Composite fabric, preparation method thereof and textile
By adjusting the weight ratio of the inner and outer fabrics and the area of the adhesive region, and by adopting a gradual composite process, the problems of curling and dimensional instability caused by uneven interlayer stress in traditional film composite fabrics in down home textile products have been solved, achieving a soft and smooth fabric surface and down-proof function.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- LUOLAI LIFESTYLE TECH CO LTD
- Filing Date
- 2026-01-30
- Publication Date
- 2026-04-28
AI Technical Summary
When traditional film composite fabrics are applied to down home textile products, they suffer from problems such as curling, dimensional instability, and poor user experience due to uneven interlayer stress. This is especially true in composite knitted fabrics, where it is difficult to achieve both down-proof and soft, smooth fabric surfaces at the same time.
Using discontinuous point-like hot melt technology, the outer knitted fabric layer, the film layer, and the inner knitted fabric layer are laminated with polyurethane hot melt adhesive. The weight ratio of the inner knitted fabric layer to the outer knitted fabric layer is controlled at 0.20-0.50:1. The area of the adhesive bonding area is adjusted, and a gradual lamination process of "strong first, then soft" is adopted to control the lamination temperature and pressure and ensure that the deformation of each layer of material is coordinated during the lamination process.
It effectively suppresses the curling phenomenon of composite fabrics, ensures the softness and smoothness of the fabric, improves the user experience, and maintains the down-proof effect and dimensional stability.
Smart Images
Figure CN121928832A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of textile technology, and in particular to a composite fabric, its preparation method, and the textile thereof. Background Technology
[0002] Down-filled home textiles are home textiles that use duck down or goose down as the main filling material. These textiles achieve their warmth by trapping still air through a three-dimensional down cluster structure. Down comforters and other down-filled home textile products require fabrics that are soft, skin-friendly, and have a down-proof effect.
[0003] To achieve down-proof performance, a film-coating technique is typically used. This involves bonding a continuous, microporous, breathable film (such as a thermoplastic polyurethane film) between two layers of textile fabric using an adhesive. This technique effectively prevents down leakage. However, the continuous film layer significantly increases the overall rigidity and "plastic feel" of the fabric, resulting in a stiff hand feel and a lack of supple drape. Furthermore, under pressure or friction, coated fabrics are prone to generating noticeable friction noise, leading to a poor user experience. Therefore, traditional film-coated fabrics are primarily used in outdoor clothing and similar applications.
[0004] When the applicant attempted to apply film lamination technology to knitted three-in-one fabrics (i.e., two layers of knitted fabric laminated together with a film), the following technical challenges were encountered: During the lamination process and subsequent treatments, due to differences in material, weight, and structural elasticity between the outer and inner knitted fabric layers, severe and irreversible shrinkage and curling easily occurred due to uneven interlayer stress. This not only resulted in uneven fabric, processing difficulties, and low yield, but the resulting curling internal stress also persisted, affecting the fabric's dimensional stability and surface smoothness. Ultimately, this led to problems such as curled corners or edges and uneven spreading in the finished textiles (e.g., down comforters), severely impacting appearance and user experience. Therefore, how to effectively suppress curling of the composite knitted fabric while achieving down-proof functionality and ensuring its dimensional stability and soft, smooth surface became a pressing technical challenge. Summary of the Invention
[0005] This application provides a composite fabric, a method for preparing the same, and a textile to solve the aforementioned technical problems.
[0006] To achieve the above objectives, the technical solution of this application is as follows:
[0007] This application provides a composite fabric, which, along its thickness direction, sequentially comprises a surface knitted fabric layer, a film layer, and an inner knitted fabric layer. The surface knitted fabric layer and the film layer, as well as the film layer and the inner knitted fabric layer, are bonded together using adhesives. The weight ratio of the inner knitted fabric layer to the surface knitted fabric layer is 0.20-0.50:1, preferably 0.30-0.50:1, and the weight of the inner knitted fabric layer is 15-70 g / m². 2 Preferably 20-65g / m 2 .
[0008] In one embodiment of this application, the thickness of the surface knitted fabric layer is 0.18-0.7 mm, preferably 0.20-0.65 mm.
[0009] In one embodiment of this application, the weight of the surface knitted fabric layer is 70-190 g / m². 2 Preferably 100-170g / m 2 .
[0010] In one embodiment of this application, the surface knitted fabric layer adopts a warp-knitted or weft-knitted structure.
[0011] In one embodiment of this application, the thickness of the inner knitted fabric layer is 0.02-0.25 mm, preferably 0.05-0.20 mm.
[0012] In one embodiment of this application, the tensile elastic recovery rate of the inner knitted fabric layer is 3%-12%, preferably 5%-8%. In one embodiment of this application, the inner knitted fabric layer adopts a warp-knitted or weft-knitted structure, preferably a weft-knitted structure.
[0013] In one embodiment of this application, the material of the inner knitted fabric layer is selected from fabrics with a chemical fiber content greater than or equal to 50 wt%.
[0014] In one embodiment of this application, the thickness of the film layer is 3-20 μm, preferably 3-15 μm.
[0015] In one embodiment of this application, the basis weight of the membrane is 3-12 g / m³. 2 Preferably 3-10 g / m 2 .
[0016] In one embodiment of this application, the membrane layer is made of polyurethane.
