Preparation method of elastic memory fabric

Abstract

A method for preparing elastic memory fabric. This relates to the field of memory fabric technology and provides a method for preparing an elastic memory fabric that is wear-resistant, does not easily turn white, and has a long service life. The method includes the following steps: S1: Spinning; the raw materials include PA chips, low-viscosity PTT chips, and high-viscosity PTT chips, with a PA to bicomponent PTT ratio of 10:90 to 30:70; a screw extruder melts the raw materials and extrudes them through a spinneret with a core-sheath structure to obtain POY (polypropylene yarn) of a core-sheath structure composite fiber, wherein the core layer is bicomponent PTT and the sheath layer is PA; S2: Texturing; the POY of the composite fiber obtained in step S1 is stretched into FDY (distilled fiber yarn) on a flat drawing machine, and then the FDY is processed on a texturing machine to obtain DTY (distilled yarn); S3: Weaving; the DTY yarn obtained in step S2 is woven into a grey fabric; S4: Dyeing and finishing; the grey fabric undergoes pretreatment, dyeing, and finishing to obtain the elastic memory fabric.

Description

Technical Field

[0001] This invention relates to the field of memory fabric technology, specifically to a method for preparing elastic memory fabric. Background Technology

[0002] Memory fabric, also known as memory cloth or shape-memory fabric, is a functional fabric that can recover its initial shape through external stimuli (such as temperature and mechanical action). Its raw materials are mostly PET (polyethylene terephthalate) or PTT (polypropylene terephthalate) fibers, possessing properties such as wrinkle-free, anti-wrinkle, and good drape, and are widely used in the production of suits, trench coats, and other garments. PTT fiber is a new type of polyester fiber with good elasticity, softness, wrinkle resistance, and dyeability, but its abrasion resistance and strength are relatively poor.

[0003] Existing bicomponent polyester fiber memory fabrics on the market generally exhibit a whitening effect under the Martindale method (ISO12947-4) 5000-cycle abrasion test, with an abrasion resistance rating below level 3. Clothing made from these fabrics is prone to whitening in areas easily exposed to the elements during daily wear (such as elbows and knees), severely impacting the garment's appearance and lifespan.

[0004] To address this technical challenge, the present invention provides a novel solution. Summary of the Invention

[0005] To address the above-mentioned technical problems, this invention provides a method for preparing an elastic memory fabric that is wear-resistant, does not easily turn white, and has a long service life.

[0006] The technical solution of this invention is as follows: A method for preparing an elastic memory fabric includes the following steps: S1: Spinning; The raw materials include PA chips, low-viscosity PTT chips and high-viscosity PTT chips, with the ratio of PA to bicomponent PTT being 10:90 to 30:70. The raw materials are melted by a screw extruder and extruded through a spinneret with a core-sheath structure to produce POY composite fibers with a core-sheath structure, wherein the core layer is bicomponent PTT and the sheath layer is PA. S2: Reload; The POY composite fiber obtained in step S1 is stretched into FDY on a flat drawing machine, and then the FDY is processed on a texturing machine to obtain DTY yarn. S3: Weaving; The DTY yarn obtained in step S2 is woven into a greige fabric; S4: Dyeing and finishing; Elastic memory fabric is produced by pre-treatment, dyeing and finishing of the greige fabric.

[0007] In step S1, the ratio of low-viscosity PTT slices to high-viscosity PTT slices is 60:40; the core layer is composed of two PTTs of different viscosities arranged side by side.

[0008] The intrinsic viscosity of the PA chips is 2.4–2.8 dL / g, and the melting point is 255–265℃; the intrinsic viscosity of the PTT chips is 0.8–1.3 dL / g, and the melting point is 225–235℃.

[0009] In step S1, the melt temperature of PA is set to 270-290°C, and the melt temperature of PTT is set to 260-280°C.

[0010] The low-viscosity PTT chips have an intrinsic viscosity of 0.8–1 dL / g and a melting point of 225–230°C; the high-viscosity PTT chips have an intrinsic viscosity of 1–1.3 dL / g and a melting point of 230–235°C.

[0011] The core layer of the composite fiber has a circular or peanut-shaped cross-section.

