A moisture-conducting and ultraviolet-proof composite textile fabric and a production device thereof

Abstract

The present application relates to the technical field of textile fabric manufacturing, and discloses a moisture-conducting and ultraviolet-proof composite textile fabric and a production equipment thereof, which is composed of an inner loose fabric layer, an outer micro-ridge fabric layer and a heat-sensitive functional treatment agent. The micro-ridge structure of the outer layer is formed by differential weaving, and the treatment agent is discontinuously deposited on the windward side of the micro-ridge by directional spraying and geometric shading effect, and the leeward side remains a breathable area. During preparation, a double-temperature-zone composite process is adopted to establish a temperature gradient by upper heating and lower cooling, and a thermal rheological blocking mechanism is used to form interface physical anchoring points while preventing the adhesive from penetrating into the inner layer. Through asymmetric structure design and precise thermal rheological control, the present application realizes excellent ultraviolet-proof and waterproof functions, while taking into account the one-way moisture-conducting and breathable performance, and solves the problems of stuffiness and hard hand feeling of traditional coated fabrics. The fabric further improves the heat and moisture exchange efficiency and enhances the wearing comfort while ensuring the stability of long-term protection performance.

Description

Technical Field

[0001] This invention relates to the field of textile fabric manufacturing technology, and in particular to a moisture-wicking and UV-protective composite textile fabric and its production equipment. Background Technology

[0002] Currently, the outdoor sports market's expectations for fabric performance have transcended a single dimension. Moisture-wicking, quick-drying, UV protection, and lightweight breathability—these seemingly contradictory properties must coexist harmoniously within the same fabric. Traditional textile manufacturers have attempted to respond to these demands by adding auxiliaries in finishing processes or altering the fabric structure through physical weaving. While the rise of nanomaterials offers new ideas, achieving the synergistic coexistence of multiple functions at the microscopic scale remains a significant technological hurdle to overcome.

[0003] To address the challenges of multifunctional integration, current mainstream solutions mostly employ physical lamination or chemical modification. Layered composite processes use hot-melt adhesive mesh to bond membrane materials with distinct functions to a base fabric, leveraging the synergistic effect of multilayer structures to achieve functional complementarity. Chemical blending technology involves incorporating functional powders during the polymer melt spinning stage, extruding them to prepare functional fibers, and then weaving them. Some processes attempt a step-by-step approach, first weaving a substrate with differential capillary effects, and then using a spray device to evenly coat the outer surface of the fabric with a protective agent, attempting to balance structural moisture wicking and surface protection.

[0004] However, the above methods have significant shortcomings in actual effectiveness. Physical lamination often introduces a dense adhesive layer, which, while bonding the fabric, also cuts off the microchannels for moisture to escape, causing the feeling of stuffiness to increase dramatically with the intensity of exercise. Although blended spinning solves the bonding problem, the functional particles are deeply embedded in the fiber matrix, resulting in low surface enrichment and difficulty in fully releasing protective efficacy, and it is also prone to failure after repeated washing. Conventional surface spraying faces the challenge of fluid control, lacking precise constraints on droplet placement, and easily forming a dense, all-encompassing film, leading to pore blockage and a significant sacrifice in breathability. Traditional hot pressing processes are limited by a uniform thermal field, making it difficult to precisely control the rheological behavior of the adhesive. At high temperatures, the viscosity of the adhesive drops sharply, making it prone to excessive penetration into the inner layers driven by capillary forces. This irreversible intrusion not only destroys the hydrophilic moisture-wicking network of the inner layers but also causes the fabric to feel stiff and rigid, rendering the moisture-wicking gradient structure ineffective, ultimately failing to meet the comfort requirements under high-intensity exercise. Summary of the Invention

[0005] The purpose of this invention is to provide a moisture-wicking and UV-protective composite textile fabric and its production equipment, which solves the problems of poor breathability and moisture wicking caused by the full-coverage coating of traditional composite fabrics, as well as the problem of stiffness and functional failure caused by the hot-pressing penetration of adhesive into the inner layer structure.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] In a first aspect, the present invention provides a moisture-wicking and UV-protective composite textile fabric, which comprises an inner fabric layer, an outer fabric layer, and a heat-sensitive functional treatment agent located between the inner and outer fabric layers; the inner fabric layer has a loose structure formed by low-tension weaving; the outer fabric layer has a micro-ridge structure formed by high-tension weaving, the micro-ridge structure having a geometric height difference; the heat-sensitive functional treatment agent is deposited in a discontinuous form on the windward side of the micro-ridge structure, and the leeward side of the micro-ridge structure retains an uncovered breathable area; the interface between the inner and outer fabric layers has physical anchoring points formed by the melting and cooling of the heat-sensitive functional treatment agent, and microporous channels formed by die pressing.

[0008] By employing the above technical solution, an integrated functional structure combining moisture absorption, unidirectional transmission, and protection was constructed. The loose structure of the inner fabric layer utilizes capillary pressure difference to rapidly capture liquid sweat from the skin surface. The microridge structure of the outer fabric layer, combined with directionally deposited functional agents, provides protection functions such as UV protection, water resistance, and abrasion resistance, while utilizing the uncovered area on the leeward side to create a direct heat and moisture exchange channel to the outside, solving the problem of poor breathability in traditional coated fabrics. The physical anchoring points at the interface ensure the structural stability of the composite fabric, while the molded microporous channels further reduce the resistance to the outward transmission of liquid water.

[0009] Preferably, the heat-sensitive functional treatment agent is prepared from raw materials comprising a main resin, a functional modifier, and a dispersion medium; the main resin is selected from at least one of low-melting-point thermoplastic polyurethane powder, copolyamide hot melt adhesive powder, or ethylene-vinyl acetate copolymer powder; the functional modifier is selected from one of water-based fluorinated acrylate emulsion, nano-silica dispersion, or benzophenone-based UV-resistant additives. More preferably, the raw material ratio is: 60-65 parts of main resin; 15-30 parts of functional modifier; 100 parts of dispersion medium; and the melting point of the heat-sensitive functional treatment agent is 65℃-80℃.