[0017] In one embodiment of this application, the outer knitted fabric layer and the film layer, as well as the film layer and the inner knitted fabric layer, are composited by discontinuous point-like hot melting.
[0018] In one embodiment of this application, the adhesive is selected from polyurethane hot melt adhesive.
[0019] In one embodiment of this application, the area of the adhesive region located between the surface knitted fabric layer and the film layer accounts for 15%-50% of the area of the film layer, preferably 20%-40%.
[0020] In one embodiment of this application, the area of the adhesive region located between the film layer and the inner knitted fabric layer accounts for 15%-50% of the area of the film layer, preferably 20%-40%.
[0021] In one embodiment of this application, the diameter of the adhesive dot is 0.05-0.5 mm, preferably 0.1-0.3 mm.
[0022] This application also provides a method for preparing the composite fabric as described above, the method comprising the following steps: The outer knitted fabric layer, the film layer, and the inner knitted fabric layer are sequentially bonded together along the thickness direction using the adhesive, and then shaped to obtain the composite fabric.
[0023] In one embodiment of this application, the setting temperature is 70-80°C, preferably 75-80°C; the setting time is 1-15 minutes, preferably 3-8 minutes.
[0024] This application also provides a textile product, which includes composite fabrics as described above or composite fabrics prepared according to the methods described above.
[0025] In one embodiment of this application, the textile is a down product, which includes the composite fabric and a filling material inside the composite fabric, the filling material including down fibers.
[0026] The beneficial effects of this application are: This application adjusts the ratio of the weight of the inner knitted fabric layer to the weight of the outer knitted fabric layer to 0.20-0.50:1, and selects a weight of 15-70 g / m². 2 The inner knitted fabric layer can reduce the overall rigidity and weight of the fabric, thereby improving the softness of the composite fabric.
[0027] In this application, by selecting a fabric with a tensile elastic recovery rate of 3%-12% as the inner knitted fabric layer, the heat shrinkage potential and elastic recovery stress of the inner knitted fabric layer during the composite process can be reduced through its low elasticity characteristics, making its physical properties closer to those of the film layer, thereby avoiding the occurrence of curling and solving the problem of dimensional instability of the composite knitted fabric.
[0028] In this application, the polyurethane hot melt adhesive has low-temperature soft activation properties. Its melting and bonding window (approximately 100-130°C) is highly matched with the "gradual cooling composite" process. It can still well wet and bond the film and the knitted fabric at low temperatures. After curing, it forms a low-modulus, high-elasticity flexible adhesive dot, thereby ensuring the softness of the composite fabric.
[0029] In this application, by adjusting the area of the adhesive region between the outer knitted fabric layer and the film layer to account for 15%-50% of the area of the film layer (i.e., the composite area), and adjusting the area of the adhesive region between the film layer and the inner knitted fabric layer to account for 15%-50% of the area of the film layer (i.e., the composite area), it is possible to ensure the composite strength while ensuring that most areas of the fabric are not "fixed" by the adhesive points, thus preserving as much freedom as possible for each layer of material to bend and slide independently, thereby ensuring the softness and quietness of the composite fabric.
[0030] In this application, by controlling the lamination process, the temperature and / or pressure of subsequent interlayer lamination steps are ensured to be no higher than those of earlier interlayer lamination steps. This "strong first, then flexible" gradual lamination strategy allows the composite material system to undergo a controlled process from initial stable adhesion to final flexible assembly. The earlier steps form strong initial bonding points under relatively high temperature and pressure; subsequent steps are carried out under relatively mild conditions, reducing secondary thermomechanical shocks to the already laminated parts and newly added layers. This lamination process helps coordinate the deformation behavior of each layer during the lamination process, thereby effectively suppressing curling caused by accumulated thermal stress and uneven shrinkage, ensuring a smooth fabric surface and dimensional stability of the composite fabric. Attached Figure Description
[0031] Figure 1 This is a schematic diagram of the structure of the composite fabric of this application.
[0032] The attached figures are labeled as follows: 1-Surface knitted fabric layer; 2-Film layer; 3-Inner knitted fabric layer. Detailed Implementation
[0033] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.
[0034] like Figure 1As shown, one embodiment of this application provides a composite fabric. Along the thickness direction, the composite fabric sequentially includes a surface knitted fabric layer 1, a film layer 2, and an inner knitted fabric layer 3. The surface knitted fabric layer 1 and the film layer 2, as well as the film layer 2 and the inner knitted fabric layer 3, are bonded together by adhesives. The weight ratio of the inner knitted fabric layer 3 to the surface knitted fabric layer 1 is 0.20-0.50:1, preferably 0.30-0.50:1, and the weight of the inner knitted fabric layer 3 is 15-70 g / m². 2 Preferably 20-65g / m 2 .
[0035] This application adjusts the weight ratio of the inner knitted fabric layer 3 to the outer knitted fabric layer 1 to 0.20-0.50:1, and selects a weight of 15-70 g / m². 2 The fabric used as the inner knitted fabric layer 3 can reduce the overall rigidity and weight of the fabric, thereby improving the softness of the composite fabric.
