A bio-based PA510 woven waterproof and moisture-permeable film-attached fabric and a preparation method thereof

Abstract

This invention discloses a bio-based PA510 woven waterproof and breathable membrane fabric and its preparation method. The fabric has a double-layer composite structure, comprising: a base fabric layer woven from bio-based PA510 yarn; and a functional membrane layer, which is bonded to one side of the base fabric layer via hot melt adhesive film. The functional membrane layer is a bio-based PU white film. This invention, by employing a composite structure of "bio-based PA510 woven fabric" and "bio-based PU white film," constructs a high-performance material system completely independent of petroleum-based raw materials, thoroughly solving the problem of poor environmental performance throughout the entire life cycle of traditional petroleum-based nylon and PU films. Through optimized base fabric weaving processes and stable bonding technology, the final fabric achieves top-level waterproof and breathable performance while maintaining a lightweight and soft feel, meeting professional outdoor protection standards and effectively compensating for the inherent performance deficiencies of bio-based nylon fabrics.

Description

Technical Field

[0001] This invention belongs to the field of textile materials technology, and in particular relates to a bio-based PA510 woven waterproof and breathable membrane fabric and its preparation method. Background Technology

[0002] Driven by the global "dual-carbon" strategy, national green industry policies, and the upgrading of downstream market demands, the textile industry urgently needs to replace highly polluting and non-renewable petroleum-based fabrics. Traditional petroleum-based nylon (PA6, PA66) and PU white film suffer from poor environmental performance and performance defects. While bio-based PA510 (100% bio-based content, renewable and biodegradable, with superior performance) and bio-based PU white film have advantages, current technologies lack mature bonding processes and adaptation solutions for lightweight bio-based nylon fabrics of 70D specification. This results in high production costs, substandard composite performance (such as low peel strength, difficulty in balancing moisture permeability and waterproofness), and a stiff feel. Currently, there is no 70D specification fully bio-based composite fabric on the market that can balance environmental friendliness, top-level protective performance, and a soft feel. Therefore, developing a novel fully bio-based composite fabric and its efficient and stable preparation method has significant practical importance and market value. Summary of the Invention

[0003] Objective of the Invention: To address the problems existing in the prior art, this invention provides a bio-based PA510 woven waterproof and breathable membrane fabric and its preparation method. The technical problems solved by this invention are as follows: 1. To address the problems of insufficient environmental friendliness and immature production processes (low efficiency, low pass rate, and high cost) of existing composite fabrics, which cannot balance environmental protection, functionality, and economy, the aim is to develop all-plant-based environmentally friendly composite fabrics, optimize the preparation process, achieve large-scale production, fill market gaps, and promote the green and high-end transformation of the textile industry.

[0004] 2. Functional Enhancement Objective: To address the issue that bio-based nylon fabrics have insufficient original waterproof and breathable properties, making them difficult to apply directly to high-end outdoor applications, this invention aims to achieve top-tier 5K / 5K protection performance while maintaining environmentally friendly properties through the composite of specific bio-based films.

[0005] 3. Environmental Innovation Objective: To address the problem that existing high-performance waterproof and breathable fabrics generally rely on petroleum-based films and have poor environmental performance throughout their entire life cycle, this invention innovatively adopts a fully bio-based composite structure of "bio-based fabric + bio-based film", which completely eliminates the dependence on petroleum-based materials while achieving the same high performance.

[0006] 4. To address the challenge of lightweight bio-based nylon fabrics simultaneously achieving top-tier protective performance (5K / 5K) and a soft feel, a 0.02mm bio-based white film is laminated onto it, achieving professional outdoor protection standards without significantly increasing weight or stiffness. Technical solution: To achieve the above-mentioned objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a bio-based PA510 woven waterproof and breathable membrane fabric, wherein the fabric has a double-layer composite structure, comprising: A base fabric layer, said base fabric layer being woven from bio-based PA510 yarn; A functional film layer is attached to one side surface of the base fabric layer by a hot melt adhesive film. The functional film layer is a bio-based PU white film.

[0007] As a specific implementation scheme, the bio-based PA510 yarn is a bio-based PA510 DTY 70D / 68F matte yarn; the thickness of the bio-based PU white film is 0.02±0.005mm.