[0010] By adopting the above technical solution, the selected main resin and modifier system not only endows the coating with specific functions such as hydrophobicity, wear resistance, or UV resistance, but its specific melting point range (65.3℃-78.0℃) also forms a precise thermodynamic match with the subsequent dual-temperature zone composite process. This melting point range ensures thermal stability under normal operating conditions while allowing for abrupt changes in state during the composite process using a relatively low temperature difference, which is the material basis for realizing the thermorheological blocking mechanism.

[0011] Secondly, the present invention provides a method for preparing a moisture-wicking and UV-protective composite textile fabric, comprising the following steps:

[0012] S1. Differentiated weaving: Applying periodically fluctuating low tension to the inner warp yarns and constant high tension to the outer warp yarns to weave a substrate with a loose inner structure and a micro-ridged outer structure.

[0013] S2, Directional Functional Finishing: The heat-sensitive functional treatment agent is atomized and sprayed onto the surface of the outer fabric layer at an angle to the normal of the fabric, so that the heat-sensitive functional treatment agent is deposited on the windward side of the micro-ridge structure;

[0014] S3, Dual-temperature zone lamination: The treated fabric is fed into a dual-temperature zone hot press device for lamination. The temperature of the upper hot press plate is controlled to be higher than the melting point of the heat-sensitive functional agent, and the temperature of the lower hot press plate is controlled to be lower than the melting point of the heat-sensitive functional agent. The fabric is then held in place under pressure to maintain its shape.

[0015] By adopting the above technical solution, this invention utilizes the synergistic effect of physical weaving structure and thermorheological control technology to achieve precise construction of functional layers and controllable composite of interfaces:

[0016] In step S1, by establishing a tension gradient between the inner and outer warp yarns, the buckling modulus and interlacing pattern of the yarns during the weaving process are altered. The high-tension outer warp yarns are under taut force, forcing the weft yarns to generate a larger buckling height, thereby forming a micro-ridge structure with a significant geometric height difference on the outer surface. This micro-ridge structure not only enhances the mechanical abrasion resistance of the outer layer but also provides the necessary geometric carrier for subsequent directional finishing.

[0017] In step S2, the geometric shielding effect from fluid dynamics is utilized. When the atomized treatment agent droplets are incident at a specific tilt angle, the microridge structure acts as a physical barrier. The droplets mainly impact and adhere to the windward side and top of the microridge, while the grooved area on the leeward side of the microridge is in the geometric shadow zone of the jet, making it difficult for droplets to reach. This selective deposition mechanism constructs a discontinuous structure at the microscale, with alternating functional coverage and breathable retention areas. While imparting protective properties to the fabric (such as UV protection and water resistance), it completely preserves the original breathable pores of the substrate, avoiding the stuffiness caused by full-coverage coatings.

[0018] In step S3, a thermal rheological blocking mechanism based on temperature gradient is established. The high-temperature field (T>Tm) of the upper hot platen provides heat enthalpy, causing the solid-state treatment agent on the surface of the micro-ridges to quickly undergo a phase change, transform into a low-viscosity melt, and wet the fiber surface under pressure to form a firm interfacial bond. At the same time, the low-temperature field (T<Tm) of the lower hot platen acts as a cold source, quickly removing the heat transferred into the fabric interior. When the molten treatment agent front attempts to penetrate into the inner layer, encountering the low-temperature field will cause its temperature to quickly drop below the melting point, and the viscosity will increase exponentially and solidify. This sudden change in rheological state constructs a physical defense line, effectively blocking the capillary penetration of the adhesive into the loose inner-layer structure, thereby ensuring the cleanliness and smoothness of the inner hydrophilic moisture-absorbing network and achieving the compatibility of high-strength bonding and unidirectional moisture-conducting functions.

[0019] Preferably, before step S2, it further includes the step of preparing a thermosensitive functional treatment agent: adding a main resin and a functional modifier into a dispersion medium, and stirring and dispersing for 1 h - 2 h at a rotation speed of 1200 rpm - 2000 rpm.

[0020] By adopting the above technical solution, the high-shear dispersion process ensures the uniform suspension of the main resin powder and the functional modifier in the solvent, prevents agglomeration, and ensures the uniformity of the droplet size during atomization, thereby improving the accuracy of directional deposition.

[0021] Preferably, in step S1, the tension of the inner warp yarns is set to 2.3 - 2.7 N; the tension range of the outer warp yarns is 4.0 N - 6.0 N, and the height difference range of the micro-ridge structure is 20 μm - 60 μm. In step S2, the inclination angle range is 20° - 45°; the atomization particle size of the thermosensitive functional treatment agent is controlled between 10 μm - 25 μm, and the atomization particle size is smaller than the height difference of the micro-ridge structure. In step S2, the spraying direction is perpendicular to the trend of the micro-ridge structure.

[0022] By adopting the above technical solution, the precisely defined process parameter window (tension, height difference, spraying angle, and particle size) realizes the matching of the micro-geometric structure. Controlling the atomization particle size below the micro-ridge height difference and配合特定的入射角度,能够最大化几何遮蔽效应,确保背风面透气区域的面积占比,优化面料的透气透湿性能。

[0023] Preferably, in step S3, the temperature of the upper hot platen is set within the range of 75°C - 90°C, the temperature of the lower hot platen is set within the range of 50°C - 65°C, and the compound pressure is set within the range of 0.20 MPa - 0.50 MPa.

[0024] By adopting the above technical solution, the temperature and pressure range is optimally matched with the melting characteristics of the treatment agent (65.3℃-78.0℃), which ensures the full melting and film formation of the upper functional agent and the timely blocking effect of the lower layer, avoiding damage to the fiber strength of the substrate due to excessively high temperature.

