treated with a waterproof and oil-repellent agent.

[0046] It is worth mentioning that when the tension dynamic feeding tension, reflected by the yarn feeding speed during the weaving of the loops, is between 2cN and 20cN, regardless of whether the three-dimensional fabric is formed through the above steps S1002A or S1002B, the surface roughness of the final three-dimensional fabric can ensure that the fabric is coated with adhesive in the future. The coated fabric will not become too stiff due to the adhesive penetrating too deeply into the fabric, nor will the peel force of the three-dimensional fabric from the adhesive be reduced due to the adhesive penetrating too deeply or too shallowly into the fabric. Moreover, the adhesive is spread more evenly on the surface of the three-dimensional fabric.

[0047] In other words, in this embodiment, yarn that does not have waterproof and oil-repellent properties is used, so the fabric formed by the yarn does not have waterproof and oil-repellent properties. However, by performing waterproof and oil-repellent treatment on the fabric, the final fabric can also have waterproof and oil-repellent properties.

[0048] The method for preparing the three-dimensional fabric includes the following steps:

[0049] S1003, the pre-treated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing.

[0050] Preferably, the drying temperature is 120~200℃, and the hot air and exhaust air velocity is ≥500r / min.

[0051] It is worth mentioning that the surface fiber roughness Ra of the three-dimensional fabric is 0.3μm-1.5μm. This allows the adhesive to remain on the surface of the three-dimensional fabric after subsequent roller coating. In other words, after adhesive application, the surface of the three-dimensional fabric allows the adhesive to remain on the surface, ensuring both the physical anchoring effect of the adhesive through a suitable microstructure and controlling the degree of adhesive penetration, resulting in a uniform, firm, and smooth adhesive layer on the fabric surface.

[0052] The method for preparing the three-dimensional fabric satisfies at least one of the following conditions:

[0053] When the fabric is laid flat, the lateral distance between the surface loops is 0.3mm-2.2mm;

[0054] The distance between the vertical height of the coil body protruding from the extension line is 0.03mm-2mm.

[0055] It is worth mentioning that when the pre-treated three-dimensional fabric is shaped by the sizing machine, 3g to 50g of waterproof and oil-repellent additive is added per liter of water, and 0.2g to 1.5g of citric acid is added per liter of water. The water repellency level of the fabric spray is 1.5 to 4, the water droplets stay on the fabric surface for ≥2 minutes, and the pH of the fabric surface is 3 to 7.

[0056] More preferably, in one embodiment, the waterproof and oil-repellent additive is processed as fluorinated and non-fluorinated functional finishing powders and liquids, and the waterproof and oil-repellent functional yarn is processed as fluorinated and non-fluorinated functional finishing powders and liquids to achieve the waterproof and oil-repellent effect.

[0057] In a preferred embodiment, the pretreated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing, which includes:

[0058] The temperature of the first washing tank is controlled at 70~95℃. Add 0.3~1.5g / L of nonionic surfactant, pH=7~9, and 0.2~0.6g / L of weak alkaline detergent. The washing speed is controlled at 6~12m / min to ensure that the contact time between the fabric and the washing solution is ≥1.5min.

[0059] In a preferred embodiment, the pre-treated three-dimensional fabric is further cleaned by high-temperature pre-washing and degreasing, including:

[0060] The temperature of the second and third water washing tanks for deep cleaning with neutral warm water is reduced to 60~70℃. A neutral cleaning agent with pH=6~7.5 is used, along with ultrasonic cleaning with a frequency of 28~40kHz. The cavitation effect is used to remove trace amounts of silicone oil and impurities from the fiber gaps.

[0061] In a preferred embodiment, the method for preparing the three-dimensional fabric further includes:

[0062] After washing with water, it needs to be rinsed with a spray at a pressure of 0.2~0.3MPa to prevent impurities from adhering again;

[0063] High-temperature drying is used to control the moisture content to below 40%.

[0064] In a preferred embodiment, the water-based adhesive can spread rapidly without shrinking or agglomerating, the surface wetting tension of the three-dimensional fabric is ≥38 mN / m, and the fabric moisture content is 0.5%~5.0%.

[0065] Example 1

[0066] After the above steps S1001, S1002A and S1003, a three-dimensional fabric with a surface roughness Ra=0.5μm is obtained. After coating, the adhesive does not slip and remains stably on the surface of the three-dimensional fabric. The adhesive layer is evenly distributed and the appearance meets the requirements for use.

[0067] Example 2

[0068] After the above steps S1001, S1002B and S1003, a three-dimensional fabric with a surface roughness Ra=1.2μm is obtained. After coating, the adhesive does not slip and remains stably on the surface of the three-dimensional fabric. The adhesive layer is evenly distributed and the appearance meets the requirements for use.

[0069] Comparative Example 1

[0070] The three-dimensional fabric with a surface roughness Ra < 0.3μm is used. The roller coating and spray adhesive processes are consistent. The surface of the fabric is too smooth and lacks the microstructure required for adhesive adhesion. After coating, the adhesive is easy to slip and shrink, and cannot stay stably on the surface of the three-dimensional fabric. The adhesive layer is unevenly distributed, the bonding force is weak, and it is easy to peel off and peel. The bonding performance and appearance do not meet the requirements for use.

