A composite fabric

Abstract

This invention discloses a composite fabric, characterized in that the composite fabric comprises a top layer, a middle layer, and a bottom layer sequentially laminated from top to bottom. The middle layer is a waterproof and breathable membrane. The top layer and the middle layer are bonded together by a first adhesive layer, and the middle layer and the bottom layer are bonded together by a second adhesive layer. Both the first and second adhesive layers are hot melt adhesive dot arrays, and the adhesive dots of the first and second adhesive layers at least partially overlap. Using this technical solution helps to improve the softness of the fabric while ensuring a certain level of breathability.

Description

Technical Field

[0001] This invention relates to the field of fabrics, specifically to a composite fabric. Background Technology

[0002] In existing technologies, waterproof jackets are generally made of woven three-layer composite fabric, including an outer layer, a middle layer, and a bottom layer. The outer layer is mostly a woven fabric of 20D-150D, which serves to be abrasion-resistant, tear-resistant, weatherproof, and provide a certain structural strength. The middle layer is mostly a PU / TPU waterproof and breathable membrane, which provides the material basis for waterproofing and breathability. The bottom layer is mostly a knitted fabric of 20D-50D, which protects the middle membrane and improves wearing comfort. In existing technologies, these three layers are mostly bonded together using a bonding process, but common bonding processes cannot simultaneously achieve both softness and breathability. Summary of the Invention

[0003] The purpose of this invention is to overcome the above-mentioned defects or problems in the prior art and to provide a composite fabric that can improve the softness of the fabric while ensuring a certain degree of breathability.

[0004] To achieve the above objectives, the following technical solution is adopted: The first technical solution relates to a composite fabric, which includes a top layer, a middle layer and a bottom layer sequentially laminated from top to bottom. The middle layer is a waterproof and breathable membrane. The top layer and the middle layer are bonded together by a first adhesive layer, and the middle layer and the bottom layer are bonded together by a second adhesive layer. Both the first adhesive layer and the second adhesive layer are hot melt adhesive dots, and the adhesive dots of the first adhesive layer and the second adhesive layer at least partially overlap.

[0005] The second technical solution is based on the first technical solution, wherein the adhesive dots of the first adhesive layer and the second adhesive layer completely overlap.

[0006] The third technical solution is based on the first technical solution, wherein the adhesive dots of the first adhesive layer and the second adhesive layer partially overlap.

[0007] The fourth technical solution is based on the second and third technical solutions, wherein the total hot melt adhesive coverage of the first adhesive layer and the second adhesive layer is 30%-40%.

[0008] The fifth technical solution is based on the first technical solution, wherein the first adhesive layer and the second adhesive layer are hot melt adhesive dot matrices formed by moisture-curing hot melt adhesive.

[0009] The sixth technical solution is based on the first technical solution, wherein the surface layer is a grid woven fabric made of 7~15D nylon 66 DTY filaments; the middle layer is a polyurethane fiber membrane, on which micropores are distributed throughout the thickness direction, the pore size of the micropores is 100nm-5μm, and the porosity of the polyurethane fiber membrane is 65%-80%; and the bottom layer is 12~15D nylon woven soft yarn.

[0010] The seventh technical solution is based on the first technical solution, wherein the basis weight of the surface layer is 20g / m2-27g / m2, the thickness of the intermediate layer is 12μm-20μm, and the basis weight of the bottom layer is 11g / m2-15g / m2.

[0011] The eighth technical solution is based on the first technical solution, wherein the interlayer peel strength of the composite fabric reaches 3.5 N / cm.

[0012] As can be seen from the above description of the present invention, compared with the prior art, the present invention has the following beneficial effects: Existing bonding processes typically include solvent-based bonding, hot melt adhesive transfer bonding, and hot melt adhesive dotting bonding. However, each of these processes has its drawbacks. Solvent-based bonding usually involves applying adhesive between the top layer and the intermediate layer, as well as between the intermediate layer and the bottom layer. While this results in high bonding strength, the adhesive can clog the micropores of the intermediate layer. Hot melt adhesive transfer bonding creates an adhesive layer that exists as a film or in a large, continuous area, reducing the fabric's moisture permeability and breathability. Ordinary hot melt adhesive dotting bonding uses a dot matrix application method, requiring a high coverage rate of adhesive dots to ensure sufficient peel strength and breathability. This invention reduces the coverage rate of adhesive dots by limiting their placement, thus improving the fabric's breathability and softness with the same amount of hot melt adhesive used.