[0025] Thirdly, the present invention provides a production equipment for moisture-wicking and UV-resistant composite textile fabrics. This equipment includes a central control unit and a differentiated weaving control system, an asymmetric orientation finishing system, and a dual-temperature zone microstructure composite control system connected to the central control unit. The differentiated weaving control system includes a sensing and monitoring module for collecting yarn tension and a dynamic execution module for adjusting the yarn feeding speed. The central control unit is configured to control the dynamic execution module to maintain constant high tension in the outer warp yarns and fluctuating low tension in the inner warp yarns. The asymmetric orientation finishing system includes a speed sensing module for monitoring the micro-ridge phase of the fabric, a posture adjustment module for adjusting the spray angle, and a micro-atomization generation module. The central control unit is configured to control the spray frequency based on speed feedback to achieve unilateral deposition. The dual-temperature zone microstructure composite control system includes an independent thermal field management module and a pressure and micro-forming module. The independent thermal field management module has two independent temperature control loops that set the upper and lower thermal field temperatures respectively. The pressure and micro-forming module is equipped with a mold with a micro-protrusion structure.

[0026] By adopting the above technical solutions, the production equipment achieves the industrial implementation of the complex process through modular integration and digital closed-loop control. The differentiated weaving control system ensures the consistency and stability of the micro-ridge structure through real-time tension feedback and dynamic adjustment. The asymmetric directional functional finishing system ensures the precise placement of functional agents on the windward side of the micro-ridge through phase monitoring and attitude adjustment. The dual-temperature zone microstructure composite control system constructs a stable vertical temperature gradient field through independent dual-loop temperature control, providing hardware support for the realization of the thermorheological blocking mechanism. The overall system achieves full-process coordination from microstructure construction to functional composite, improving production efficiency and product quality stability.

[0027] In summary, the present invention has at least one of the following beneficial technical effects:

[0028] 1. This invention constructs an asymmetric substrate structure with a loose inner core and micro-ridges on the outer core, and combines it with directional functional finishing technology. Utilizing the geometric shielding effect generated by the micro-ridges, the heat-sensitive functional treatment agent is deposited only on the windward side, while the leeward side retains a breathable area directly exposed to the outside. This discontinuous distribution pattern endows the fabric with excellent UV protection and water resistance while effectively avoiding the clogging of capillary pores caused by traditional full-coverage coatings, achieving a perfect balance between protective function and breathability.

[0029] 2. This invention utilizes the thermorheological blocking mechanism in a dual-temperature zone composite process. By establishing a temperature gradient field perpendicular to the fabric thickness direction, the melting and solidification behavior of the treatment agent is precisely controlled. The high temperature in the upper layer causes the treatment agent to melt and form physical anchoring points, ensuring strong interlayer bonding; the low temperature in the lower layer rapidly removes heat, forcing the melt viscosity at the penetration front to rise sharply and freeze, effectively blocking the capillary penetration of the adhesive into the inner layer, thus completely preserving the hydrophilic moisture-absorbing network and soft hand feel of the inner fabric.

[0030] 3. The microridge structure used in this invention not only serves as a geometric carrier for the deposition of functional agents but also acts as a physical barrier. In practical use, the raised microridge structure can withstand the main mechanical friction, protecting the functional layers deposited on the sides of the microridges and the edges of the grooves from direct wear. Combined with the microporous channels formed by mold pressing, this fabric ensures long-term protective performance stability while further improving the efficiency of moisture and heat exchange and enhancing wearing comfort. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of the composite textile fabric of the present invention;

[0032] Figure 2 This is a system framework diagram of the production equipment of the present invention.

[0033] Among them, 1. Inner fabric layer; 2. Outer fabric layer; 3. Heat-sensitive functional treatment agent; 4. Loose structure; 5. Microridge structure; 6. Windward side; 7. Leeward side; 8. Microporous channels. Detailed Implementation

[0034] See attached document Figure 1 This invention discloses a moisture-wicking and UV-protective composite textile fabric, comprising an inner fabric layer 1, an outer fabric layer 2, and a heat-sensitive functional treatment agent 3 located between the inner and outer fabric layers 1 and 2. The inner fabric layer 1, due to the use of low-tension weaving during its preparation, exhibits a relatively loose structure 4 with fluffy fiber arrangement. The outer fabric layer 2, due to the use of constant high-tension weaving during its preparation, exhibits a tightly arranged fiber structure with a periodically undulating micro-ridge structure 5, wherein there is a geometric height difference of approximately 40 μm between the crests and troughs of this micro-ridge structure 5.

[0035] The heat-sensitive functional treatment agent 3 is constrained by the directional spraying process with a 30° angle and vertical direction. It is deposited in a discontinuous form only on the windward side 6 of the undulating features of the micro-ridge structure 5, while the leeward side 7 of the micro-ridge structure 5 remains clean and retains a breathable area that is not covered by the treatment agent.

[0036] At the interface between the inner fabric layer 1 and the outer fabric layer 2, there are physical anchoring points formed by the melting, pressure and cooling solidification of the heat-sensitive functional treatment agent 3 during the dual-temperature zone hot pressing process (these anchoring points are mainly located in the outer layer and near the interface, and do not penetrate deeply into the loose structure of the inner layer), and microporous channels 8 that penetrate the interface formed by mechanical pressing of the mold under a pressure of 0.35 MPa.

[0037] Preparation Examples 1-3:

[0038] Preparation Example 1:

[0039] It is mainly used to prepare a heat-sensitive functional processing agent, for the preferred embodiment. The specific preparation process is as follows:

[0040] First, accurately weigh 60 parts by weight of low-melting-point thermoplastic polyurethane (TPU) powder as the main resin, with a particle size distribution controlled at 5-10 μm and a nominal softening point of 70-72℃. At the same time, weigh 30 parts by weight of waterborne fluorinated acrylate emulsion with a solid content of 30% as a functional modifier to impart hydrophobic and oleophobic properties to the coating, and weigh 100 parts by weight of a mixed solvent prepared from deionized water and isopropanol in a volume ratio of 8:2 as the dispersion medium.

[0041] Next, the mixed solvent was added to a high-speed dispersion vessel with a temperature control jacket. Aqueous fluorinated acrylate emulsion and thermoplastic polyurethane powder were added sequentially under low-speed stirring. Then the speed of the dispersion vessel was increased to 1500 rpm and stirred continuously at a constant temperature of 40°C for 2 hours until the solid powder was completely and uniformly dispersed, thus obtaining a stable emulsion-like treatment agent.