[0071] Comparative Example 2

[0072] Using a three-dimensional fabric with a surface roughness Ra>1.5μm and employing the same roller coating and spray adhesive process, the excessive surface roughness of the fabric causes a large amount of adhesive to penetrate into the deep pores of the fabric, resulting in insufficient effective adhesive layer content on the surface. At the same time, the adhesive layer has poor elasticity, with some areas having excessively thin adhesive layers or excessively thick layers. This also leads to adhesive waste and changes in the basic properties of the fabric, making it unable to meet the usage requirements.

[0073] Comparative Example 3

[0074] Using the same three-dimensional fabric as in the example, without surface hydrophilic treatment, the surface wetting tension of the fabric was measured to be 32 mN / m (<38 mN / m). The fabric was adjusted to a moisture content of 0.2% and 12.0%, both exceeding the 0.5%~5.0% range. Coating was performed using the same coating process and water-based adhesive system as in the example. Upon contact with the fabric, the adhesive immediately shrank, coagulated, and formed beads, failing to spread quickly and evenly, and unable to form a continuous adhesive film. After curing, the adhesive layer was unevenly distributed and had poor adhesion, lacking the good spreading and bonding effects of the example.

[0075] Those skilled in the art should understand that the embodiments of the present invention described above are merely examples and do not limit the invention. The objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been shown and explained in the embodiments, and any modifications or variations of the implementation of the present invention may be made without departing from the stated principles.

Claims

1. A method for preparing a three-dimensional fabric, characterized in that, The method for preparing the three-dimensional fabric includes the following steps: S1001, feed yarn at a predetermined yarn feeding speed to form a pre-treated three-dimensional fabric; dynamically feed tension of 2cN-20cN according to the tension reflected by the predetermined yarn feeding speed when weaving loops, so as to complete the adjustment of the fabric surface roughness. S1002, the pre-treated three-dimensional fabric is set by a setting machine; the yarn used in the three-dimensional fabric weaving has waterproof and oil-proof functions, or the pre-treated three-dimensional fabric is waterproofed and oil-proofed by a waterproof and oil-proof auxiliary agent when setting the three-dimensional fabric. S1003, the pre-treated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing.

2. The method for preparing three-dimensional fabric according to claim 1, characterized in that, The fiber yarn raw material is selected from at least one of the following: polyethylene terephthalate fiber, polypropylene terephthalate fiber, polybutylene terephthalate fiber, polyvinyl chloride fiber, polypropylene fiber, polyamide fiber, polyacrylonitrile fiber, acetate fiber, or polyvinyl alcohol formal fiber.

3. The method for preparing the three-dimensional fabric according to claim 1 or 2, characterized in that, Drying temperature 120~200℃, hot air and exhaust air velocity ≥500r / min.

4. The method for preparing three-dimensional fabric according to claim 1, characterized in that, The surface fiber roughness of the fabric is Ra 0.3μm-1.5μm.

5. The method for preparing three-dimensional fabric according to claim 4, characterized in that, It satisfies at least one of the following conditions: When the fabric is laid flat, the lateral distance between the surface loops is 0.3mm-2.2mm; When the fabric is laid flat, the coil body protrudes from the extension line by a distance of 0.03mm-2mm from the vertical height of the coil body.

6. The method for preparing three-dimensional fabric according to claim 1, characterized in that, When the pre-treated three-dimensional fabric is set by a setting machine, 3g to 50g of waterproof and oil-repellent additive is added per liter of water, and 0.2g to 1.5g of citric acid is added per liter of water. The fabric spray water repellency level is 1.5 to 4, water droplets stay on the fabric surface for ≥2 minutes, and the fabric surface pH is 3 to 7.

7. The method for preparing three-dimensional fabric according to claim 1, 4, or 5, characterized in that, The pre-treated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing, including: The temperature of the first washing tank is controlled at 70~95℃. Add 0.3~1.5g / L of nonionic surfactant, pH=7~9, and 0.2~0.6g / L of weak alkaline detergent. The washing speed is controlled at 6~12m / min to ensure that the contact time between the fabric and the washing solution is ≥1.5min.

8. The method for preparing three-dimensional fabric according to claim 7, characterized in that, The pre-treated three-dimensional fabric is cleaned by high-temperature pre-washing and degreasing, including: The temperature of the second and third water washing tanks for deep cleaning with neutral warm water is reduced to 60~70℃. A neutral cleaning agent with pH=6~7.5 is used, along with ultrasonic cleaning with a frequency of 28~40kHz. The cavitation effect is used to remove trace amounts of silicone oil and impurities from the fiber gaps.

9. The method for preparing the three-dimensional fabric according to claim 8, characterized in that, The method for preparing the three-dimensional fabric further includes: After washing with water, it needs to be rinsed with a spray at a pressure of 0.2~0.3MPa to prevent impurities from adhering again; High-temperature drying is used to control the moisture content to below 40%.

10. The method for preparing three-dimensional fabric according to claim 9, characterized in that, The surface wetting tension of the three-dimensional fabric is ≥38 mN / m, and the moisture content of the fabric is 0.5%~5.0%.