An ultra-lightweight functional fabric, a preparation method and application thereof

Abstract

This invention discloses an ultralightweight functional fabric, its preparation method, and its applications. The fabric has a three-layer composite structure, comprising, from the outside to the inside: an ultralightweight, high-tear-resistance outer layer, an ultra-high-permeability, non-porous hydrophilic membrane middle layer, and an ultrathin inner layer; the total weight of the fabric does not exceed 45 g / m². The ultralightweight, high-tear-resistance outer layer is woven from yarns with a fineness not exceeding 10D and a warp / weft fineness ratio not equal to 1; the ultra-high-permeability, non-porous hydrophilic membrane middle layer has a thickness of 4-7 μm and a weight of 4-7 g / m²; the ultrathin inner layer has a weight of not more than 11 g / m². During preparation, the three layers are sequentially laminated using a two-stage concave-convex dotted transfer roller lamination process. This invention, through the refined design of each layer and optimized lamination process, achieves a comprehensive performance of high water pressure resistance, high moisture permeability, and high tear resistance at an ultralight weight below 45 g / m², while also possessing a soft hand feel. It can be widely used in outdoor clothing such as jackets, windbreakers, windbreakers, raincoats, and sun-protective clothing.

Description

Technical Field

[0001] This invention belongs to the field of textile fabric technology, specifically relating to a three-layer composite functional fabric that combines ultralightness, high waterproofness, high moisture permeability and high tear resistance, as well as its preparation method and application. Background Technology

[0002] With the increasing popularity of outdoor sports, lightweight and high protection have become important development directions for outdoor clothing fabrics. Windproof, waterproof, and breathable are key indicators for evaluating the performance of outdoor clothing. Currently, the industry has various technical solutions attempting to balance the lightweight and functionality of fabrics.

[0003] Most windproof fabrics on the market are made of high-density coarse-denier fabrics, which contain high-shrinkage yarns, but their windproof, waterproof, and water-pressure resistance is often inferior to laminated or coated fabrics. Others use high-density fine-denier fabrics with coating or lamination processes, but these fabrics are often too heavy, and coated fabrics lack water pressure resistance. Lightweight three-layer laminated fabrics on the market are typically around 50g / m². 2 All of the above are stiff and extremely inconvenient to store. Even the lighter ones weigh over 50g and are on the stiffer side.

[0004] Therefore, how to achieve high performance indicators while maintaining an ultra-light weight of less than 45g / m² has become a technical challenge that urgently needs to be solved in this field. Summary of the Invention

[0005] Objective of the Invention: To address the shortcomings of existing technologies, this invention provides an ultralightweight functional fabric, its preparation method, and its applications. This fabric achieves ultralight weight (total weight not exceeding 45 g / m²) while also possessing excellent waterproof, breathable, and tear-resistant properties.

[0006] Technical solution: In the first aspect, the present invention discloses an ultralight functional fabric, wherein the fabric has a three-layer composite structure, comprising, from the outside to the inside: an ultralight and high tear-resistant outer layer, an ultra-high permeability non-porous hydrophilic membrane middle layer, and an ultrathin inner layer; the total weight of the fabric does not exceed 45g / m².

[0007] As an optimization: the ultra-lightweight and high tear-resistant surface layer is an ultra-fine denier woven fabric, and the thickness of its warp and weft yarns does not exceed 10D.

[0008] As an optimization: the ratio of the thickness of the warp yarn to the thickness of the weft yarn is not 1.

[0009] As an optimization: the intermediate layer of the ultra-high permeability, non-porous hydrophilic membrane is made of a specific polymer, whose main chain and side chains contain a large number of hydrophilic groups. Furthermore, these polymers are continuously and uniformly distributed, forming a film with a thickness of 4-7 μm and a basis weight of 4-7 g / m³. 2 .

[0010] As an optimization: the weight of the ultra-thin inner layer does not exceed 11 g / m², and the yarn thickness of the inner layer does not exceed 8D.