[0036] In one embodiment of this application, the thickness of the surface knitted fabric layer 1 is 0.18-0.7 mm, preferably 0.20-0.65 mm; the weight of the surface knitted fabric layer 1 is 70-190 g / m². 2 Preferably 100-170g / m 2 The outer knitted fabric layer 1 adopts a warp-knitted or weft-knitted structure, preferably a weft-knitted structure, to further improve the softness and feel of the composite fabric; the outer knitted fabric layer 1 is preferably a fabric containing cellulose fibers to enhance the skin-friendliness and comfort of the composite fabric. Cellulose fibers can be listed as cotton fibers, silk fibers, lyocell fibers, modal fibers, etc.
[0037] In one embodiment of this application, the thickness of the inner knitted fabric layer 3 is 0.02-0.25 mm, preferably 0.05-0.20 mm; the tensile elastic recovery rate (referring to the tensile elastic recovery rate along the radial and weft directions) of the inner knitted fabric layer 3 is 3%-12%, preferably 5%-8%; the inner knitted fabric layer 3 adopts a warp-knitted or weft-knitted structure; the material of the inner knitted fabric layer 3 is selected from fabrics with a chemical fiber content greater than or equal to 50 wt%.
[0038] In this application, by selecting a fabric with a tensile elastic recovery rate of 3%-12% as the inner knitted fabric layer 3, the heat shrinkage potential and elastic recovery stress of the inner knitted fabric layer 3 during the composite process can be reduced by the low elasticity characteristics, making its physical properties closer to those of the film layer 2, thereby avoiding the occurrence of curling and solving the problem of dimensional instability of the composite knitted fabric.
[0039] In one embodiment of this application, the thickness of film layer 2 is 3-20 μm, preferably 3-15 μm, more preferably 8-10 μm; the basis weight of film layer 2 is 3-12 g / m³. 2 Preferably 3-10 g / m 2 The material of membrane layer 2 is polyurethane.
[0040] In one embodiment of this application, the outer knitted fabric layer 1 and the film layer 2, as well as the film layer 2 and the inner knitted fabric layer 3, are composited by discontinuous point-like hot melt bonding, and the adhesive is selected from polyurethane hot melt adhesive.
[0041] In this application, the polyurethane hot melt adhesive has low-temperature soft activation properties. Its melting and bonding window (approximately 100-130°C) is highly matched with the "gradual cooling and bonding" process. It can still well wet and bond the film and the knitted fabric at low temperatures. After curing, it forms a low-modulus, high-elasticity flexible adhesive dot, thereby ensuring the softness of the composite fabric.
[0042] In one embodiment of this application, the area of the adhesive region located between the outer knitted fabric layer 1 and the film layer 2 accounts for 15%-50% of the area of the film layer 2 (i.e., the composite area), preferably 20%-40%; the area of the adhesive region located between the film layer 2 and the inner knitted fabric layer 3 accounts for 15%-50% of the area of the film layer 2 (i.e., the composite area), preferably 20%-40%.
[0043] In this application, by adjusting the area of the adhesive region between the outer knitted fabric layer 1 and the film layer 2 to account for 15%-50% of the area of the film layer 2 (i.e., the composite area), and by adjusting the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 to account for 15%-50% of the area of the film layer 2 (i.e., the composite area), it is possible to ensure composite strength while preventing most areas of the fabric from being "fixed" by adhesive points. This preserves the freedom of independent bending and sliding of each layer as much as possible, thereby ensuring the softness and noise reduction of the composite fabric. In this application, the area of the film layer refers to the surface area of the film layer.
[0044] In one embodiment of this application, the diameter of the adhesive dot is 0.05-0.5 mm, preferably 0.1-0.3 mm.
[0045] This application also provides a method for preparing the composite fabric as described above, the method comprising the following steps: Composite fabric is produced by bonding the surface knitted fabric layer, the film layer, and the inner knitted fabric layer together sequentially along the thickness direction using an adhesive and then shaping them.
[0046] Specifically, there are two methods for preparing composite fabrics: Method 1: S1.1 The surface knitted fabric layer 1 and the film layer 2 are bonded together with an adhesive and then cured. S1.2 Then, the film layer 2 is bonded to the inner knitted fabric layer 3 with an adhesive, cured again, and shaped to obtain the composite fabric.
[0047] In one embodiment of this application, in step S1.1, the compounding temperature is 110-125℃, preferably 115-120℃; the compounding pressure is 0.20-0.40MPa, preferably 0.25-0.35MPa, more preferably 0.28-0.30MPa; and the curing time is greater than or equal to 12 hours. In step S1.2, the compounding temperature is lower than that in step S1.1, and the compounding pressure is lower than that in step S1.1; the compounding temperature in step S1.2 is 100-115℃, preferably 105-110℃; the compounding pressure is 0.10-0.30MPa, preferably 0.15-0.25MPa; the re-curing time is 24-48 hours, preferably 30-48 hours; the setting temperature is 70-80℃, preferably 75-80℃; and the setting time is 1-15 minutes, preferably 3-8 minutes.
[0048] Method 2: S2.1 The film layer 2 is bonded to the inner knitted fabric layer 3 using an adhesive, and then cured; S2.2 Then, the film layer 2 is bonded to the knitted fabric layer 1 with an adhesive, cured again, and shaped to obtain the composite fabric.