[0042] Finally, a small amount of the prepared emulsion was cast onto a glass plate to form a film and dried. The thermal properties were tested using a differential scanning calorimeter (DSC) at a heating rate of 10℃ / min. The results showed that the melting endothermic peak temperature (i.e., melting point Tm) of the treatment agent was approximately 71.5℃.

[0043] Preparation Example 2:

[0044] It is mainly used to prepare a heat-sensitive functional treatment agent with a high melting point for implementation schemes requiring high heat resistance or high strength. The specific preparation process is as follows:

[0045] First, weigh 60 parts by weight of copolyamide (PA) hot melt adhesive powder as the main resin, with a nominal melting point range of 78-80℃. At the same time, weigh 20 parts by weight of nano silica dispersion to enhance the wear resistance and micro-roughness of the coating, and 100 parts by weight of a mixed solvent of ethanol and water as the dispersion medium.

[0046] Next, the dispersion medium was placed in an ultrasonic dispersion container. First, nano-silica dispersion was added and ultrasonically vibrated to prevent agglomeration. Then, copolyamide hot melt adhesive powder was added. The mixture was transferred to a mechanical mixer and stirred and dispersed at 1200 rpm for 90 minutes to obtain a uniform suspension.

[0047] Finally, differential scanning calorimetry was performed according to the same standards as in Preparation Example 1. The test results showed that the peak temperature of the melting endothermic peak (i.e., the melting point Tm) of the treatment agent was approximately 80°C.

[0048] Preparation Example 3:

[0049] It is mainly used to prepare a heat-sensitive functional treatment agent with a low melting point, for use in heat-sensitive fabrics or low-temperature energy-saving implementation schemes. The specific preparation process is as follows:

[0050] First, weigh 65 parts by weight of ethylene-vinyl acetate copolymer (EVA) powder as the main resin, and select a grade with high vinyl acetate content to ensure a low melting point. At the same time, weigh 15 parts by weight of benzophenone-based UV-resistant additives that have been micron-level ground to improve the fabric's aging resistance, and 100 parts by weight of deionized water containing a small amount of wetting agent.

[0051] Next, the ethylene-vinyl acetate copolymer powder and the UV-resistant additive were added to deionized water and subjected to high-shear emulsification dispersion at room temperature. The rotation speed was set to 2000 rpm and the duration was 1 hour to obtain a stable dispersion.

[0052] Finally, differential scanning calorimetry was performed according to the same standards as in Preparation Example 1. The test results showed that the peak temperature of the melting endothermic peak (i.e., the melting point Tm) of the treatment agent was approximately 65°C.

[0053] Examples 1-3:

[0054] Example 1:

[0055] This embodiment provides a method for preparing a moisture-wicking and UV-protective composite textile fabric. The preferred process parameters of this invention are used for preparation, and the specific process is as follows: First, a differentiated weaving process is carried out. The warp tension is independently controlled by a differentiated weaving control system. The inner layer warp is controlled in a periodic fluctuation low tension mode, with the tension set at about 2.5N and accompanied by slight fluctuations, so that the inner layer forms a relatively loose moisture-absorbing structure. The outer layer warp is controlled in a constant high tension mode, with the tension set at 5.0N, forcing the outer layer surface to form a micro-ridge structure with a specific height difference (about 40μm).

[0056] Subsequently, a directional functional finishing process was carried out. The intermediate melting point treatment agent (Tm≈71.5℃) obtained in Preparation Example 1 was selected. The nozzle angle of the asymmetric directional functional finishing system was adjusted so that its spray axis was at a 30° angle with the normal of the fabric and the spray direction was perpendicular to the direction of the micro ridge. At the same time, the atomized particle size was controlled to be about 18μm, so that it was smaller than the height difference of the micro ridge. Under these conditions, the treatment agent droplets were mainly deposited on the windward side of the micro ridge, while the leeward side remained clean.

[0057] Finally, a dual-temperature zone lamination process is performed. Based on the melting point characteristics of the treatment agent, the temperature of the upper hot platen is set to 82℃ (higher than the melting point of the treatment agent), and the temperature of the lower hot platen is set to 60℃ (lower than the melting point of the treatment agent). The pressure is maintained at 0.35MPa for 90s. During the lamination process, the high-temperature thermal field of the upper layer causes the coating to melt rapidly into a film and generate adhesive force, while the low-temperature thermal field of the lower layer effectively blocks the liquid coating from penetrating into the inner layer. At the same time, the lower mold is used to press micropores at the interface, ultimately producing a composite fabric with both high-strength adhesion and one-way moisture-wicking function.

[0058] Example 2:

[0059] This embodiment provides a method for preparing a moisture-wicking and UV-protective composite textile fabric, suitable for scenarios with higher requirements for abrasion resistance and bonding strength. The specific process is as follows: First, in the weaving stage, the tension of the outer layer warp yarns is increased to 6.0N, thereby forming a more pronounced micro-ridge structure with a larger height difference (approximately 60μm) on the outer layer surface; then, in the finishing stage, the high-melting-point treatment agent (Tm≈78.0℃) obtained in Preparation Example 2 is selected. To match the higher micro-ridge structure, the spray angle is increased to 45°, and the atomized particle size is correspondingly increased to 25μm to ensure that the coating can effectively cover the windward side; finally, in the composite stage, to match the high melting point of the treatment agent, the temperature setting of the dual-temperature zone is correspondingly increased. The temperature of the upper hot platen is set to 90℃ to ensure sufficient melting, and the temperature of the lower hot platen is set to 65℃ to maintain the condensation blocking effect. The composite is completed under a relatively high pressure of 0.50MPa, resulting in a composite fabric with a dense structure and excellent strength.

