Durable moisture-wicking, anti-static, lining-free downproof fabric and its processing technology

Abstract

This invention relates to the field of textile fabric technology, specifically to a durable, moisture-wicking, antistatic, lint-free down-proof fabric and its processing technology, comprising: weaving with nylon fully drawn yarn as warp and core-sheath composite yarn as weft, wherein the core layer of the core-sheath composite yarn is a block amide copolymer with hydrophilic segments; the weft yarn naturally shrinks back to form a differentiated structure with the warp yarn supporting and the weft yarn tightening; multiple calendering flattens the weft yarn, and the warp yarn bends and extends between adjacent flat weft yarns to form tortuous down-proof gaps; and a one-bath water-repellent finishing process. The block amide copolymer in the weft yarn core layer of this invention contains hydrophilic segments such as PEG or PTMG, which form charge dissipation pathways through moisture absorption, resulting in durable antistatic properties. The one-bath water-repellent finishing process achieves a synergistic effect of antistatic and water repellency. Simultaneously, the down-proof function is achieved through the tortuous physical down-proof gaps formed by the weft yarn's own shrinkage combined with temperature-dependent calendering, with both warp and weft down leakage meeting the requirement of ≤15 threads.

Description

Technical Field

[0001] This invention relates to the field of textile fabric technology, specifically to a durable, moisture-wicking, anti-static, lining-free, down-proof fabric and its processing technology. Background Technology

[0002] Down-free fabrics, by eliminating the need for an inner lining and reducing weight, have become the mainstream choice for lightweight warmth solutions. However, existing down-free fabrics still have significant issues regarding functional synergy.

[0003] The antistatic function lacks durability and affects the fabric's appearance. Existing solutions mainly rely on conductive threads for stitching or post-treatment antistatic agents: conductive threads are usually black, which can cause horizontal stripes to show through on light-colored fabrics; antistatic agents gradually lose their effectiveness after repeated washing. In addition, recently disclosed coating solutions (such as vacuum sputtering deposition of nano-metal films) and chemical coating solutions (such as electrospinning to form an inner lining film and then hot-pressing and bonding) all rely on surface additional layers for antistatic function, which are at risk of wear and peeling off during washing and friction, resulting in insufficient durability.

[0004] The contradiction between down-proofness and hand feel is difficult to reconcile. Existing down-proof solutions without lining mostly employ lamination, coating, or constant temperature calendering. Lamination and coating result in a stiff fabric hand feel and poor breathability; while constant temperature calendering does not add a chemical coating, the fabric hand feel is still stiff, and none of the above solutions simultaneously solve the problem of synergistic antistatic and water-repellent properties.

[0005] Currently, the industry still largely relies on surface-applied methods to give fabrics anti-fleece and antistatic functions, and there is no systematic solution that starts from the yarn itself and combines physical structure for anti-fleece properties. Summary of the Invention

[0006] The purpose of this invention is to provide a durable, moisture-wicking, antistatic, lining-free downproof fabric and its processing technology, in order to solve the problems of poor antistatic durability of existing lining-free downproof fabrics, the need to rely on conductive yarns or coatings which affect the appearance of light-colored fabrics, the reliance on coatings or films for downproofing which results in a stiff feel, and the difficulty in simultaneously achieving antistatic and water-repellent functions.

[0007] To achieve the above-mentioned objectives, the technical solution adopted by this invention is as follows: The processing technology for durable, moisture-wicking, anti-static, lining-free, and down-proof fabric includes the following steps: S1. Weaving: Weaving is carried out using fully drawn nylon yarn as warp and core-sheath composite structure yarn as weft, wherein: the core-sheath composite structure yarn has a conventional nylon sheath layer and a block amide copolymer core layer, and the block amide copolymer has hydrophilic segments. S2, Moisture Absorption and Shrinkage: The warp yarns maintain dimensional stability, while the weft yarns naturally shrink back, forming a differentiated physical structure where the warp yarns provide support and the weft yarns tighten. S3. Calendering: Multiple calendering passes are used, with the calendering temperature decreasing and the calendering pressure increasing in each pass. This flattens the weft yarn cross section into a flat shape, and the warp yarn bends and extends between adjacent flat weft yarns, forming a tortuous anti-fleece gap. S4. Water-repellent finishing: Water-repellent finishing is carried out using a paraffin-aluminum soap one-bath method, with two dips and two nips, and the nip-out rate is 80%-100%, with the nip-out temperature being 35℃-40℃; then it is set at 140℃-160℃.