[0049] In one embodiment of this application, in step S2.1, the compounding temperature is 115-120℃, preferably 118-120℃; the compounding pressure is 0.25-0.35MPa, preferably 0.28-0.35MPa; and the curing time is greater than or equal to 12 hours. In step S2.2, the compounding temperature is lower than that in step S2.1, and the compounding pressure is lower than that in step S2.1. In step S2.2, the compounding temperature is 105-110℃, preferably 108-110℃; the compounding pressure is 0.15-0.25MPa, preferably 0.18-0.25MPa; the re-curing time is 24-48 hours, preferably 30-48 hours; the setting temperature is 70-80℃, preferably 75-80℃; and the setting time is 1-15 minutes, preferably 3-8 minutes.
[0050] In this application, by controlling the lamination process, the temperature and / or pressure of subsequent interlayer lamination steps are ensured to be no higher than those of earlier interlayer lamination steps. This "strong first, then flexible" gradual lamination strategy allows the composite material system to undergo a controlled process from initial stable adhesion to final flexible assembly. The earlier steps form strong initial bonding points under relatively high temperature and pressure; subsequent steps are carried out under relatively mild conditions, reducing secondary thermomechanical shocks to the already laminated parts and newly added layers. This lamination process helps coordinate the deformation behavior of each layer during the lamination process, thereby effectively suppressing curling caused by accumulated thermal stress and uneven shrinkage, ensuring a smooth fabric surface and dimensional stability of the composite fabric.
[0051] Another embodiment of this application also provides a textile, which includes the composite fabric described above or the composite fabric prepared according to the method described above.
[0052] In one embodiment of this application, the textile is a down product, which includes a composite fabric as described above and a filling material within the composite fabric, the filling material including down fibers. Examples of down products include down comforters, down jackets, and down pants.
[0053] Furthermore, the meaning of "and / or" throughout the text is to include three parallel solutions. Taking "A and / or B as an example" includes solution A, solution B, or a solution that satisfies both A and B. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of a person skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.
[0054] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.
[0055] Example 1 like Figure 1 As shown, this embodiment provides a composite fabric. Along the thickness direction, the composite fabric sequentially includes a surface knitted fabric layer 1, a film layer 2, and an inner knitted fabric layer 3. The surface knitted fabric layer 1 and the film layer 2, as well as the film layer 2 and the inner knitted fabric layer 3, are bonded together by adhesives. The weight ratio of the inner knitted fabric layer 3 to the surface knitted fabric layer 1 is approximately 0.22:1.
[0056] Specifically, the composite fabric is prepared according to the following steps: S1. At a temperature of 120℃ and a pressure of 0.30MPa, a commercially available polyurethane hot melt adhesive is used to bond the surface knitted fabric layer 1 and the film layer 2 together via a discontinuous point-like hot melt technology. The surface knitted fabric layer 1 is made of 60S modal fiber and 20D spandex, with a thickness of 0.50mm and a weight of 155g / m². 2 Weft-knitted fabric (commercially available); film layer 2 uses a thickness of 10μm and a weight of 8g / m². 2 The thermoplastic polyurethane film (i.e., TPU film, commercially available); the area of the adhesive region located between the surface knitted fabric layer 1 and the film layer 2 accounts for 35% of the area of the film layer 2 (i.e., the composite area); the diameter of the adhesive point is 0.2 mm; Next, it is placed in a tension-free and relaxed state for 18 hours for maturation. S2. Then, at a temperature of 100℃ and a pressure of 0.20MPa, polyurethane hot melt adhesive (commercially available) is used to bond the film layer 2 and the inner knitted fabric layer 3 together using a discontinuous point-like hot melt technique. The inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.10mm and a weight of 35g / m². 2 The weft-knitted fabric has a tensile elastic recovery rate of 8% in both warp and weft directions (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics"); the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounts for 35% of the area of the film layer 2; the diameter of the adhesive point is 0.2mm; Subsequently, the material was placed in a tension-free, relaxed state for 36 hours to undergo a second curing process, and then loosely shaped at 75°C for 5 minutes (i.e., shaped in a tension-free, relaxed state, the same below) to obtain the composite fabric.
[0057] Example 2 The difference between this embodiment and Embodiment 1 is that: the film layer 2 has a thickness of 8 μm and a basis weight of 5 g / m. 2 The polyurethane nanofiber nonwoven membrane (custom-produced by the upstream manufacturer according to the applicant's requirements).
[0058] Example 3 like Figure 1 As shown, this embodiment provides a composite fabric. Along the thickness direction, the composite fabric sequentially includes a surface knitted fabric layer 1, a film layer 2, and an inner knitted fabric layer 3. The surface knitted fabric layer 1 and the film layer 2, as well as the film layer 2 and the inner knitted fabric layer 3, are bonded together by adhesives. The weight ratio of the inner knitted fabric layer 3 to the surface knitted fabric layer 1 is 0.20:1.