[0013] In the first technical solution, by restricting the position of the adhesive dots in the first adhesive layer and the second adhesive layer, the adhesive dots in the first adhesive layer and the second adhesive layer at least partially overlap. Since the hot melt adhesive itself has a certain hardness, compared with not restricting the position of the adhesive dots in the first adhesive layer and the second adhesive layer, under the same adhesive force, allowing the adhesive dots in the first adhesive layer and the second adhesive layer to at least partially overlap can minimize the coverage of adhesive dots. A lower coverage of adhesive dots means that the distance between adhesive dots can be increased, which is beneficial to improving the softness of the fabric and reducing the occupation of the effective area of ​​the waterproof and breathable membrane by adhesive dots, which is more conducive to improving the breathability of the fabric.

[0014] In the first technical solution, the adhesive dots of the first adhesive layer and the second adhesive layer at least partially overlap, so that the overlapping adhesive dots form a point-to-point reinforced bond, which is beneficial to improving the interlayer peel strength and further improving the softness of the fabric.

[0015] In the second technical solution, the adhesive dots of the first adhesive layer and the second adhesive layer are completely overlapped. Compared with the at least partial overlap in the first technical solution, this reduces the coverage of adhesive dots, which is beneficial to improving the softness and breathability of the fabric.

[0016] In the third technical solution, the adhesive dots of the first adhesive layer and the second adhesive layer partially overlap. This partial overlap, compared to non-overlapping, reduces the coverage of the adhesive dots, which helps improve the softness and breathability of the fabric.

[0017] In the fourth technical solution, the total hot melt adhesive coverage of the first adhesive layer and the second adhesive layer is 30%-40%. Compared with fabrics with an adhesive coverage of less than 30%, fabrics with an adhesive coverage of more than 30% have higher interlayer adhesion, which helps to avoid bubbling caused by weak interlayer adhesion. Compared with fabrics with an adhesive coverage of more than 40%, fabrics with an adhesive coverage of less than 40% have better softness and stronger breathability.

[0018] In the fifth technical solution, the first adhesive layer and the second adhesive layer are hot melt adhesive lattices formed by moisture-curing hot melt adhesive. This type of hot melt adhesive can be melted and applied and cured at a low temperature of 80-110℃. Compared with ordinary hot melt adhesive, it is beneficial to avoid damage to the waterproof and breathable membrane caused by high temperature.

[0019] In the sixth technical solution, 7-15D nylon 66 DTY filament is used as the surface layer and 12-15D nylon 66 filament as the bottom layer, both of which are ultra-fine denier fibers. Compared to ordinary 20D-150D woven fabric as the surface layer, 20D-50D knitted fabric is advantageous in maintaining good tear resistance while ensuring that the surface and bottom layers have extremely low basis weight. Furthermore, this fabric itself has higher softness, which helps to improve the fabric's suppleness.

[0020] In the sixth technical solution, the intermediate layer is a polyurethane fiber membrane with micropore sizes controlled between 100 nm and 5 μm. This pore size range effectively prevents liquid water penetration while allowing water vapor molecules to pass freely, providing a waterproof and breathable material basis for the composite fabric of this application.

[0021] In the seventh technical solution, the basis weight of the surface layer is between 20G / M2 and 27G / M2, which, under the premise of good tear resistance, is conducive to achieving lightweight composite fabric.

[0022] In the seventh technical solution, the weight of the bottom layer is between 11G / M2 and 15G / M2, which is conducive to achieving lightweight composite fabric under the premise of good tear resistance.