[0008] Preferably, the main components of the fully drawn nylon yarn and the conventional nylon monofilament sheath are the same, both being nylon 6 or nylon 66.

[0009] Preferably, the flexible segments in the block amide copolymer are selected from PTMG or PEG, and the rigid segments are selected from PA6 or PA66.

[0010] Preferably, step S3 employs three-stage differential temperature calendering: the first stage has a calendering temperature of 150℃-170℃ and a calendering pressure of 40kgf / cm²-60kgf / cm²; the second stage has a calendering temperature of 130℃-155℃ and a calendering pressure of 50kgf / cm²-70kgf / cm²; and the third stage has a calendering temperature of 110℃-135℃ and a calendering pressure of 60kgf / cm²-80kgf / cm².

[0011] Preferably, the vehicle speed in step S3 is 15m / min-25m / min.

[0012] Preferably, the fabric structure obtained by weaving in step S1 is a plain weave or a twill weave.

[0013] Preferably, in step S1, the weft density is 148±2 threads / inch and the weft width is 69.6±2 inches; in step S2, the weft density increases to 156±1.5 threads / inch and the weft width decreases to 62.8±1.0 inches.

[0014] Preferably, the finished weft density in step S4 is 154±1.0 threads / inch, and the finished width is 57.0±0.5 inches.

[0015] The present invention also provides a durable, moisture-wicking, antistatic, lining-free, and down-proof fabric made using the above-described processing technology.

[0016] The fabric's water repellency rating meets the requirement of ≥3 in GB / T 4745-2012 standard, and its down-proofness is tested by the friction method in GB / T12705.1-2024. Both warp and weft down-proofness meet the requirement of ≤15 threads.

[0017] Compared with the prior art, the present invention has the following beneficial effects: The warp yarn of this invention is made of conventional nylon, and the weft yarn is made of core-sheath composite yarn with the core layer being a block amide copolymer. The block amide copolymer contains hydrophilic segments such as PEG or PTMG, which form charge dissipation pathways through moisture absorption. The antistatic function comes from the moisture absorption and conductivity mechanism of the core layer material, which is an intrinsic property of the fiber material and has durable antistatic properties.

[0018] Meanwhile, the block amide copolymer in the weft core layer has a higher shrinkage rate than conventional nylon in a humid environment, which allows the weft yarn to shrink naturally without relying on external force when it comes off the weaving machine. The down-proof function is achieved by the weft yarn shrinkage combined with the tortuous physical down-proof gaps formed by the temperature-controlled calendering. No coating or film is required. The down-proof performance is tested according to the friction method of GB / T 12705.1-2024. Both warp and weft down-proofing meet the requirement of ≤15 threads. Moreover, the multiple temperature-controlled calenderings maintain the soft hand feel of the fabric while achieving down-proofing.

[0019] The application scenarios and functional scope of this invention are different. When used for chemical fiber quilt and duvet cover fabrics, it does not involve water-repellent function; while when used for down jacket lining-free down-proof fabrics, it achieves a water repellency level of ≥3 through a one-bath low-temperature setting and finishing process, and the antistatic and water-repellent functions are synergistically achieved on the same fabric, while protecting the activity of hydrophilic segments in the core layer block amide copolymer. Detailed Implementation Example 1

[0020] This embodiment provides a processing technology for a durable, moisture-wicking, anti-static, lining-free, down-proof fabric, including the following steps: S1. Weaving: Using 20D / 24F fully drawn nylon 6 yarn as warp and 30D / 26F core-sheath composite yarn as weft, a plain weave structure is produced on a water jet loom. The reed count is 64 downs / inch, the weft density is 148 ends / inch, the width is 69.6 inches, and the total warp count is 13,300 ends. The nylon 6 fully drawn yarn provides a stable warp skeleton for the fabric.