[0059] Specifically, the composite fabric is prepared according to the following steps: S1. At a temperature of 110℃ and a pressure of 0.3MPa, a commercially available polyurethane hot melt adhesive is used to bond the surface knitted fabric layer 1 and the film layer 2 together using a discontinuous point-like hot melt technology. The surface knitted fabric layer 1 is made of 60S modal fiber and 20D spandex, with a thickness of 0.6mm and a weight of 190g / m². 2 Weft-knitted fabric (commercially available); film layer 2 uses a thickness of 3μm and a weight of 3g / m². 2 The polyurethane film (commercially available); the area of the adhesive region between the surface knitted fabric layer 1 and the film layer 2 accounts for 15% of the area of the film layer 2 (i.e., the composite area); the diameter of the adhesive point is 0.3 mm; Next, it is placed in a tension-free and relaxed state for 12 hours for maturation. S2. Then, at a temperature of 100℃ and a pressure of 0.10MPa, polyurethane hot melt adhesive (commercially available) is used to bond the film layer 2 and the inner knitted fabric layer 3 together using a discontinuous point-like hot melt technique. The inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.1mm and a weight of 38g / m². 2 The weft-knitted fabric has a tensile elastic recovery rate of 12% in both warp and weft directions (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics"); the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounts for 15% of the area of the film layer 2; the diameter of the adhesive point is 0.3mm; Subsequently, the material was placed in a tension-free, relaxed state for 24 hours to undergo a second curing process, and then loosely set at 70°C for 15 minutes to obtain the composite fabric.
[0060] Example 4 like Figure 1 As shown, this embodiment provides a composite fabric. Along the thickness direction, the composite fabric sequentially includes a surface knitted fabric layer 1, a film layer 2, and an inner knitted fabric layer 3. The surface knitted fabric layer 1 and the film layer 2, as well as the film layer 2 and the inner knitted fabric layer 3, are bonded together by adhesives. The weight ratio of the inner knitted fabric layer 3 to the surface knitted fabric layer 1 is approximately 0.50:1.
[0061] Specifically, the composite fabric is prepared according to the following steps: S1. At a temperature of 125℃ and a pressure of 0.4MPa, a commercially available polyurethane hot melt adhesive is used to bond the surface knitted fabric layer 1 and the film layer 2 together using a discontinuous point-like hot melt technology. The surface knitted fabric layer 1 is made of 60S modal fiber and 20D spandex, with a thickness of 0.24mm and a weight of 70g / m². 2 Weft-knitted fabric (commercially available); film layer 2 uses a thickness of 20μm and a weight of 12g / m². 2 The polyurethane film (commercially available); the area of the adhesive region between the surface knitted fabric layer 1 and the film layer 2 accounts for 50% of the area of the film layer 2 (i.e., the composite area); the diameter of the adhesive point is 0.4 mm; Next, it is placed in a tension-free and relaxed state for 18 hours for maturation. S2. Then, at a temperature of 115℃ and a pressure of 0.30MPa, polyurethane hot melt adhesive (commercially available) is used to bond the film layer 2 and the inner knitted fabric layer 3 together using a discontinuous point-like hot melt technique. The inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.25mm and a weight of 35g / m². 2 The weft-knitted fabric has a tensile elastic recovery rate of 8% in both warp and weft directions (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics"); the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounts for 50% of the area of the film layer 2; the diameter of the adhesive point is 0.4mm; Subsequently, the material was placed in a tension-free, relaxed state for 48 hours to undergo a second curing process, and then loosely set at 80°C for 1 minute to obtain the composite fabric.
[0062] Example 5 like Figure 1 As shown, this embodiment provides a composite fabric. Along the thickness direction, the composite fabric sequentially includes a surface knitted fabric layer 1, a film layer 2, and an inner knitted fabric layer 3. The surface knitted fabric layer 1 and the film layer 2, as well as the film layer 2 and the inner knitted fabric layer 3, are bonded together by adhesives. The weight ratio of the inner knitted fabric layer 3 to the surface knitted fabric layer 1 is approximately 0.47:1.
[0063] Specifically, the composite fabric is prepared according to the following steps: S1. At a temperature of 115℃ and a pressure of 0.25MPa, a commercially available polyurethane hot melt adhesive is used to bond the surface knitted fabric layer 1 and the film layer 2 together using a discontinuous point-like hot melt technology. The surface knitted fabric layer 1 is made of 60S modal fiber and 20D spandex, with a thickness of 0.53mm and a weight of 150g / m². 2Weft-knitted fabric (commercially available); film layer 2 uses a thickness of 8μm and a weight of 5g / m². 2 The polyurethane nanofiber membrane (custom-produced by the upstream manufacturer according to the applicant's needs); the area of the adhesive region located between the surface knitted fabric layer 1 and the membrane layer 2 accounts for 25% of the area of the membrane layer 2 (i.e., the composite area); the diameter of the adhesive point is 0.2 mm. Next, it is placed in a tension-free and relaxed state for 18 hours for maturation. S2. Then, at a temperature of 110℃ and a pressure of 0.20MPa, polyurethane hot melt adhesive (commercially available) is used to bond the film layer 2 and the inner knitted fabric layer 3 together using a discontinuous point-like hot melt technique. The inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.20mm and a weight of 70g / m². 2 The weft-knitted fabric has a tensile elastic recovery rate of 5% in both warp and weft directions (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics"); the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounts for 25% of the area of the film layer 2; the diameter of the adhesive point is 0.2mm; Subsequently, the material was placed in a tension-free, relaxed state for 48 hours to undergo a second curing process, and then loosely set at 75°C (i.e., in a tension-free, relaxed state) for 5 minutes to obtain the composite fabric.