[0008] As a specific implementation scheme, the base fabric layer is a plain weave, with a warp density of 155-165 threads / inch and a weft density of 105-115 threads / inch.

[0009] Secondly, the present invention provides a method for preparing the aforementioned bio-based PA510 woven waterproof and breathable membrane fabric, comprising the following steps: (1) Weaving: Bio-based PA510 yarn is selected as warp and weft yarns and woven using an air-jet loom to obtain the base fabric; during the weaving process, the warp yarns are not sized, the weaving speed is 600-700 rpm, and the main jet pressure is 0.35-0.40 MPa. (2) Dyeing and finishing: The base fabric obtained in step (1) is subjected to pre-forming, open-width scouring, dyeing, dehydration and opening, and final setting to obtain the finished base fabric; (3) Post-processing and bonding: a. Pretreatment: The finished base fabric and bio-based PU white film obtained in step (2) are subjected to equilibration treatment in a constant temperature and humidity environment; b. Adhesive application and bonding: Hot melt adhesive film is used as the bonding medium. The pretreated finished base fabric and the bio-based PU white film are hot-pressed together on a multi-roller hot melt laminating machine; the bonding temperature is 130±2℃, and the bonding pressure is 4.0±0.2 kgf / cm². 2 The vehicle speed is 16-20 meters per minute; c. Rapid cooling: The laminated composite material is immediately cooled and shaped by a water roller; d. Curing: The rapidly cooled composite material is cured at 40-45℃ for 24-48 hours to obtain the final finished fabric.

[0010] As a specific implementation scheme, in step (1), the weaving is carried out using an air-jet loom equipped with an electronic multi-arm sheathing device, a shaped reed, and an electronic take-up and electronic warp feeding system; the fabric structure is plain weave, the warp density of the greige fabric is 165-175 threads / inch, the weft density of the greige fabric is 115-120 threads / inch, and the width of the fabric on the loom is 190-195 cm.

[0011] As a specific implementation scheme, the pre-forming temperature is 185-190℃, the time is 30-40 seconds, and the overfeed is 3-5%; the flat-width scouring temperature is 80-85℃, and neutral conditions are adopted; the dyeing adopts an airflow dyeing machine, uses acidic or neutral dyes, and is carried out at a pH value of 4-5 and a temperature of 98±2℃.

[0012] As a specific implementation plan, in step (2), the final shaping temperature is 150-160℃, the time is 40-50 seconds, and an overfeed of 8-12% is applied.

[0013] As a specific implementation plan, in step (3), the pretreatment conditions are: temperature 25±2℃, relative humidity 65±5%, and time 20-30 hours.

[0014] As a specific implementation plan, in step (3), the hot melt adhesive film is an environmentally friendly polyester hot melt adhesive film with a basis weight of 12-15 gsm and a melting point of 115℃; the temperature of the cold water roller is 10-15℃.

[0015] The key innovations of this invention are as follows: 1. A fully bio-based composite of "bio-based PA510 fabric" and "bio-based PU white film" has been achieved. This is not a simple replacement, but rather the creation of a high-performance material system that is completely independent of petroleum-based raw materials from the source.

[0016] 2. By laminating a bio-based PU white film of a specific thickness (e.g., 0.02mm), the lightweight 70D bio-based nylon fabric achieves top-tier waterproof and breathable performance (e.g., 5K / 5K) required for professional outdoor applications without significantly increasing weight or stiffness. This solves the problem of simultaneously achieving lightweight design, top-level protection, and a soft feel. The aforementioned 5K / 5K refers to hydrostatic pressure (mmH2O) and moisture permeability (g / m³). 2 .24h), that is, 5000mmH2O and 5000g / m 2 24h.

[0017] Beneficial effects: Compared with the prior art, the present invention has the following advantages: 1. By adopting a composite structure of "bio-based PA510 woven fabric" and "bio-based PU white film," a high-performance material system that is completely independent of petroleum-based raw materials has been constructed from the source. This not only responds to the global "dual carbon" strategy and meets the needs of green industry policies and market upgrades, but also completely solves the problem of poor environmental performance throughout the entire life cycle of traditional petroleum-based nylon and PU film.