[0060] Example 3:

[0061] This embodiment provides a method for preparing a moisture-wicking and UV-protective composite textile fabric, suitable for the preparation of lightweight or heat-sensitive fabrics. The specific process is as follows: First, in the weaving stage, the tension of the outer warp yarn is reduced to 4.0N, resulting in a relatively shallow micro-ridge structure (height difference of about 20μm). Next, in the finishing stage, the low-melting-point treatment agent (Tm≈65.3℃) obtained in Preparation Example 3 is selected. Given the low height of the micro-ridges, in order to prevent the coating from crossing the micro-ridges and causing contamination, the spraying angle is reduced to 20°, and the atomized particle size is precisely controlled to about 10μm. Finally, in the composite stage, based on the low melting point characteristics of the treatment agent, the temperature settings of the dual-temperature zones are correspondingly reduced. The temperature of the upper hot platen is set to 75℃, and the temperature of the lower hot platen is set to 50℃. The composite is completed under a gentle pressure of 0.20MPa, ensuring effective bonding while minimizing heat consumption and thermal damage to the fabric fibers.

[0062] Comparative Examples 1-4:

[0063] Comparative Example 1:

[0064] Compared to Example 1, the differences are as follows: a traditional padding process is used instead of the second step of directional finishing, allowing the treatment agent to fully impregnate the fabric; and a conventional uniform-temperature hot-pressing process is used instead of the third step of dual-temperature zone lamination, with both the upper and lower hot-pressing plates set at 85°C. All other raw materials and process parameters remain the same.

[0065] Comparative Example 2:

[0066] Compared to Example 1, the difference lies in that, during the third step of dual-temperature zone lamination, the temperature of the lower hot press plate is set to 82°C, meaning the temperatures of both the upper and lower hot press plates are the same and both higher than the melting point of the treatment agent (71.5°C), thus eliminating the low-temperature blocking mechanism. All other raw materials and process parameters remain the same.

[0067] Comparative Example 3:

[0068] Compared to Example 1, the difference lies in the fact that the treatment agent used in the second step was changed to a polyester-based high-temperature resistant hot melt adhesive with a melting point of 110°C, resulting in the upper hot press plate temperature (82°C) being lower than the melting point of the treatment agent. All other raw materials and process parameters remain the same.

[0069] Comparative Example 4:

[0070] Compared to Example 1, the difference lies in that: during the first weaving step, the outer warp yarns are not subjected to high tension, and the same low-tension weaving as the inner layer is used, thus preventing the formation of a micro-ridge structure with a significant height difference on the outer surface. All other raw materials and process parameters remain the same.

[0071] Test Examples 1-4:

[0072] Test Example 1: Feasibility Verification of Basic Processes

[0073] Test instructions:

[0074] Fabrics prepared in Examples 1, 2, and 3 were selected as test subjects. All samples were conditioned for 24 hours in a standard atmospheric environment with a temperature of 20±2℃ and a relative humidity of 65±4% before testing to eliminate the influence of differences in moisture regain on the test results.

[0075] Thickness testing: Performed according to ISO 5084 "Textiles — Determination of thickness of textiles and textile products". A digital fabric thickness gauge, 2000 mm, was used. 2 A circular pressure foot was used to apply a pressure of 1 kPa. Five points were measured at different locations on the sample, and the arithmetic mean was taken.

[0076] Tensile strength test: Performed according to ISO 13934-1 "Tensive strength test of fabrics". Prepare a warp specimen with a width of 50 mm, set the tensile speed to 100 mm / min, and the clamp spacing to 200 mm. Measure the maximum force at which the specimen breaks.

[0077] Abrasion resistance test: Performed according to ISO 12947-2 "Textiles—Determination of abrasion resistance of fabrics by the Martindale process—Part 2: Determination of specimen breakage". The friction load was set at 9 kPa, and the test ended when two or more yarns on the specimen broke. The number of abrasion cycles was recorded.

[0078] The test results for the basic physical performance of each embodiment are shown in Table 1.

[0079] Table 1. Basic physical properties of fabrics under different process parameters

[0080] Sample number Fabric thickness (mm) Meridional fracture strength (N) Abrasion resistance (times) Example 1 0.672 843.5 46,200 Example 2 0.814 935.2 59,150 Example 3 0.543 708.9 33,400

[0081] Results Analysis: The data in Table 1 show that the three composite fabrics prepared by this invention meet the requirements for outdoor functional clothing in terms of thickness, mechanical strength and abrasion resistance (usually requiring warp strength >600N and abrasion resistance >20,000 cycles).

[0082] The data dispersion reflects the specific regulatory effect of process parameters on the performance of the finished product: Example 2 used a higher outer warp tension (6.0N) and a polyamide treatment agent containing nano-silica, resulting in a denser microridge structure and higher hardness of the treatment agent. Therefore, the breaking strength and abrasion resistance were the highest among the three groups. Example 3 used a lower tension parameter (4.0N) and a softer ethylene-vinyl acetate copolymer treatment agent, resulting in a reduction in the overall fabric thickness and a corresponding decrease in strength and abrasion resistance, but still within the acceptable range, and is more suitable for lightweight applications.

[0083] Comprehensive analysis shows that the asymmetric tension structure (loose inner layer / dense outer layer) constructed by the differentiated weaving control system does not compromise the overall mechanical stability of the fabric. The dual-temperature zone microstructure composite control system, through precise thermorheological management, achieves functional layer composite while avoiding damage to the strength of the substrate fibers due to excessively high temperatures. These results confirm the stable industrial production feasibility of this invention within a wide range of process parameter windows (e.g., tension 4.0N-6.0N, temperature 75℃-90℃).

[0084] Test Example 2: Verification of Moisture-wicking and Anti-fouling Performance

[0085] The fabrics prepared in Example 1, Comparative Example 1, and Comparative Example 2 were selected as test subjects. All samples underwent standard atmospheric conditioning treatment.

[0086] Inner layer contact angle test: This was performed using an optical contact angle meter. The sample was laid flat on the sample stage with the inner layer (skin-contact side) facing upwards. The seated drop method was used, with a drop volume of 5 μL of deionized water. A high-speed camera captured an image 1 second after the droplet contacted the sample surface, and the contact angle was calculated using ellipse fitting. If the droplet completely spreads or penetrates within 1 second, it was recorded as 0°. Five different locations were tested for each sample group.