[0011] As an optimization: the ultra-thin inner layer is one of double-combed warp-knitted fabric, ultra-thin circular knitted fabric, or woven fabric.

[0012] Secondly, this invention discloses a method for preparing an ultralightweight functional fabric, comprising the following steps: Step 1, pre-treating the ultralightweight, high-tear-resistance surface layer, including: desizing, dyeing, drying, water-repellent treatment, baking, and calendering; Step 2, laminating an ultra-high permeability, non-porous hydrophilic membrane interlayer with the fabric, transferring hot melt adhesive to the membrane surface of the ultra-high permeability, non-porous hydrophilic membrane interlayer using a dotted transfer roller, then laminating the membrane and fabric together using a pressure roller, cooling and winding, and completing the cross-linking reaction of the membrane and fabric in a curing chamber to obtain a surface composite layer; Step 3, transferring hot melt adhesive to the membrane surface of the surface composite layer using a dotted transfer roller, laminating the adhesive-coated surface of the ultrathin inner layer and the surface composite layer together using a pressure roller, cooling and winding, and completing the cross-linking reaction of the membrane and lining in a curing chamber to obtain the ultralightweight functional fabric with the three-layer composite structure.

[0013] As an optimization: In steps two and three, the dot pattern of the raised dot transfer roller is diamond-shaped or round, the size of a single pattern is 0.3-0.6mm, the transfer temperature is 90-120℃, the pressure roller pressure is 0.25-0.5MPa, and the cooling temperature is 15-25℃.

[0014] As an optimization: the ultra-lightweight and high tear-resistant surface layer is woven on a loom with a precision electronic warp feed and an active yarn braking device. During weaving, a multi-nozzle segmented weft insertion process is adopted, with 8-12 auxiliary nozzles and a reed tooth density of 45-125 teeth / inch.

[0015] Thirdly, this invention discloses the application of an ultralight functional fabric in the preparation of outdoor clothing, and the resulting fabric can be made into jackets, windbreakers, windbreakers, raincoats or sun-protective clothing.

[0016] Beneficial effects: Compared with the prior art, the present invention has the following advantages: 1. Ultra-lightweight: This invention achieves ultra-lightweight by systematically designing the material, yarn fineness, and weight of each layer of the fabric. The total weight of the three-layer composite fabric is successfully controlled below 45g / m² (39g / m² in Example 1 and 35g / m² in Example 2), which is far lower than 62g / m² in Comparative Document 1 and 58g / m² in Comparative Document 2.

[0017] 2. High waterproof performance: The water pressure resistance of the fabric of this invention reaches JIS L 1092 B 21000mmH2O or more, which is more than 3 times that of comparative document 1 and more than 1.5 times that of comparative document 2, meeting the stringent requirements for waterproof performance in extreme outdoor environments.

[0018] 3. High moisture permeability: The moisture permeability of the fabric of this invention reaches more than 24000g / m²·24h according to JIS L 1099 B-1, which is more than 2.7 times that of comparative document 1 and more than 1.7 times that of comparative document 2, ensuring that sweat can be quickly discharged during strenuous exercise and keeping the wearer dry and comfortable.

[0019] 4. Excellent mechanical properties: The tear strength of the fabric of this invention reaches more than 8N, and it still maintains good tear resistance under the premise of ultra-lightweight, meeting the durability requirements of outdoor clothing.

[0020] 5. Soft feel: The three-layer ultra-thin structure of the fabric of this invention, combined with the dot-matrix transfer adhesive composite process, maximizes the soft feel of the fabric, overcomes the defect of stiffness in coated fabrics, and improves wearing comfort.