[0018] 2. By optimizing the base fabric weaving process and stable bonding technology, the final fabric achieves top-level waterproof and breathable performance (such as 5K / 5K level) while maintaining a lightweight and soft feel, meeting professional outdoor protection standards and effectively compensating for the shortcomings of the original performance of bio-based nylon fabrics. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the fabric structure (plain weave) of the base fabric layer in an embodiment of the present invention. Detailed Implementation

[0020] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Example

[0021] 1. Raw material ratio Yarn selection: Yarn 1: Bio-based PA510 DTY 70D / 68F matte yarn is used, which can provide the fabric with good moisture absorption and good mechanical properties.

[0022] Yarn 2: Using bio-based PA510 DTY 70D / 68F matte yarn can provide the fabric with good moisture absorption and good mechanical properties.

[0023] The warp and weft yarns in the fabric are of uniform specifications: bio-based PA510 DTY 70D / 68F matte yarn. Using warp and weft yarns of the same specification can optimize the weaving process, improve the efficiency and pass rate of base fabric weaving, and reduce the difference in warp and weft performance. This avoids the white film from delamination and damage due to uneven stress on the fabric during the bonding process, laying the foundation for large-scale production.

[0024] 2. Weaving process The weaving process utilizes Tsudakoma's air-jet looms. The looms are equipped with an electronic multi-arm shedding system, which allows for precise programming and control of the rise and fall of each warp yarn, ensuring clear shedding even at high warp densities. A coordinated jetting system with main and auxiliary nozzles, along with a shaped reed, creates an airflow channel, enabling low-pressure, high-speed weft insertion. This effectively reduces friction on the warp and weft yarns, making it particularly suitable for fine denier synthetic filaments, minimizing yarn damage and fuzz. The beat-up mechanism uses short reed feet with a high-rigidity rocker arm, ensuring smooth reed movement and sufficient beat-up force, resulting in even and tight weft yarns and a smooth, clean fabric surface. Electronic take-up and electronic warp feed (EJR, EBC) are equipped to control warp and weft yarn tension in real time, maintaining constant tension throughout the weaving process and effectively preventing defects such as uneven weave and sparse weave patterns.

[0025] The warp yarns are made of bio-based PA510 DTY 70D / 68F matte lightweight mesh. Due to their good yarn cohesion, no sizing is required during warping, and they are arranged with low tension and uniformity. The weft yarns use the same specification yarns and are stably fed through a weft feeder. The fabric structure is plain weave (1 / 1), with a greige warp density of 171 ends / inch (corresponding to a finished warp density of 162 ends / inch, considering approximately 5% shrinkage in the warp direction after finishing), and a greige weft density of 117 ends / inch (corresponding to a finished weft density of 111 ends / inch). The fabric width is set to 193 cm (target finished width 183 cm). Weaving parameters are set as follows: machine speed 650 rpm, main jet pressure 0.38 MPa, auxiliary jet timing adjusted in segments, and back beam height and warp stop position finely adjusted in real time according to warp tension to ensure clear shedding and stable weft insertion. Through the above process, a high-density, delicate, and smooth fabric surface is achieved.

[0026] Organizational structure such as Figure 1 As shown, the white area represents warp yarns made of bio-based nylon 510 yarn (no / low tension), while the black dotted area represents weft yarns made of bio-based nylon 510 yarn (directional high-speed tension), resulting in a fabric surface with varying warp and weft tensions and a unique style. 3. Dyeing and finishing process research and development The design, based on the characteristics of bio-based nylon four-way stretch jacquard fabric, focuses on balancing fiber performance, elasticity retention, pattern clarity, and dimensional stability. The entire process begins with pretreatment, starting with pre-setting (185℃, 35 seconds, 3% overfeed) to eliminate weaving stress and initially stabilize the width and elasticity. A flat-width scouring process (80℃, neutral conditions) is performed to remove oils and impurities, preparing for uniform dyeing. The dyeing process uses an airflow dyeing machine and acid / neutral dyes. Under low tension and a pH of 4-5, the heating rate of 1℃ / min (to 98℃) and the holding time are strictly controlled to achieve uniform dyeing and protect the elasticity of the spandex.