[0087] Liquid Moisture Transport Index (OMMC) Test: Performed according to AATCC™ 195, "Test of Liquid Moisture Management Performance". Using a Liquid Moisture Management Tester (MMT), the sample is placed between upper and lower concentric sensors, with the inner layer facing upwards. Simulated sweat (sodium chloride solution with a conductivity of 16 mS / cm) is dripped into the center of the inner layer of the sample. The moisture content change on both sides of the sample is continuously monitored over 120 seconds. The instrument automatically calculates the OMMC value (range 0-1, higher values ​​indicate better overall unidirectional moisture transport performance) based on the inner layer immersion time, unidirectional transport capacity, and spreading speed.

[0088] The test results of the inner surface wettability and moisture-wicking properties of each group of samples are shown in Table 2.

[0089] Table 2. Test data on wettability and moisture-wicking properties of the inner layer of the fabric

[0090] Sample number Inner water contact angle (°) Liquid Moisture Transport Index (OMMC) Penetration status notes Example 1 0 (Spreads out instantly) 0.842 The inner layer is dry and free of coating spots. Comparative Example 1 114.7 0.085 The inner layer is hydrophobic, causing severe clogging. Comparative Example 2 86.3 0.321 The inner layer has obvious glue spots, indicating severe penetration.

[0091] Results analysis: The data in Table 2 reveal the decisive impact of different process routes on the fabric's liquid management capability.

[0092] The inner contact angle of Example 1 is 0°, and the OMMC value is as high as 0.842, indicating that water can be quickly captured by the fiber network after contacting the inner layer and unidirectionally transmitted to the outer layer. This confirms the synergistic effect of the asymmetric directional functional finishing system and the double-temperature zone composite process: the treatment agent is only deposited on the windward side of the outer micro-ridges, and during the composite process, the low-temperature field (60 °C < Tm 71.5 °C) of the lower hot pressing plate forces the polymer resin at the contact interface to quickly undergo a phase change, changing from the molten state to a high-viscosity solid or semi-solid state. This rheological blocking effect effectively restrains the penetration of the resin into the inner capillary channels under the drive of pressure, retaining the hydrophilic channels of the inner woven structure.

[0093] In Comparative Example 1, integral padding was used, and the treatment agent uniformly coated the inner and outer layer fibers, resulting in an inner contact angle as high as 114.7°, serious hydrophobicity, a low OMMC value, and complete loss of the moisture absorption and sweat discharge function.

[0094] Although directional spraying was used in Comparative Example 2, the contact angle data (86.3°) and the low OMMC value (0.321) indicate that its inner layer was significantly contaminated. This is because the low-temperature blocking mechanism (lower plate 82 °C > Tm) was cancelled during hot pressing composite, and the treatment agent always remained in a low-viscosity molten fluid state in the thickness direction. Under the action of mechanical pressure, the melt underwent Darcy flow penetration, passed through the fabric pores to reach the inner layer, and blocked the hydrophilic capillaries of the inner layer after cooling, resulting in the failure of unidirectional moisture conduction.

[0095] In summary, the temperature gradient setting in the double-temperature zone micro-structure composite control system is a necessary technical feature to prevent the penetration of the functional layer and maintain the hydrophilic moisture conduction function of the inner layer.

[0096] Test Example 3: Verification of air permeability

[0097] Test description: The fabrics prepared in Example 1 and Comparative Example 4 were selected as the test objects. The specimens were balanced for 24 hours under standard atmospheric conditions before testing.

[0098] Air permeability test: It was carried out in accordance with the standard of ISO9237 "Textiles - Determination of the air permeability of fabrics". A fully automatic air permeability meter was used, with a test area of 20 cm 2 set, and the pressure drop was set to 100 Pa. The specimen was flatly clamped on the test head, the suction fan was started, and the air flow rate (mm / s) vertically passing through the specimen was recorded after the air flow was stable. 10 test points were randomly selected for each specimen for measurement, and the single-point data was recorded to observe the uniformity.

[0099] The measured air permeability data of each group of specimens are shown in Table 3.

[0100] Table 3. Record table of fabric air permeability test data

[0101] Sample number Test point 1 (mm / s) Test point 2 (mm / s) Test point 3 (mm / s) Test point 4 (mm / s) Test point 5 (mm / s) Average air permeability (mm / s) Coefficient of variation (CV%) Example 1 127.4 119.8 132.5 121.3 125.6 125.3 3.82 Comparative Example 4 68.2 61.5 64.9 59.8 63.4 63.6 4.95

[0102] Results analysis: Table 3 shows that the average air permeability of Example 1 is about twice that of Comparative Example 4, and both used the exact same spraying parameters (angle 30°, flow rate and type of treatment agent).

[0103] The data discrepancies directly validated the physical synergy mechanism between the differentiated weaving control system and the asymmetric directional functional finishing system: In Example 1, a micro-ridge structure with a height difference of approximately 40 μm was constructed on the outer layer through high-tension weaving. When functional agent droplets were incident at a 30° angle, the geometry of the micro-ridges produced a significant physical shadowing effect. The droplets were mainly trapped on the windward side and top of the micro-ridges, while the grooved areas on the leeward side of the micro-ridges were not covered by the coating, preserving the original fabric pores. These unblocked areas constituted a high-density microscopic air-permeable channel, thus maintaining an overall air permeability at a high level (>120 mm / s).

[0104] Comparative Example 4, due to the absence of high tension, exhibited a smooth outer surface (height difference < 5 μm). In the absence of microridges to block the flow, despite the use of inclined spraying, droplets wetted and spread upon contact with the surface, tending to connect and form continuous or quasi-continuous film structures. This large-area film-forming behavior sealed off most of the pores between the yarns, resulting in a significant increase in airflow resistance and a decrease in air permeability (-63 mm / s).

[0105] The conclusion shows that relying solely on directional spraying technology is insufficient to achieve high breathability. It is necessary to combine it with a micro-ridge substrate with specific geometric height differences and utilize the principle of geometric shielding to construct a discontinuous functional layer in order to effectively resolve the contradiction between waterproofing (coating coverage) and breathability (pore retention).