[0064] Example 6 The difference between this embodiment and embodiment 4 is that: The outer knitted fabric layer 1 is made of 60S modal fiber and 20D spandex, with a thickness of 0.7mm and a weight of 190g / m². 2 Weft-knitted fabric (commercially available); The inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.02mm and a weight of 38g / m². 2 Furthermore, the warp and weft tensile elastic recovery rates are both 12% (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics"); Membrane layer 2 has a thickness of 15 μm and a basis weight of 12 g / m. 2 Polyurethane film (commercially available); At a temperature of 125℃ and a pressure of 0.40MPa, polyurethane hot melt adhesive (commercially available) is used to bond the film layer 2 and the inner knitted fabric layer 3 using a discontinuous point hot melt technique. The area of the adhesive region between the outer knitted fabric layer 1 and the film layer 2 accounts for 50% of the area of the film layer 2 (i.e., the composite area); the diameter of the adhesive point is 0.4mm. Then, at a temperature of 115℃ and a pressure of 0.30MPa, polyurethane hot melt adhesive (commercially available) was used to bond the film layer 2 to the surface knitted fabric layer 1 using a discontinuous point hot melt technique; the diameter of the adhesive point was 0.4mm.
[0065] Example 7 The difference between this embodiment and Embodiment 1 is that: The outer knitted fabric layer 1 is made of 60S modal fiber and 20D spandex, with a thickness of 0.6mm and a weight of 150g / m². 2 Weft-knitted fabric (commercially available); The inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.12mm and a weight of 38g / m². 2 Furthermore, the warp and weft tensile elastic recovery rates are both 7.5% (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics"); Membrane layer 2 has a thickness of 10 μm and a basis weight of 8 g / m. 2 Polyurethane film (commercially available); At a temperature of 118℃ and a pressure of 0.30MPa, polyurethane hot melt adhesive (commercially available) is used to bond the film layer 2 and the inner knitted fabric layer 3 using a discontinuous point hot melt technique. The area of the adhesive region between the outer knitted fabric layer 1 and the film layer 2 accounts for 30% of the area of the film layer 2 (i.e., the composite area); the diameter of the adhesive point is 0.2mm. Then, at a temperature of 108℃ and a pressure of 0.20MPa, polyurethane hot melt adhesive (commercially available) was used to bond the film layer 2 to the outer knitted fabric layer 1 using a discontinuous point hot melt technique; the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounted for 30% of the area of the film layer 2; the diameter of the adhesive point was 0.2mm.
[0066] Example 8 The difference between this embodiment and Embodiment 1 is that: The outer knitted fabric layer 1 is made of 60S modal fiber and 20D spandex, with a thickness of 0.24mm and a weight of 70g / m². 2 Weft-knitted fabric (commercially available); The inner knitted fabric layer 3 is made of 75D / 144F low-elastic polyester yarn with a thickness of 0.25mm and a weight of 35g / m². 2 Furthermore, the warp and weft tensile elastic recovery rates are both 3% (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics"); Membrane layer 2 has a thickness of 3 μm and a basis weight of 3 g / m. 2 Polyurethane film (commercially available); At a temperature of 115℃ and a pressure of 0.25MPa, polyurethane hot melt adhesive (commercially available) is used to bond the film layer 2 and the inner knitted fabric layer 3 using a discontinuous point hot melt technique. The area of the adhesive region between the outer knitted fabric layer 1 and the film layer 2 accounts for 15% of the area of the film layer 2 (i.e., the composite area); the diameter of the adhesive point is 0.2mm. Then, at a temperature of 105℃ and a pressure of 0.15MPa, polyurethane hot melt adhesive (commercially available) was used to bond the film layer 2 to the outer knitted fabric layer 1 using a discontinuous point hot melt technique; the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounted for 15% of the area of the film layer 2; the diameter of the adhesive point was 0.2mm.
[0067] Comparative Example 1 The difference between this comparative example and Example 1 is that the inner knitted fabric layer 3 is made of 75D / 144F low-elastic polyester yarn with a thickness of 0.08mm and a weight of 30g / m². 2 Furthermore, the warp and weft tensile elastic recovery rates are both 8% (commercially available, tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics").
[0068] The difference between this comparative example and Example 1 is that the weight ratio of the inner knitted fabric layer 3 to the outer knitted fabric layer 1 is 30:160≈0.19:1<0.2:1.
[0069] Comparative Example 2 The difference between this comparative example and Example 1 is that the inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.18mm and a weight of 85g / m². 2 Furthermore, the weft-knitted fabric has a tensile elastic recovery rate of 8% in both the warp and weft directions (tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics").
[0070] The difference between this comparative example and Example 1 is that the weight ratio of the inner knitted fabric layer 3 to the outer knitted fabric layer 1 is 85:160≈0.53:1>0.5:1.
[0071] Comparative Example 3 The difference between this comparative example and Example 1 is that the inner knitted fabric layer 3 is made of 75D / 144F low-elasticity polyester yarn with a thickness of 0.18mm and a weight of 80g / m². 2Furthermore, the weft-knitted fabric has a tensile elastic recovery rate of 8% in both the warp and weft directions (tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics").
[0072] The difference between this comparative example and Example 1 is that the weight of the inner knitted fabric layer 3 is >70 g / m². 2 .
[0073] Comparative Example 4 The difference between this comparative example and Example 1 is that the composite temperature in step S2 is 120°C and the composite pressure in step S2 is 0.3 MPa. That is, the composite temperature in step S2 is the same as the composite temperature in step S1 and the composite pressure in step S2 is the same as the composite pressure in step S1.