[0023] In the seventh technical solution, the thickness of the intermediate waterproof and breathable membrane is controlled between 12μm and 20μm. When the thickness of the intermediate layer is greater than 12μm, it helps to avoid the intermediate layer breaking due to insufficient strength during wear when stretched. When the thickness of the intermediate layer is less than 20μm, it helps to improve the softness of the fabric.

[0024] In the eighth technical solution, the interlayer peel strength of the composite fabric reaches 3.5 N / cm. Compared with fabrics with a peel strength of less than 3.5 N / cm, this helps to avoid separation, bubbling or slippage between the layers when the fabric is stretched during wear or under the mechanical conditions of repeated machine washing. Attached Figure Description

[0025] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments are briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the composite fabric structure in the embodiment.

[0027] Key reference numerals in the attached drawings: 1. Top layer; 2. First adhesive layer; 3. Intermediate layer; 4. Second adhesive layer; 5. Bottom layer; 6. Adhesive dot. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are preferred embodiments of the present invention and should not be considered as excluding other 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.

[0029] Unless otherwise expressly defined, the use of terms such as "first," "second," or "third" in the claims, description, and accompanying drawings of this invention is for distinguishing different objects and not for describing a specific order.

[0030] Unless otherwise expressly defined, in the claims, description, and accompanying drawings of this invention, the use of directional terms such as "center," "lateral," "longitudinal," "horizontal," "vertical," "top," "bottom," "inner," "outer," "upper," "lower," "front," "rear," "left," "right," "clockwise," and "counterclockwise" to indicate orientation or positional relationships is based on the orientation and positional relationships shown in the accompanying drawings and is only for the convenience of describing the invention and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the specific scope of protection of this invention.

[0031] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims, description and drawings of this invention should be interpreted broadly to refer to any connection in which there is no displacement or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection and fixed connection by other means or components.

[0032] In the claims, description and accompanying drawings of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."

[0033] Example Figure 1 The composite fabric shown in this embodiment is as follows: Figure 1As shown, the composite fabric, from top to bottom, includes a top layer 1, a first adhesive layer 2, an intermediate layer 3, a second adhesive layer 4, and a bottom layer 5. In this embodiment, the top layer 1 is a woven fabric made of 7D nylon 66 DTY filaments with a grid pattern and a weight of 26 g / m². In other embodiments, it can also be a woven fabric made of nylon filaments of other finenesses between 7 and 15D. The first adhesive layer 2 is a hot melt adhesive dot array of 6, including adhesive dots 6, with a density of 2600 dots / square inch. The intermediate layer 3 is a polyurethane fiber membrane, specifically a PU nanoporous membrane. The polyurethane fiber membrane has micropores distributed throughout its thickness direction, with a pore size of 100 nm-5 μm. The porosity of the polyurethane fiber membrane is 65%, and its thickness is 0.02 mm. The second adhesive layer 4 is a hot melt adhesive dot array of 6, including adhesive dots 6, with a density of 2600 dots / square inch. The bottom layer 5 is a woven nylon 66 filament yarn with a weight of 14 g / m². In other embodiments, it can also be a woven nylon yarn of other fineness within the range of 12-15 D. In this embodiment, the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 completely overlap. In other embodiments, the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 partially overlap. In this embodiment, the total coverage of the hot melt adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 is 30%-40%, and the first adhesive layer 2 and the second adhesive layer 4 are hot melt adhesive dots 6 arrays formed by moisture-curing hot melt adhesive. In this embodiment, the interlayer peel strength of the composite fabric reaches 3.5 N / cm.

[0034] This embodiment provides a composite fabric, which is composed of a surface layer 1, a first adhesive layer 2, a middle layer 3, a second adhesive layer 4, and a bottom layer 5. The preparation method of this fabric is as follows: Step 1: Material Selection. The top layer 1 is made of 7~15D nylon 66 DTY filament woven grid woven fabric; the middle layer 3 is made of PU nanoporous membrane; the bottom layer 5 is made of 12~15D nylon woven soft yarn; the hot melt adhesive is moisture-reactive dotted hot melt adhesive, and the reaction temperature is 80-120℃.