[0106] Test Example 4: Verification of Interfacial Adhesion Performance

[0107] Test description: The fabrics prepared in Example 1 and Comparative Example 3 were selected as test subjects.

[0108] Interlayer peel strength test: Performed according to ISO 2411 "Determination of adhesion strength of coatings on rubber or plastic coated fabrics". The prepared composite fabric was cut into strips with a warp length of 200 mm and a weft width of 50 mm. Since this invention uses discontinuous point-like composites, the ends of the samples (50 mm) needed to be manually pre-peeled before testing. The pre-peeled ends were clamped in the upper and lower fixtures of an electronic fabric strength tester, and a tensile speed of 100 mm / min was set for a 180° peel test. The instrument automatically recorded the force fluctuations during the peeling process, taking the average force within the effective stroke as the peel strength, and observing the damage morphology of the peeled surface. Five samples were prepared for each group for testing.

[0109] The interfacial adhesion mechanical data and failure modes of each group of samples are recorded in Table 4.

[0110] Table 4. Test data on interlayer peel strength and failure mode of fabrics, unit (N / 50mm)

[0111] Sample number Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Average peel strength Interface destruction patterns Example 1 16.4 15.8 17.2 16.1 15.5 16.2 Cohesive failure of the adhesive layer or fiber breakage (good adhesion) Comparative Example 3 1.2 0.8 1.5 0.9 1.1 1.1 The interface is completely delaminated (adhesion failure).

[0112] Results Analysis: The data and failure modes in Table 4 intuitively reflect the decisive role of thermodynamic matching in composite quality.

[0113] The average peel strength of Example 1 reached 16.2 N / 50 mm, and the peel interface mostly showed cohesive failure of the adhesive layer itself or breakage of the substrate fibers. This indicates that during the dual-temperature zone microstructure composite process, the heat energy (82°C) provided by the upper hot press successfully overcame the thermodynamic phase transition barrier (Tm≈71.5°C) of the treatment agent. After absorbing heat, the treatment agent underwent a solid-liquid phase transition, changing from a highly elastic state to a viscous flow state, fully wetting the fiber bundles on the surface of the outer microridge, and forming effective mechanical interlocking under pressure.

[0114] The peel strength of Comparative Example 3 was only 1.1 N / 50 mm, a relatively low value. Furthermore, the sample underwent interfacial delamination under slight stress, resulting in a smooth peel surface with no obvious colloid residue. This is because the melting point of the treatment agent used in this group (110℃) was much higher than the set temperature of the upper hot platen (82℃). During the lamination process, the treatment agent remained in an unmelted glassy or highly elastic state, unable to flow or wet, and the temporary contact generated solely by physical pressure could not form chemical bonds or physical anchoring.

[0115] This test confirms that the core logic of the dual-temperature zone microstructure composite control system lies in establishing a precise temperature gradient window: the upper thermal zone temperature must be higher than the melting point of the functional agent to ensure adhesion, while the lower thermal zone temperature must be lower than the melting point of the functional agent to ensure blocking. Any deviation of the temperature parameters of either side from the thermodynamic matching range (such as insufficient thermal energy in the upper thermal zone in Comparative Example 3) will lead to failure of the product structure or performance.

[0116] See attached document Figure 2 This invention provides an integrated production equipment system for realizing the above-mentioned composite fabric preparation process. The system adopts a modular design architecture to ensure precise coordination between each process step. From an overall logical architecture perspective, the equipment uses a high-performance data processing core as the central control unit. This unit establishes bidirectional communication connections with three downstream functional execution subsystems via an industrial fieldbus, achieving digital closed-loop control of the entire process, including fabric physical structure construction, precise deposition of functional agents, and thermorheological shaping and composite bonding. The three subsystems are connected in series according to the process flow, each undertaking different physical and chemical processing tasks.

[0117] The differentiated weaving control system is located at the beginning of the production line, and its main function is to construct a base fabric with a specific asymmetric micro-topological structure. At the hardware level, this system includes a high-precision sensing and monitoring module and a dynamic execution module. The sensing and monitoring module is deployed at key nodes in the warp yarn feeding path, capable of collecting dynamic tension values ​​of the inner and outer yarn bundles in real time and feeding them back to the control center. The dynamic execution module integrates a high-response servo drive unit, used to adjust the angular velocity of the yarn feed rollers in milliseconds according to instructions. At the control logic level, the central control unit runs a dual-channel adjustment algorithm, issuing instructions to the inner and outer execution mechanisms respectively: for the outer warp yarn channel, the system maintains a constant high tension output to force the fabric surface to bulge and form micro-ridges; for the inner warp yarn channel, the system applies a periodically fluctuating low-tension loading mode, thereby forming a loose three-dimensional moisture-absorbing network on the inside.

[0118] The asymmetric directional functional finishing system receives the woven fabric and is responsible for depositing heat-sensitive functional agents onto the micro-ridge structure surface in a specific spatial distribution. This system integrates a speed sensing module, an attitude adjustment module, and a micro-mist generation module. The speed sensing module uses photoelectric encoders and machine vision components to capture the fabric's linear velocity and the phase position signals of the micro-ridges in real time. The attitude adjustment module, composed of a multi-axis robotic arm, can drive the spraying device to precisely adjust its incident angle relative to the fabric normal within a range of 0 to 90 degrees. The micro-mist generation module uses high-frequency ultrasound or high-pressure airflow technology to transform the liquid treatment agent into a uniform micron-sized droplet cluster. Based on the timing signals fed back from the speed sensing module, the central control unit executes synchronous control logic, dynamically adjusting the spraying frequency and flow rate to ensure that the droplets accurately impact and deposit on the windward side of the micro-ridge structure under inertia, while keeping the leeward side clean, thus achieving a discontinuous distribution of functional areas.