[0074] Comparative Example 5 The difference between this comparative example and Example 1 is that the inner knitted fabric layer 3 is made of 75D / 144F low-elastic polyester yarn with a thickness of 0.10mm and a weight of 35g / m². 2 Furthermore, the weft-knitted fabric has a tensile elastic recovery rate of 14% in both the warp and weft directions (tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics").
[0075] The difference between this comparative example and Example 1 is that the tensile elastic recovery rate of the inner knitted fabric layer 3 is >12%.
[0076] Comparative Example 6 The difference between this comparative example and Example 1 is that the inner knitted fabric layer 3 is made of 75D / 144F low-elastic polyester yarn with a thickness of 0.10mm and a weight of 35g / m². 2 Furthermore, the weft-knitted fabric has a tensile elastic recovery rate of 2% in both the warp and weft directions (tested according to "FZ / T 70006-2022 Test Method for Tensile Elastic Recovery Rate of Knitted Fabrics").
[0077] The difference between this comparative example and Example 1 is that the tensile elastic recovery rate of the inner knitted fabric layer 3 is <3%.
[0078] Comparative Example 7 The difference between this comparative example and Example 1 is that polyamide hot melt adhesive (i.e., PA hot melt adhesive) is used instead of polyurethane hot melt adhesive.
[0079] Comparative Example 8 The difference between this comparative example and Example 1 is that the area of the adhesive region between the outer knitted fabric layer 1 and the film layer 2 accounts for 80% of the area of the film layer 2, and the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounts for 80% of the area of the film layer 2.
[0080] The difference between this comparative example and Example 1 is that the ratio of the area of the adhesive region to the area of the film layer 2 is >50%.
[0081] Comparative Example 9 The difference between this comparative example and Example 1 is that the area of the adhesive region between the outer knitted fabric layer 1 and the film layer 2 accounts for 10% of the area of the film layer 2, and the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 accounts for 10% of the area of the film layer 2.
[0082] The difference between this comparative example and Example 1 is that the ratio of the area of the adhesive region to the area of the film layer 2 is less than 15%.
[0083] test The appearance of the composite fabrics prepared in each embodiment and comparative example was observed, and the results are shown in Table 1. The "fabric softness" of the composite fabrics prepared in each embodiment and comparative example was tested. The specific steps were as follows: after conditioning under standard atmospheric conditions for at least 12 hours, three circular samples with an area of 100 cm² were cut from the composite fabric along a stepped pattern, avoiding seams and other areas. Using an electronic balance with an accuracy of 0.001g and a fabric thickness gauge with an accuracy of 0.001mm, the mass and thickness of each sample were measured, and the unit area mass W (μg / cm²) and thickness t (cm) were calculated. The linear density L (μg / cm) of each sample was calculated according to the formula L = W×t, and the fabric type was determined based on the L value (L < 280μg / cm is ultralight fabric, 280μg / cm ≤ L ≤ 1200μg / cm is lightweight fabric). Subsequently, each sample was tested using a fabric hand feel tester (Faboy). Before the test, the corresponding sample type, weight and thickness parameters were set in the device software. The instrument directly outputs the fabric softness F value score. The higher the F value, the softer the fabric. The arithmetic mean of the test results of 3 samples was taken as the final fabric softness of the sample. The test results are shown in Table 1.
[0084] The peel strength of the composite fabrics prepared in each embodiment and comparative example was tested according to "FZT 80007 1-2006 Test method for peel strength of fused interlining garments". The results are shown in Table 1. The composite fabrics prepared in each embodiment and comparative example were used to make down comforters with the same filling amount. The noise level of the down comforters was tested. The specific steps were as follows: After conditioning, the sample was laid flat in a soundproof room, folded along the long side of the sample, gently smoothed, and placed with the right side facing up to form a double-layer sample; a high-precision sound level meter was turned on, and the upper right front corner of the double-layer sample was held in hand. Simulating the daily process of getting up and turning the comforter, the sample was folded to the left at a constant speed, with the part of the sample held falling to the upper left front corner of the double-layer sample. The sample was then folded back to its original position at a constant speed, restoring the double-layer sample to its state before folding. This was recorded as one test cycle, which took 2 seconds. The average decibel value of the sound generated by 5 consecutive test cycles was recorded. The sound decibel value was then measured 6 times. The highest and lowest values were removed, and the arithmetic mean of the remaining five sets of data was taken as the final result. The results are shown in Table 1.
[0085] Table 1 Test Results
[0086] Note: A noise level of <35dB indicates that the device has a noise reduction effect.
[0087] As shown in Table 1, compared with Comparative Examples 1, 2, and 3, the composite fabric of Example 1 exhibits improved fabric softness (F-value). This result indicates that the present application achieves this by adjusting the weight ratio of the inner knitted fabric layer 3 to the outer knitted fabric layer 1 to 0.20-0.50:1, and selecting a weight of 15-70 g / m². 2 The fabric used as the inner knitted fabric layer 3 can reduce the overall rigidity and weight of the fabric, thereby improving the softness of the composite fabric.