[0035] Step Two: Design and Selection of the Carving Wheel. Based on the yarn thickness and fabric thickness of the top layer 1 and bottom layer 5, design the pattern of the carving wheel and the depth of the adhesive dots 6. Controlled by a suspended pressure system, the adhesive dots 6 penetrate into the fabric to a depth of 30%-40% of the fabric thickness, while the amount of adhesive floating on the fabric surface accounts for 70%-60%.

[0036] Step 3: Bonding of Top Layer 1 and Intermediate Layer 3. Apply adhesive to Top Layer 1 using the carving wheel selected in Step 2. Before applying adhesive, mark a 0-degree mark on the edge of the carving wheel as a reference positioning point. When bonding Top Layer 1 and Intermediate Layer 3, use this 0-degree mark as the starting point for alignment and bonding. After bonding, allow it to cure at room temperature or under suitable conditions for at least 20 hours to ensure the hot melt adhesive fully cross-links and cures, guaranteeing bonding strength.

[0037] Step 4: Laying the bottom layer 5. Using the carving wheel selected in Step 2, apply adhesive to the bottom layer 5. Then, rewind the composite semi-finished product of "Top Layer 1 - Middle Layer 3" that has been laminated and cured in Step 3. When laminating the bottom layer 5, use the same 0-degree engraving line on the carving wheel and the starting point left during the lamination of Top Layer 1 in Step 3 as alignment references for a second lamination. Through this process control, the adhesive dots 6 from the first lamination and the second lamination are essentially overlapped, meaning the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 are essentially overlapped.

[0038] When using the above scheme to prepare composite fabric, the use of a suspended pressure system during the preparation process ensures that the adhesive dots 6 penetrate into the fabric to a depth of 30%-40% of the fabric thickness, while the amount of adhesive floating on the fabric surface accounts for 70%-60%. This helps to avoid excessive adhesive penetration, improves the hand feel of the composite fabric, and the overlapping adhesive dots 6 can form point-to-point reinforced bonding, which helps to improve the interlayer peel strength.

[0039] In this embodiment, by restricting the position of the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4, the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 are at least partially overlapped. Since the hot melt adhesive itself has a certain hardness, compared with not restricting the position of the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4, under the same adhesive force, allowing the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 to at least partially overlap can minimize the coverage of the adhesive dots 6. A lower coverage of adhesive dots 6 means that the spacing between adhesive dots 6 can be increased, which is beneficial to improving the softness of the fabric and can reduce the occupation of the effective area of ​​the waterproof and breathable membrane by the adhesive dots 6, which is more conducive to improving the breathability of the fabric.

[0040] In this embodiment, the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 at least partially overlap, so that the overlapping adhesive dots 6 form a point-to-point reinforced bond, which is beneficial to improving the interlayer peel strength and further improving the softness of the fabric.

[0041] In this embodiment, the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 are completely overlapped. Compared with the at least partial overlap in the first technical solution, this reduces the coverage of adhesive dots 6, which is beneficial to improving the softness and breathability of the fabric.

[0042] In this embodiment, the adhesive dots 6 of the first adhesive layer 2 and the second adhesive layer 4 partially overlap. This partial overlap, compared to non-overlapping, reduces the coverage of the adhesive dots 6, which is beneficial for improving the softness and breathability of the fabric.

[0043] In this embodiment, the total coverage of hot melt adhesive dots 6 in the first adhesive layer 2 and the second adhesive layer 4 is 30%-40%. Compared with fabrics with a coverage of less than 30% of adhesive dots 6, fabrics with a coverage of more than 30% of adhesive dots 6 have higher interlayer adhesion, which helps to avoid bubbling caused by weak interlayer adhesion. Compared with fabrics with a coverage of more than 40% of adhesive dots 6, fabrics with a coverage of less than 40% of adhesive dots 6 have better softness and stronger breathability.