[0021] 6. Solving technical problems: The fabric of this invention achieves comprehensive performance of high water pressure resistance, high moisture permeability and high tear resistance in the ultra-lightweight range of less than 45g / m², solving the long-standing technical problem of the inability to achieve both lightweight and high performance in existing technologies. Detailed Implementation

[0022] The technical solutions in the embodiments of the present invention will be clearly and completely described below, so that those skilled in the art can better understand the advantages and features of the present invention, thereby making a clearer definition of the scope of protection of the present invention. The embodiments described in this invention are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0023] Example 1 A method for preparing an ultralightweight functional fabric includes the following steps: Step 1: Surface Preparation: 5D ultrafine denier nylon yarns are selected for both warp and weft, with a warp-to-weft yarn ratio of 1:1. The fabric is woven on a water-jet loom equipped with precision electronic warp feed and a positive yarn braking device. The weaving process employs multi-nozzle segmented weft insertion, with 10 auxiliary nozzles and a reed tooth density of 85 teeth / inch. After finishing, the greige fabric undergoes desizing, dyeing, and drying, followed by a water-repellent finishing process. It is then baked at 150℃ and finally calendered to obtain the surface fabric.

[0024] Step 2, Intermediate Membrane Preparation: Select an ultra-high permeability non-porous hydrophilic membrane intermediate layer with a thickness of 5μm and a basis weight of 5g / m² (made of polyurethane hydrophilic polymer).

[0025] Step 3, Inner layer preparation: Select an ultra-thin double-combed warp-knitted fabric with a weight of 9g / m² and a yarn fineness of 5D as the inner layer.

[0026] Step 4, First Lamination: Using a diamond-shaped dotted transfer roller (0.45mm per dot), hot melt adhesive is transferred to one side of the film at 110℃. The surface layer treated in Step 1 is then laminated to the adhesive-coated surface of the film under a pressure of 0.35MPa using a pressure roller, followed by cooling with a 20℃ cooling roller and winding. Subsequently, it is placed in a curing chamber at 40℃ for 48 hours to complete the crosslinking reaction, resulting in the surface film composite layer.

[0027] Step 5, Second Lamination: Using the same diamond-shaped dotted transfer roller (0.45mm per dot), transfer the hot melt adhesive to the surface of the outer film composite layer at 110℃. Lay the inner layer prepared in Step 3 onto the adhesive-coated surface of the film using a pressure roller under a pressure of 0.35MPa, then cool it with a 20℃ cooling roller and wind it up. Place it again in a curing chamber at 40℃ for 48 hours to obtain the final three-layer composite fabric.

[0028] The fabric prepared in Example 1 was subjected to performance tests, and the results are as follows: Total weight: 39 g / m²; Water pressure resistance (GB / T4744): 12000 mmH2O; Moisture permeability (GB / T 14272.2 Method B): 15000 g / m²·24h; Tear strength (GB / T3917.1): 9.5N in the warp and 9.0N in the weft.

[0029] Example 2 The process is basically the same as in Example 1, except that: 1. The outer layer uses 3D warp yarns and 7D ultra-fine denier nylon yarns, with a warp / weft thickness ratio of approximately 0.43; 2. The middle film is a hydrophilic film with a thickness of 4μm and a basis weight of 4g / m²; 3. The inner layer uses an ultra-thin circular knitted fabric with a basis weight of 7g / m² and a yarn thickness of 3D; 4. In the composite process, the transfer temperature is adjusted to 100℃ and the pressure roller pressure is adjusted to 0.4MPa.

[0030] The performance test results are as follows: Total weight: 35 g / m²; Water pressure resistance (JIS L 1092 B): 22000 mmH2O; Moisture permeability (JIS L 1099 B-1): 25000 g / m²·24h; Tear strength (GB / T 3917.1): 8.5N in the warp and 8.8N in the weft.

[0031] Comparative Example 1 A commercially available three-layer lightweight waterproof jacket fabric with a weight of 52 g / m² was selected as a comparative example and subjected to the same standard performance tests. The results showed that its water pressure resistance was 8000 mmH₂O (GB / T 4744), its moisture permeability was 8000 g / m²·24h (GB / T 14272.2 Method B), and its hand feel was noticeably stiffer.