[0021] Wherein: the monofilaments in the core-sheath composite structure yarn have a core-sheath structure, with the sheath being nylon 6 and the core being a block amide copolymer. The flexible segments of the block amide copolymer are PEG (PEG as a hydrophilic segment), and the rigid segments are PA6. The shrinkage rate is higher than that of conventional nylon in a humid environment, causing the weft yarn to naturally shrink after weaving. At the same time, the hydrophilic segments form charge dissipation pathways through moisture absorption. The antistatic function comes from the moisture absorption and conductivity mechanism of the core, which is an intrinsic property of the fiber material and has durable antistatic properties.

[0022] S2. Moisture Absorption and Shrinkage: After weaving, the weft yarns naturally shrink due to moisture absorption by the core layer, tightening the fabric width from 69.6 inches to 62.8 inches and increasing the weft density from 148 threads / inch to 156 threads / inch. Nylon 6 fully drawn yarn, with its low shrinkage and high strength, ensures the warp yarns remain dimensionally stable during this process, creating a differentiated physical structure where the warp yarns provide support and the weft yarns tighten.

[0023] S3. Calendering: Most of the tightening work is completed through the moisture absorption and shrinkage of the core layer. The purpose of calendering is to consolidate the formed structure, smooth the surface, and eliminate stress.

[0024] Specifically, a three-stage temperature-controlled calendering process is employed, with each stage running at a speed of 20 m / min. This flattens the weft yarn cross-section, causing the warp yarns to bend and extend between adjacent flattened weft yarns, forming a zigzag anti-fleece gap. Among these: The first calendering temperature is 160℃ and the calendering pressure is 50kgf / cm2. The appropriate pressure allows the weft yarn to be softened by heat and fixed at the same time. The block amide copolymer core layer of the weft yarn softens but does not flow in this range, and the shrinkage structure of the weft yarn is fixed, further locking the physical relationship between the warp and weft yarns.

[0025] The second calendering temperature is 140℃ and the calendering pressure is 60kgf / cm2. At this time, the weft yarn has been set and the temperature is lower than that of the first calendering. The weft yarn will not shrink further, but the surface still retains a certain degree of plasticity and elasticity. The fabric is further compacted but the yarn is not softened excessively to avoid a stiff feel.

[0026] The third calendering process involves a temperature of 120℃ and a pressure of 70 kgf / cm². This temperature is below the softening point of nylon and only performs surface smoothing. The higher pressure eliminates the internal stress generated in the first two processes, preserving the fabric's soft feel. Furthermore, this low-temperature range is significantly lower than the conventional high-temperature setting of 170-190℃, protecting the moisture absorption and electrical conductivity of the hydrophilic segments in the weft core layer.

[0027] S4. Water-repellent finishing: After calendering, water-repellent finishing is carried out using a paraffin-aluminum soap one-bath method, followed by two dips and two nips, with a 100% nip-out rate and a nip-out temperature of 40℃. Then, it is set at 150℃. The finished product has a width of 57.0 inches and a weft density of 154 threads / inch, which meets the lower limit of the crosslinking requirements of the water-repellent agent and protects the antistatic activity of the block amide copolymer in the core layer.

[0028] The formula for the paraffin-aluminum soap slurry is as follows: paraffin 50g / L, aluminum acetate 50g / L, caustic soda 10g / L, rosin 15g / L, gelatin 18g / L, and stearic acid 5g / L. To prepare the paraffin-aluminum soap slurry, first mix the rosin, stearic acid, gelatin, and caustic soda, heat to 65℃, then pour in molten paraffin and stir continuously until fully emulsified. Next, slowly add the emulsion to the dissolved aluminum acetate solution, stirring thoroughly until homogeneous. Finally, add water until the emulsion concentration is 20g / L.

[0029] The fabric in this embodiment does not have any additional film, coating, plating, or conductive yarn. Testing showed that the fabric obtained in this embodiment achieves a water repellency rating of level 3, meeting the requirement of ≥ level 3 in GB / T 4745-2012 standard; down-proofness was tested using the friction method in GB / T 12705.1-2024, with 7 warp down fibers and 9 weft down fibers, both meeting the requirement of ≤15 down fibers; air permeability was tested according to GB / T 5453-1997 standard, with an air permeability rate of 1.45 mm / s to 1.555 mm / s; pilling resistance was tested according to GB / T 4802.1-2008 standard, reaching level 4; abrasion resistance was tested according to GB / T 21196.2-2007 standard, reaching 12,000 cycles; the voltage of the weft friction band is approximately one-fifth that of conventional nylon, an effect derived from the hygroscopic and conductive mechanism of the hydrophilic segments in the yarn core, providing durable antistatic properties.