[0044] In this embodiment, the first adhesive layer 2 and the second adhesive layer 4 are hot melt adhesive dots 6 arrays formed by moisture-curing hot melt adhesive. This type of hot melt adhesive can be melted and applied and cured at a low temperature of 80-110℃. Compared with ordinary hot melt adhesive, it is beneficial to avoid damage to the waterproof and breathable membrane caused by high temperature.

[0045] In this embodiment, 7-15D nylon 66 DTY filament is used as the surface layer 1 and 12-15D nylon 66 filament is used as the bottom layer 5, both being ultra-fine denier fibers. Compared to ordinary 20D-150D woven fabric as the surface layer 1 and 20D-50D knitted fabric, this method helps to maintain good tear resistance while ensuring that the surface layer 1 and bottom layer 5 have extremely low weight, and the fabric itself has higher softness, which helps to improve the softness of the fabric.

[0046] In this embodiment, the intermediate layer 3 is a polyurethane fiber membrane with micropore sizes controlled between 100 nm and 5 μm. This pore size range effectively prevents liquid water penetration while allowing water vapor molecules to pass freely, providing a waterproof and breathable material basis for the composite fabric of this application.

[0047] In this embodiment, the weight of the surface layer 1 is between 20g / m² and 27g / m², which, under the premise of good tear resistance, is conducive to achieving lightweight composite fabric.

[0048] In this embodiment, the weight of the bottom layer 5 is between 11g / m2 and 15g / m2, which is conducive to achieving lightweight composite fabric under the premise of good tear resistance.

[0049] In this embodiment, the thickness of the waterproof and breathable membrane in the intermediate layer 3 is controlled between 12μm and 20μm. When the thickness of the intermediate layer 3 is greater than 12μm, it helps to avoid breakage of the intermediate layer 3 due to insufficient strength during wear and stretching. When the thickness of the intermediate layer 3 is less than 20μm, it helps to improve the softness of the fabric.

[0050] In this embodiment, the interlayer peel strength of the composite fabric reaches 3.5 N / cm. Compared with fabrics with a peel strength of less than 3.5 N / cm, this helps to avoid separation, bubbling, or slippage between the layers of the fabric during limb stretching during wear and under the mechanical conditions of repeated machine washing.

[0051] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.

Claims

1. A composite fabric, characterized in that, The composite fabric comprises a top layer, a middle layer, and a bottom layer, which are sequentially laminated from top to bottom. The middle layer is a waterproof and breathable membrane. The top layer and the middle layer are bonded together by a first adhesive layer, and the middle layer and the bottom layer are bonded together by a second adhesive layer. Both the first adhesive layer and the second adhesive layer are hot melt adhesive dots, and the adhesive dots of the first adhesive layer and the second adhesive layer at least partially overlap.

2. The composite fabric as described in claim 1, characterized in that, The adhesive dots of the first adhesive layer and the second adhesive layer are completely overlapped.

3. The composite fabric as described in claim 1, characterized in that, The adhesive dots of the first adhesive layer and the second adhesive layer partially overlap.

4. A composite fabric as described in claims 2 and 3, characterized in that, The total hot melt adhesive coverage of the first and second adhesive layers is 30%-40%.

5. The composite fabric as described in claim 1, characterized in that, The first adhesive layer and the second adhesive layer are hot melt adhesive dot arrays formed by moisture-curing hot melt adhesive.

6. The composite fabric as described in claim 1, characterized in that, The top layer is a checkered woven fabric made of 7~15D nylon 66 DTY filaments; the middle layer is a polyurethane fiber membrane with micropores distributed throughout the thickness direction, the pore size of which is 100nm-5μm and the porosity of which is 65%-80%; the bottom layer is 12~15D nylon woven soft yarn.

7. The composite fabric as described in claim 1, characterized in that, The basis weight of the top layer is 20g / m²-27g / m², the thickness of the intermediate layer is 12μm-20μm, and the basis weight of the bottom layer is 11g / m²-15g / m².

8. A composite fabric as described in claim 1, characterized in that, The interlayer peel strength of the composite fabric reaches 3.5 N / cm.

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