[0032] In summary, the fabric of this invention achieves a combination of high water pressure resistance, high moisture permeability, and high tear resistance within the ultra-lightweight range of below 45g / m², solving the long-standing technical problem of the inability to achieve both lightweight and high performance in existing technologies.

[0033] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An ultralightweight functional fabric, characterized in that: The fabric has a three-layer composite structure, consisting of, from the outside to the inside: an ultra-lightweight and highly tear-resistant outer layer, an ultra-high permeability non-porous hydrophilic membrane middle layer, and an ultra-thin inner layer; the total weight of the fabric does not exceed 45g / m².

2. The ultralightweight functional fabric according to claim 1, characterized in that: The ultra-lightweight, high-tear-resistance surface layer is made of ultra-fine denier woven fabric, with the thickness of both the warp and weft yarns not exceeding 10D.

3. The ultralightweight functional fabric according to claim 2, characterized in that: The ratio of the thickness of the warp yarn to the thickness of the weft yarn is not 1.

4. The ultralightweight functional fabric according to claim 1, characterized in that: The ultra-high permeability, non-porous hydrophilic membrane interlayer is made of specific polymers, both of which contain a large number of hydrophilic groups on their main and side chains. These polymers are continuously and uniformly distributed, resulting in a 4-7 μm thick film with a basis weight of 4-7 g / m³. 2 .

5. The ultralightweight functional fabric according to claim 1, characterized in that: The weight of the ultra-thin inner layer does not exceed 11 g / m², and the yarn thickness of the inner layer does not exceed 8D.

6. The ultralightweight functional fabric according to claim 5, characterized in that: The ultra-thin inner layer is one of double-combed warp-knitted fabric, ultra-thin circular knitted fabric, or woven fabric.

7. A method for preparing an ultralightweight functional fabric as described in any one of claims 1-6, characterized in that: The process includes the following steps: Step 1: Pre-treatment of the ultra-lightweight, high-tear-resistance surface layer, including: desizing, dyeing, drying, water-repellent treatment, baking, and calendering; Step 2: The ultra-high transparency non-porous hydrophilic membrane interlayer is laminated with the fabric. Hot melt adhesive is transferred to the membrane surface of the ultra-high transparency non-porous hydrophilic membrane interlayer through a dotted transfer roller. The membrane and fabric are then laminated together by a pressure roller. After cooling and winding, the cross-linking reaction between the membrane and fabric is completed in a curing chamber to obtain the surface film composite layer. Step 3: Transfer hot melt adhesive to the film surface of the outer film composite layer using a dotted transfer roller. Then, bond the adhesive-coated surfaces of the ultra-thin inner layer and the outer film composite layer together using a pressure roller. After cooling and winding, the cross-linking reaction between the film and the inner material is completed in a curing chamber to obtain the ultra-lightweight functional fabric with the three-layer composite structure.

8. The preparation method according to claim 7, characterized in that: In steps two and three, the dot pattern of the raised dot transfer roller is diamond-shaped or round, with a single dot size of 0.3-0.6 mm, a transfer temperature of 90-120℃, a pressure roller pressure of 0.25-0.5 MPa, and a cooling temperature of 15-25℃.

9. The ultralightweight functional fabric according to claim 1, characterized in that: The ultra-lightweight, high-tear-resistance surface layer is woven on a loom with a precision electronic warp feed and an active yarn braking device. During weaving, a multi-nozzle segmented weft insertion process is used, with 8-12 auxiliary nozzles and a reed tooth density of 45-125 teeth / inch.

10. The application of the ultralightweight functional fabric according to any one of claims 1-6 in the preparation of outdoor clothing, characterized in that: The resulting fabric can be made into jackets, windbreakers, windbreakers, raincoats, or sun-protective clothing.