[0027] The finishing stage includes dehydration and final setting. In a needle-setting machine, at 150℃ for 40 seconds, a 10% overfeed is applied and the finished width is precisely controlled. Softening and other functional additives can be added at the same time, followed by thorough cooling. The entire process follows the path of "pre-setting and stabilizing the base fabric—soft dyeing—precise setting," with low tension control throughout to ensure the finished product achieves ideal quality with uniform color, long-lasting elasticity, and clear patterns.

[0028] 4. Post-processing A 0.02mm thick bio-based PU white film is laminated onto the finished fabric that has been dyed and finalized using hot melt adhesive film bonding technology. This imparts additional functions such as windproof and water-repellent properties to the fabric while maintaining its original elasticity and breathability. Pretreatment: The single fabric is equilibrated for 24 hours in a constant temperature and humidity environment of 25±2℃ and 65±5% relative humidity to ensure that its moisture content is stable, the width is consistent and there is no internal stress. This is the basis for avoiding shrinkage, wrinkles or uneven bonding during the subsequent bonding process.

[0029] Adhesive application and bonding: The adhesive application and bonding process is completed on a multi-roller hot melt laminating machine, using environmentally friendly polyester (PES) hot melt adhesive film (12 gsm, melting point approximately 115℃) as the bonding medium. The heating roller temperature is set at 130±2℃ to ensure the adhesive film is completely melted and has good fluidity. The bonding pressure is controlled at 4.0±0.2 kgf / cm² to ensure that the adhesive layer uniformly and fully impregnates and bonds the fabric and PU film without adhesive seepage or bubbles. The machine speed is stabilized at 18 m / min to provide sufficient effective time for hot pressing and bonding. After bonding, the composite material must immediately pass through a set of 10℃ cold water rollers for rapid cooling and shaping, allowing the molten hot melt adhesive to quickly crystallize and solidify, initially locking the composite structure.

[0030] Curing: The fabric must be hung in a curing room at 40°C for 36 hours to complete the curing process. This step is crucial for perfecting the crystallization of hot melt adhesive, eliminating internal stress, and achieving the final peel strength.

[0031] The testing process includes key indicators such as peel strength, moisture permeability, hydrostatic pressure resistance, and surface flatness, to ensure a strong bond, a flexible feel, and a composite effect that combines functionality and aesthetics.

[0032] Comparative Example 1 Petroleum-based PA6 and petroleum-based PU films were used to replace the bio-based PA510 DTY 70D / 68F and bio-based PU white film, and everything else was the same as in Example 1.

[0033] Comparative Example 2 Petroleum-based PA6 was used to replace the bio-based PA510 DTY 70D / 68F, and everything else was the same as in Example 1.

[0034] Test case performance testing This test example demonstrates the performance testing of the product prepared above, and the test results are shown in Table 1 below.

[0035] Tensile strength was tested according to GB / T 1040.3-2006 "Determination of tensile properties of plastics - Part 3: Test conditions for films and sheets"; Peel strength was tested according to FZ / T 80007.1-2023; The hydrostatic pressure was tested according to GB / T4744-2013; The moisture permeability was tested according to GB / T 12704.2-2009 "Textiles - Test methods for moisture permeability of fabrics - Part 2: Evaporation method"; The hydrostatic pressure resistance was tested using ASTM D5385, "Standard Test Method for Hydrostatic Pressure Resistance of Waterproof Membranes". Table 1 Performance test results of each product

[0036] As can be seen from the results in Table 1 above, Example 1, which uses bio-based nylon 510 as the fabric component, exhibits excellent waterproof and breathable properties, especially with a high hydrostatic pressure retention rate before and after washing. Comparative Examples 1 and 2, which use petroleum-based nylon fibers as a substitute, immediately show a decrease in the mechanical properties of the products, and their breathability is also far lower than that of Example 1.

[0037] The fabric obtained by this invention can be used in the following applications: 1. High-performance outdoor sports and protective products Primarily used in the manufacture of outdoor clothing and equipment requiring windproof, water-repellent properties and freedom of movement (such as lightweight jackets, softshell pants, and ski linings). This patent utilizes bio-based materials and a stable composite process to provide reliable protection while ensuring the fabric's soft feel and breathability.