[0012] In step S1, the PA slices contain 0.5wt% to 2wt% maleic anhydride graft compatibilizer.

[0013] The maleic anhydride graft compatibilizer is maleic anhydride grafted PA.

[0014] The fabric has an elastic recovery rate of over 70%, and both its warp and weft tear strengths are greater than 6N.

[0015] The beneficial effects of this invention are: This invention discloses a method for preparing elastic memory fabric, innovatively employing a PTT / PA core-sheath composite spinning technique. While retaining the memory properties of PTT, it uses PA as a sheath to provide circumferential isolation and protection for PTT, fully leveraging the advantages of both fibers while compensating for their respective shortcomings, significantly improving the abrasion resistance of the composite PTT fiber. The composite fiber is then processed into DTY yarn and woven into a fabric, combined with a unique dyeing and finishing process, ultimately producing a high-performance memory fabric. The fabric obtained by this invention underwent 5000 abrasion tests using the Martindale method (ISO12947-4), showing no significant change in appearance and achieving an abrasion resistance rating of 4 or higher, completely solving the defect of whitening after abrasion in traditional bicomponent polyester fiber memory fabrics.

[0016] This invention's groundbreaking innovation not only enhances the aesthetics and durability of memory fabrics but also provides consumers with a higher quality wearing experience. It is applicable to various fields such as high-end fashion, sportswear, outdoor equipment, and functional clothing, and has broad market application prospects. Attached Figure Description

[0017] Figure 1 This is a schematic flowchart of the preparation method of the elastic memory fabric of the present invention. Detailed Implementation

[0018] The following is in conjunction with the appendix Figure 1 This further illustrates the present invention.

[0019] The present invention discloses a method for preparing an elastic memory fabric, comprising the following steps: S1: Spinning; Raw materials include PA chips, low-viscosity PTT chips, and high-viscosity PTT chips, with a PA to bicomponent PTT ratio of 10:90 to 30:70. After drying, the raw materials are fed into the hopper of a screw extruder. The screw extruder melts the raw materials and extrudes them through a spinneret with a core-sheath structure, forming nascent fibers with PA encapsulating bicomponent PTT. The nascent fibers are cooled by ring blowing at a temperature of 10-15°C and a humidity of 65%. The cooled fibers are then coated with an oiling agent and wound into tubes for collection, thus obtaining POY (pre-oriented yarn) composite fibers with a core-sheath structure. The core layer is bicomponent PTT, which provides elasticity and softness; the sheath layer is PA, which provides surface properties of the fiber, such as abrasion resistance and dyeability.

[0020] S2: Texturing; The POY composite fiber obtained in step S1 is stretched into FDY (fully drawn yarn) on a flat drawing machine, and then the FDY is processed on a texturing machine to obtain DTY (drawn textured yarn) yarn.

[0021] S3: Weaving; Weaving the DTY yarn obtained in step S2 into a greige fabric.

[0022] S4: Dyeing and finishing; Pre-treatment, dyeing and finishing of greige fabric to produce elastic memory fabric.

[0023] In step S1, the ratio of low-viscosity PTT chips to high-viscosity PTT chips is 60:40; the core layer is composed of two PTTs of different viscosities side by side, that is, one side of the core layer is low-viscosity PTT and the other side is high-viscosity PTT; the PTTs with viscosity difference will produce asymmetric shrinkage during heat treatment, which strengthens the three-dimensional crimp of the fiber and improves the fiber elasticity.

[0024] The intrinsic viscosity of PA chips is 2.4–2.8 dL / g, and the melting point is 255–265℃; the intrinsic viscosity of PTT chips is 0.8–1.3 dL / g, and the melting point is 225–235℃.

[0025] In step S1, the melt temperature of PA is set to 270-290℃, and the melt temperature of PTT is set to 260-280℃.

[0026] The intrinsic viscosity of low-viscosity PTT chips is 0.8–1 dL / g, and the melting point is 225–230℃; the intrinsic viscosity of high-viscosity PTT chips is 1–1.3 dL / g, and the melting point is 230–235℃.

[0027] The core layer of the composite fiber has a circular or peanut-shaped cross-section.