[0088] As shown in Table 1, compared with Comparative Example 4, the composite fabric of Example 1 exhibits significantly improved appearance and enhanced softness. This result demonstrates that, in this application, by controlling the composite process, the temperature and / or pressure of subsequent interlayer bonding steps are kept no higher than those of earlier interlayer bonding steps. This "strong first, then soft" gradual composite strategy allows the composite material system to undergo a controlled process from initial stable bonding to final flexible assembly. The earlier steps form strong initial bonds under relatively high temperatures and pressures; subsequent steps are performed under relatively mild conditions, reducing secondary thermomechanical shocks to the already bonded portions and newly added layers. This composite process helps coordinate the deformation behavior of each layer during the composite process, effectively suppressing curling caused by accumulated thermal stress and uneven shrinkage, ensuring a smooth fabric surface and dimensional stability of the composite fabric.
[0089] As shown in Table 1, the appearance of the composite fabric in Example 1 is significantly improved compared to Comparative Examples 5 and 6. This result indicates that, in this application, by selecting a fabric with a tensile elastic recovery rate of 3%-12% as the inner knitted fabric layer 3, the thermal shrinkage potential and elastic recovery stress of the inner knitted fabric layer 3 during the composite process can be reduced through its low elasticity characteristics, making its physical properties closer to those of the film layer 2. This avoids curling and solves the problem of dimensional instability in the composite knitted fabric.
[0090] As shown in Table 1, the softness of the composite fabric prepared in Example 1 is significantly improved compared to Comparative Example 7. This result indicates that the polyurethane hot melt adhesive in this application possesses low-temperature softening and activation characteristics. Its melt bonding window (approximately 100-130°C) is highly compatible with the "gradual cooling bonding" process, allowing it to effectively wet and bond the film and knitted fabric even at low temperatures. Furthermore, after curing, it forms low-modulus, highly elastic flexible adhesive dots, thus ensuring the softness of the composite fabric.
[0091] As shown in Table 1, compared with Comparative Example 8, the down comforter made of the composite fabric of Example 1 has significantly improved softness and significantly decreased noise level; compared with Comparative Example 9, the peel strength of the composite fabric of Example 1 has significantly improved. These results indicate that, in this application, by adjusting the area of the adhesive region between the outer knitted fabric layer 1 and the film layer 2 to account for 15%-50% of the area of the film layer 2 (i.e., the composite area), and by adjusting the area of the adhesive region between the film layer 2 and the inner knitted fabric layer 3 to account for 15%-50% of the area of the film layer 2 (i.e., the composite area), it is possible to ensure composite strength while preventing most areas of the fabric from being "fixed" by adhesive points, thus preserving as much freedom as possible for the independent bending and sliding of each layer, thereby ensuring the softness and noise reduction of the composite fabric.
[0092] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.
Claims
1. A composite fabric, comprising, along its thickness direction, a surface knitted fabric layer, a film layer, and an inner knitted fabric layer, wherein the surface knitted fabric layer and the film layer, as well as the film layer and the inner knitted fabric layer, are bonded together by adhesives, characterized in that, The weight ratio of the inner knitted fabric layer to the outer knitted fabric layer is 0.20-0.50:1, and the weight of the inner knitted fabric layer is 15-70 g / m². 2 .
2. The composite fabric as described in claim 1, characterized in that, The thickness of the outer knitted fabric layer is 0.18-0.7 mm; And / or, the weight of the surface knitted fabric layer is 70-190 g / m². 2 ; And / or, the surface knitted fabric layer adopts a warp-knitted or weft-knitted structure.
3. The composite fabric as described in claim 1, characterized in that, The thickness of the inner knitted fabric layer is 0.02-0.25 mm; And / or, the tensile elastic recovery rate of the inner knitted fabric layer is 3%-12%; And / or, the inner knitted fabric layer adopts a warp-knitted or weft-knitted structure; And / or, the material of the inner knitted fabric layer is selected from fabrics with a chemical fiber content greater than or equal to 50 wt%.
4. The composite fabric as described in claim 1, characterized in that, The thickness of the film layer is 3-20 μm; And / or, the basis weight of the membrane is 3-12 g / m³. 2 ; And / or, the membrane layer is made of polyurethane; And / or, the outer knitted fabric layer and the film layer, as well as the film layer and the inner knitted fabric layer, are composited by discontinuous point-like hot melting.
5. The composite fabric as described in claim 1 or 4, characterized in that, The adhesive is selected from polyurethane hot melt adhesive.
6. The composite fabric as described in claim 5, characterized in that, The area of the adhesive region located between the surface knitted fabric layer and the film layer accounts for 15%-50% of the area of the film layer; And / or, the area of the adhesive region located between the film layer and the inner knitted fabric layer accounts for 15%-50% of the area of the film layer; And / or, the diameter of the adhesive dots is 0.05-0.5 mm.
7. The method for preparing the composite fabric according to any one of claims 1-6, characterized in that, The method for preparing the composite fabric includes the following steps: The outer knitted fabric layer, the film layer, and the inner knitted fabric layer are sequentially bonded together along the thickness direction using the adhesive, and then shaped to obtain the composite fabric.
8. The method for preparing the composite fabric as described in claim 7, characterized in that, The setting temperature is 70-80℃, and the setting time is 1-15 minutes.
9. A textile product, characterized in that, The textiles include composite fabrics as described in any one of claims 1-6 or composite fabrics prepared according to the method described in any one of claims 6-8.
10. The textile as claimed in claim 9, characterized in that, The textile is a down product, which includes the composite fabric and a filling material, including down fibers, that fills the composite fabric.