[0038] 2. Fashionable outdoor apparel Suitable for urban commuter clothing that combines everyday style with practicality (such as windproof jackets and multi-functional windbreakers). The combination of environmentally friendly bio-based materials and composite technology meets the market's multiple demands for product aesthetics, functionality, and sustainability.

[0039] 3. Specialized workwear and uniforms Designed for industry uniforms that require maintaining a professional image and offer certain protective features (such as logistics and field work uniforms). The patented technology provides water-repellent and easy-care properties, enhancing practicality, while the fabric's dimensional stability and crisp appearance ensure both appropriateness and durability of the work attire.

[0040] The embodiments of the present invention have been described in detail above with reference to specific examples. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A bio-based PA510 woven waterproof and breathable membrane fabric, characterized in that, The fabric has a double-layer composite structure, including: A base fabric layer, said base fabric layer being woven from bio-based PA510 yarn; A functional film layer is attached to one side surface of the base fabric layer by a hot melt adhesive film. The functional film layer is a bio-based PU white film.

2. The bio-based PA510 woven waterproof and breathable membrane fabric according to claim 1, characterized in that, The bio-based PA510 yarn is a bio-based PA510 DTY 70D / 68F matte yarn; the thickness of the bio-based PU white film is 0.02±0.005mm.

3. The bio-based PA510 woven waterproof and breathable membrane fabric according to claim 1, characterized in that, The base fabric layer is a plain weave, with a warp density of 155-165 threads / inch and a weft density of 105-115 threads / inch.

4. The method for preparing the bio-based PA510 woven waterproof and breathable membrane fabric according to any one of claims 1-3, characterized in that, Includes the following steps: (1) Weaving: Bio-based PA510 yarn is selected as warp and weft yarns and woven using an air-jet loom to obtain the base fabric; during the weaving process, the warp yarns are not sized, the weaving speed is 600-700 rpm, and the main jet pressure is 0.35-0.40 MPa. (2) Dyeing and finishing: The base fabric obtained in step (1) is subjected to pre-forming, open-width scouring, dyeing, dehydration and opening, and final setting to obtain the finished base fabric; (3) Post-fitting and finishing: a. Pretreatment: The finished base fabric and bio-based PU white film obtained in step (2) are subjected to equilibration treatment in a constant temperature and humidity environment; b. Adhesive application and bonding: Hot melt adhesive film is used as the bonding medium. The pretreated finished base fabric and the bio-based PU white film are hot-pressed together on a multi-roller hot melt laminating machine; the bonding temperature is 130±2℃, and the bonding pressure is 4.0±0.2 kgf / cm². 2 The vehicle speed is 16-20 meters per minute; c. Rapid cooling: The laminated composite material is immediately cooled and shaped by a water roller; d. Curing: The rapidly cooled composite material is cured at 40-45℃ for 24-48 hours to obtain the final finished fabric.

5. The preparation method according to claim 4, characterized in that, In step (1), the weaving is carried out using an air-jet loom equipped with an electronic multi-arm shedding device, a shaped reed, and an electronic take-up and electronic warp feeding system; the fabric structure is plain weave, the warp density of the greige fabric is 165-175 threads / inch, the weft density of the greige fabric is 115-120 threads / inch, and the width of the fabric on the loom is 190-195 cm.

6. The preparation method according to claim 4, characterized in that, In step (2), the pre-forming temperature is 185-190℃, the time is 30-40 seconds, and the overfeed is 3-5%; the flat-width scouring temperature is 80-85℃, and neutral conditions are used; the dyeing is carried out using an airflow dyeing machine, using acidic or neutral dyes, at a pH of 4-5 and a temperature of 98±2℃.

7. The preparation method according to claim 4, characterized in that, In step (2), the final setting temperature is 150-160℃, the time is 40-50 seconds, and an overfeed of 8-12% is applied.

8. The preparation method according to claim 4, characterized in that, In step (3), the pretreatment conditions are: temperature 25±2℃, relative humidity 65±5%, and time 20-30 hours.

9. The preparation method according to claim 4, characterized in that, In step (3), the hot melt adhesive film is an environmentally friendly polyester hot melt adhesive film with a basis weight of 12-15 gsm and a melting point of 115℃; the temperature of the cold water roller is 10-15℃.

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