[0028] In step S1, the PA slices are mixed with 0.5wt% to 2wt% maleic anhydride graft compatibilizer to improve the interfacial bonding and compatibility between PTT and PA.

[0029] The maleic anhydride graft compatibilizer is maleic anhydride grafted PA.

[0030] The fabric width is 100-200cm, the elastic elongation is 5%-30%, and the elastic recovery rate is greater than 70%; the fabric weight ranges from 30 to 250g / ㎡; the tear strength of both the warp and weft directions of the fabric is greater than 6N. Example 1:

[0031] The spinning raw materials were PA chips with an intrinsic viscosity of 2.6 dL / g and a melting point of 260℃, low-viscosity PTT chips with an intrinsic viscosity of 0.9 dL / g and a melting point of 227℃, and high-viscosity PTT chips with an intrinsic viscosity of 1.2 dL / g and a melting point of 232℃. The ratio of PA to bicomponent PTT was 30:70, and the ratio of low-viscosity PTT chips to high-viscosity PTT chips was 60:40. The PA chips contained 1.2 wt% maleic anhydride-grafted PA (masterbatch method). The melt temperature of PA was set at 280℃, the melt temperature of low-viscosity PTT at 260℃, and the melt temperature of high-viscosity PTT at 270℃. The spinning raw materials were melted using a screw extruder and extruded through a spinneret with a core-sheath structure to produce POY composite fibers with a core-sheath structure; the core layer consisted of two parallel bicomponent PTT chips with a circular cross-sectional shape; the sheath layer was PA. The obtained composite fiber POY was stretched into FDY on a flat drawing machine, and then the FDY was processed on a texturing machine to obtain DTY yarn with a specification of 50D / 24F. Testing showed that the dry heat crimp elongation of the DTY yarn was 51.16%, the dry heat shrinkage was 6.74%, and the dry heat crimp shrinkage was 33.85%. The DTY yarn was woven into a greige fabric using a woven plain weave structure with a weave density of 141x113 threads / in. The greige fabric underwent pretreatment: oils, sizing agents, and impurities were removed from the fibers at a temperature of 95℃ and a speed of 30m / min. Dyeing was then performed using liquid flow dyeing under acidic conditions, with a dye bath pH of 5 and a dyeing temperature of 95℃, and a leveling agent was added. Finally, finishing was carried out using an eight-section oven for heat setting at a temperature of 150℃ and a speed of 40m / min, followed by a water-repellent finishing process to obtain the elastic memory fabric.

[0032] The tested fabric has a width of 150cm, an elastic elongation of 10%, an elastic recovery rate of 73%, a weight of 105g / ㎡, a warp tear strength of 7N, a weft tear strength of 6.5N, an abrasion resistance rating of 4 (Martindale method), and a water repellency rating of 4. Example 2:

[0033] The spinning raw materials were PA chips with an intrinsic viscosity of 2.8 dL / g and a melting point of 265℃, low-viscosity PTT chips with an intrinsic viscosity of 1.0 dL / g and a melting point of 230℃, and high-viscosity PTT chips with an intrinsic viscosity of 1.3 dL / g and a melting point of 235℃. The ratio of PA to bicomponent PTT was 20:80, and the ratio of low-viscosity PTT chips to high-viscosity PTT chips was 60:40. The PA chips contained 2 wt% maleic anhydride graft compatibilizer. The melt temperature of PA was set at 290℃, the melt temperature of low-viscosity PTT at 260℃, and the melt temperature of high-viscosity PTT at 280℃. The spinning raw materials were melted using a screw extruder and extruded through a core-sheath structure spinneret to produce core-sheath structured composite fiber POY; wherein the core layer is composed of two parallel bicomponent PTTs with a peanut-shaped cross-section; and the sheath layer is PA. The obtained composite fiber POY was stretched into FDY on a flat drawing machine, and then the FDY was processed on a texturing machine to obtain DTY yarn with a specification of 70D / 48F. Testing showed that the dry heat crimp elongation of the DTY yarn was 49.01%, the dry heat shrinkage was 6.81%, and the dry heat crimp shrinkage was 32.89%. The DTY yarn was woven into a greige fabric using a woven plain weave structure with a weave density of 117x93 threads / in. The greige fabric underwent pretreatment: oils, sizing agents, and impurities were removed from the fibers at a temperature of 95℃ and a speed of 30m / min. Dyeing was then performed using liquid flow dyeing under acidic conditions, with a dye bath pH of 6 and a dyeing temperature of 95℃, and a leveling agent was added. Finally, finishing was carried out using an eight-section oven for heat setting at a temperature of 150℃ and a speed of 40m / min, followed by a water-repellent finishing process to obtain the elastic memory fabric.