[0119] The dual-temperature zone microstructure composite control system is located at the end of the production line, responsible for the final shaping of the composite fabric and the functional blocking of the interface. The core of this system is an independent thermal field management module, which has two physically isolated temperature control loops that independently adjust the working temperatures of the upper and lower hot press plates, thereby establishing a precise temperature gradient field perpendicular to the fabric thickness. The pressure and microforming module is equipped with precision hydraulic or servo electric cylinders to apply constant composite pressure. Its lower mold surface has a pre-fabricated array of micro-protrusions to press microporous channels at the interface during the composite process. The central control unit incorporates thermorheological control logic, which automatically calculates and sets the temperature thresholds of the upper and lower hot zones based on pre-input functional agent melting point data. It consistently maintains the upper hot zone temperature above the agent melting point to induce resin melting and bonding, while simultaneously maintaining the lower hot zone temperature below the agent melting point to utilize the condensation effect to block resin penetration, thus establishing a process environment of upper-heat bonding and lower-cooling blocking.

Claims

1. A moisture-wicking and UV-protective composite textile fabric, characterized in that, The composite textile fabric consists of an inner fabric layer (1), an outer fabric layer (2), and a heat-sensitive functional treatment agent (3) located between the inner fabric layer (1) and the outer fabric layer (2); The inner fabric layer (1) has a loose structure (4) formed by low-tension weaving. The outer fabric layer (2) has a micro-ridge structure (5) formed by high-tension weaving, and the micro-ridge structure (5) has a geometric height difference; The heat-sensitive functional treatment agent (3) is deposited in a discontinuous form on the windward side (6) of the microridge structure (5), while the leeward side (7) of the microridge structure (5) retains an uncovered breathable area. The interface between the inner fabric layer (1) and the outer fabric layer (2) has physical anchoring points formed by the melting and cooling of the heat-sensitive functional treatment agent (3), and microporous channels (8) formed by mold pressing.

2. The moisture-wicking and UV-protective composite textile fabric according to claim 1, characterized in that, The heat-sensitive functional treatment agent is prepared from raw materials comprising a main resin, a functional modifier, and a dispersion medium; The main resin is selected from at least one of low-melting-point thermoplastic polyurethane powder, copolyamide hot melt adhesive powder, or ethylene-vinyl acetate copolymer powder; The functional modifier is selected from one of the following: water-based fluorinated acrylate emulsion, nano silica dispersion, or benzophenone-based UV-resistant additives.

3. The moisture-wicking and UV-protective composite textile fabric according to claim 2, characterized in that, The heat-sensitive functional treatment agent is made from raw materials comprising the following parts by weight: The main resin is 60-65 parts; The functional modifier is 15-30 parts; 100 parts of the dispersion medium; The melting point of the heat-sensitive functional treatment agent is 65℃-80℃.

4. The moisture-wicking and UV-protective composite textile fabric according to claim 1, characterized in that, The preparation of the moisture-wicking and UV-protective composite textile fabric includes the following steps: S1. Differentiated weaving: Applying periodically fluctuating low tension to the inner warp yarns and constant high tension to the outer warp yarns to weave a substrate with a loose inner structure and a micro-ridged outer structure. S2, Directional Functional Finishing: The heat-sensitive functional treatment agent is atomized and sprayed onto the surface of the outer fabric layer at an angle to the fabric normal, so that the heat-sensitive functional treatment agent is deposited on the windward side of the micro-ridge structure; S3, Dual-temperature zone lamination: The treated fabric is fed into a dual-temperature zone hot press device for lamination. The temperature of the upper hot press plate is controlled to be higher than the melting point of the heat-sensitive functional treatment agent, and the temperature of the lower hot press plate is controlled to be lower than the melting point of the heat-sensitive functional treatment agent. The fabric is then held in place under pressure to maintain its shape.

5. The moisture-wicking and UV-protective composite textile fabric according to claim 4, characterized in that, Before step S2, the method further includes the step of preparing the heat-sensitive functional treatment agent: The main resin and the functional modifier are added to the dispersion medium and stirred and dispersed at a speed of 1200rpm-2000rpm for 1h-2h.

6. The moisture-wicking and UV-protective composite textile fabric according to claim 4, characterized in that, In step S1, the tension of the inner warp yarn is set to 2.3-2.7N; the tension of the outer warp yarn is set to 4.0N-6.0N; and the height difference of the micro-ridge structure is set to 20μm-60μm.

7. The moisture-wicking and UV-protective composite textile fabric according to claim 4, characterized in that, In step S2, the tilt angle ranges from 20° to 45°; the atomized particle size of the thermosensitive functional treatment agent is controlled between 10μm and 25μm, and the atomized particle size is smaller than the height difference of the microridge structure.

8. The moisture-wicking and UV-protective composite textile fabric according to claim 4, characterized in that, In step S2, the direction of the spray is perpendicular to the orientation of the microridge structure.

9. The moisture-wicking and UV-protective composite textile fabric according to claim 4, characterized in that, In step S3, the temperature setting range of the upper hot platen is 75℃-90℃, the temperature setting range of the lower hot platen is 50℃-65℃, and the composite pressure setting range is 0.20MPa-0.50MPa.

10. A production equipment for a moisture-wicking and UV-protective composite textile fabric, used to prepare the moisture-wicking and UV-protective composite textile fabric according to any one of claims 1-9, characterized in that, The production equipment includes a central control unit and a differentiated weaving control system, an asymmetric directional functional finishing system, and a dual-temperature zone microstructure composite control system connected to the central control unit. The differentiated weaving control system includes a sensing and monitoring module for collecting yarn tension and a dynamic execution module for adjusting the yarn feeding speed. The central control unit is configured to control the dynamic execution module to keep the outer warp yarns at a constant high tension and the inner warp yarns at fluctuating low tension. The asymmetric orientation finishing system includes a speed sensing module for monitoring the micro-ridge phase of the fabric, an attitude adjustment module for adjusting the spray angle, and a micro-mist generation module. The central control unit is configured to achieve unilateral deposition based on speed feedback to control the spray frequency. The dual-temperature zone microstructure composite control system includes an independent thermal field management module and a pressure and microforming module. The independent thermal field management module is equipped with two independent temperature control loops to set the upper thermal field temperature and the lower thermal field temperature respectively. The pressure and microforming module is equipped with a mold with a micro-protrusion structure.

Images