[0034] Tests showed that the fabric produced had a width of 135cm, an elastic elongation of 18%, an elastic recovery rate of 80%, a weight of 128g / ㎡, a warp tear strength of 8N, a weft tear strength of 7N, an abrasion resistance rating of 5 (Martindale method), and a water repellency rating of 5. Example 3:

[0035] The spinning raw materials were PA chips with an intrinsic viscosity of 2.8 dL / g and a melting point of 265℃, low-viscosity PTT chips with an intrinsic viscosity of 1.0 dL / g and a melting point of 230℃, and high-viscosity PTT chips with an intrinsic viscosity of 1.3 dL / g and a melting point of 235℃. The ratio of PA to bicomponent PTT was 20:80, and the ratio of low-viscosity PTT chips to high-viscosity PTT chips was 60:40. The PA chips contained 2 wt% maleic anhydride-grafted PA. The melt temperature of PA was set at 290℃, the melt temperature of low-viscosity PTT at 260℃, and the melt temperature of high-viscosity PTT at 280℃. The spinning raw materials were melted using a screw extruder and extruded through a core-sheath structure spinneret to produce core-sheath structured composite fiber POY; wherein the core layer is composed of two parallel bicomponent PTTs with a peanut-shaped cross-section; and the sheath layer is PA. The obtained composite fiber POY was stretched into FDY on a flat drawing machine, and then the FDY was processed on a texturing machine to obtain DTY yarn with a specification of 100D / 48F. Testing showed that the dry heat crimp elongation of the DTY yarn was 49.87%, the dry heat shrinkage was 5.27%, and the dry heat crimp shrinkage was 33.27%. The DTY yarn was woven into a greige fabric using a woven plain weave structure with a weave density of 101x80 threads / in. The greige fabric underwent pretreatment: oils, sizing agents, and impurities were removed from the fibers at a temperature of 95℃ and a speed of 30m / min. Dyeing was then performed using liquid dyeing under acidic conditions, with a dye bath pH of 6 and a dyeing temperature of 95℃, and a leveling agent was added. Finally, finishing was carried out using an eight-section oven for heat setting at a temperature of 150℃ and a speed of 40m / min, followed by a water-repellent finishing process to obtain the elastic memory fabric.

[0036] The fabric produced was tested and found to have a width of 135cm, an elastic elongation of 23%, an elastic recovery rate of 83%, a weight of 150g / ㎡, a warp tear strength of 8N, a weft tear strength of 7.5N, an abrasion resistance rating of 5 (Martindale method), and a water repellency rating of 5. Example 4:

[0037] The spinning raw materials were PA chips with an intrinsic viscosity of 2.4 dL / g and a melting point of 255℃, low-viscosity PTT chips with an intrinsic viscosity of 0.8 dL / g and a melting point of 225℃, and high-viscosity PTT chips with an intrinsic viscosity of 1.0 dL / g and a melting point of 230℃. The ratio of PA to bicomponent PTT was 10:90, and the ratio of low-viscosity PTT chips to high-viscosity PTT chips was 60:40. The PA chips contained 0.5 wt% maleic anhydride-grafted PA. The melt temperature of PA was set at 270℃, the melt temperature of low-viscosity PTT at 260℃, and the melt temperature of high-viscosity PTT at 280℃. The spinning raw materials were melted using a screw extruder and extruded through a core-sheath structure spinneret to obtain core-sheath structured composite fiber POY; wherein the core layer is composed of two parallel bicomponent PTT chips with a circular cross-sectional shape; and the sheath layer is PA. The obtained composite fiber POY was stretched into FDY on a flat drawing machine, and then the FDY was processed on a texturing machine to obtain DTY yarn with a specification of 150D / 96F. Testing showed that the dry heat crimp elongation of the DTY yarn was 48.32%, the dry heat shrinkage was 5.87%, and the dry heat crimp shrinkage was 34.92%. The DTY yarn was woven into a greige fabric using a woven plain weave structure with a weave density of 82x65 threads / in. The greige fabric underwent pretreatment: removing oils, sizing agents, and impurities from the fibers at a temperature of 95℃ and a speed of 30m / min. Dyeing was then performed using liquid dyeing under acidic conditions, with a dye bath pH of 4, a dyeing temperature of 95℃, and the addition of a leveling agent. Finally, finishing was carried out using an eight-section oven for heat setting at a temperature of 150℃ and a speed of 40m / min to obtain the elastic memory fabric.

[0038] The fabric produced was tested and found to have a width of 120cm, an elastic elongation of 25%, an elastic recovery rate of 85%, a weight of 183g / ㎡, a warp tear strength of 8.5N, a weft tear strength of 7.5N, and an abrasion resistance rating of 4 (Martindale method).

[0039] Regarding the content disclosed in this invention, the following points need to be explained: (1) The embodiments disclosed in this invention are merely examples, and the technical solutions implemented by other equivalent modifications fall within the scope of protection of this invention; (2) Where there is no conflict, the technical features disclosed in this invention can be combined with each other to obtain new embodiments; The above are merely specific embodiments disclosed in this invention, but the scope of protection of this invention is not limited thereto. Any technical solutions obtained by those skilled in the art after modifying or transforming certain technical features based on the content disclosed in this invention should be within the scope of protection of this invention.

Claims

1. A method for preparing an elastic memory fabric, characterized in that, Includes the following steps: S1: Spinning; The raw materials include PA chips, low-viscosity PTT chips and high-viscosity PTT chips, with the ratio of PA to bicomponent PTT being 10:90 to 30:

70. The raw materials are melted by a screw extruder and extruded through a spinneret with a core-sheath structure to produce POY composite fibers with a core-sheath structure, wherein the core layer is bicomponent PTT and the sheath layer is PA. S2: Reload; The POY composite fiber obtained in step S1 is stretched into FDY on a flat drawing machine, and then the FDY is processed on a texturing machine to obtain DTY yarn. S3: Weaving; The DTY yarn obtained in step S2 is woven into a greige fabric; S4: Dyeing and finishing; Elastic memory fabric is produced by pre-treatment, dyeing and finishing of the greige fabric.

2. The method for preparing an elastic memory fabric according to claim 1, characterized in that, In step S1, the ratio of low-viscosity PTT slices to high-viscosity PTT slices is 60:40; the core layer is composed of two PTTs of different viscosities arranged side by side.

3. The method for preparing an elastic memory fabric according to claim 1, characterized in that, The intrinsic viscosity of the PA chips is 2.4–2.8 dL / g, and the melting point is 255–265℃; the intrinsic viscosity of the PTT chips is 0.8–1.3 dL / g, and the melting point is 225–235℃.

4. The method for preparing an elastic memory fabric according to claim 1, characterized in that, In step S1, the melt temperature of PA is set to 270-290°C, and the melt temperature of PTT is set to 260-280°C.

5. The method for preparing an elastic memory fabric according to claim 1, characterized in that, The low-viscosity PTT chips have an intrinsic viscosity of 0.8–1 dL / g and a melting point of 225–230°C; the high-viscosity PTT chips have an intrinsic viscosity of 1–1.3 dL / g and a melting point of 230–235°C.

6. The method for preparing an elastic memory fabric according to claim 1, characterized in that, The core layer of the composite fiber has a circular or peanut-shaped cross-section.

7. The method for preparing an elastic memory fabric according to claim 1, characterized in that, In step S1, the PA slices contain 0.5wt% to 2wt% maleic anhydride graft compatibilizer.

8. The method for preparing an elastic memory fabric according to claim 7, characterized in that, The maleic anhydride graft compatibilizer is maleic anhydride grafted PA.

9. The method for preparing an elastic memory fabric according to claim 1, characterized in that, The fabric has an elastic recovery rate of over 70%, and both its warp and weft tear strengths are greater than 6N.

Images