[0030] It should be noted that in some other examples, the monofilament sheath in the warp and core-sheath composite yarns can also be nylon 66; the flexible segments in the block amide copolymer are selected from PTMG while the rigid segments are selected from PA66; the fabric structure can also be a basic structure or a variation of a twill weave.

[0031] The foregoing has shown and described the basic principles, main features and advantages of this invention. Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are only illustrative of the principles of this invention. Various changes and modifications can be made to this invention without departing from the spirit and scope of this invention. All such changes and modifications fall within the scope of this invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A process for the production of a durable moisture-absorbing antistatic non-dope-proof coated fabric characterized by, Includes the following steps: S1. Weaving: Weaving is carried out using fully drawn nylon yarn as warp and core-sheath composite structure yarn as weft, wherein: the core-sheath composite structure yarn has a conventional nylon sheath layer and a block amide copolymer core layer, and the block amide copolymer has hydrophilic segments. S2, Moisture Absorption and Shrinkage: The warp yarns maintain dimensional stability, while the weft yarns naturally shrink back, forming a differentiated physical structure where the warp yarns provide support and the weft yarns tighten. S3. Calendering: Multiple calendering passes are used, with the calendering temperature decreasing and the calendering pressure increasing in each pass. This flattens the weft yarn cross section into a flat shape, and the warp yarn bends and extends between adjacent flat weft yarns, forming a tortuous anti-fleece gap. S4. Water-repellent finishing: Water-repellent finishing is carried out using a paraffin-aluminum soap one-bath method, with two dips and two nips, and the nip-out rate is 80%-100%, with the nip-out temperature being 35℃-40℃; then it is set at 140℃-160℃.

2. The process for manufacturing a durable moisture-absorbing anti-static lycra-free non-pilling fabric according to claim 1, wherein: The main components of the fully drawn nylon yarn and the conventional nylon monofilament sheath are the same, both being nylon 6 or nylon 66.

3. The process for manufacturing a durable moisture-absorbing anti-static lycra-free non-pilling fabric according to claim 1, wherein: The flexible segments in the block amide copolymer are selected from PTMG or PEG, and the rigid segments are selected from PA6 or PA66.

4. The process for manufacturing a durable moisture absorbent anti-static, non-dope, non-pilling fabric according to claim 1, wherein: In step S3, three-stage differential temperature calendering is used. The first stage has a calendering temperature of 150℃-170℃ and a calendering pressure of 40 kgf / cm². 2 -60kgf / cm 2 The second calendering process involves a calendering temperature of 130℃-155℃ and a calendering pressure of 50 kgf / cm². 2 -70kgf / cm 2 The third calendering process has a calendering temperature of 110℃-135℃ and a calendering pressure of 60 kgf / cm. 2 -80kgf / cm 2 .

5. The process for manufacturing a durable moisture-absorbing anti-static lycra-free non-pilling fabric according to claim 4, wherein: The vehicle speed in step S3 is 15m / min-25m / min.

6. The process for manufacturing a durable moisture-absorbing anti-static lycra-free non-pilling fabric according to claim 1, wherein: The fabric structure obtained by weaving in step S1 is either plain weave or twill weave.

7. The process for manufacturing a durable moisture absorbent antistatic, non-dope, non-pilling fabric according to claim 1, wherein: In step S1, the weft density is 148±2 threads / inch and the weft width is 69.6±2 inches; in step S2, the weft density increases to 156±1.5 threads / inch and the weft width shrinks to 62.8±1.0 inches.

8. The processing technology for the durable moisture-wicking, antistatic, lining-free, and down-proof fabric according to claim 7, characterized in that: The finished product weft density in step S4 is 154±1.0 threads / inch, and the finished product width is 57.0±0.5 inches.

9. A durable, moisture-wicking, antistatic, lining-free, down-proof fabric manufactured using the processing technology described in any one of claims 1 to 5.

10. The durable moisture-wicking, antistatic, lining-free, and down-proof fabric according to claim 9, characterized in that: The fabric's water repellency rating meets the requirement of ≥3 in GB / T 4745-2012 standard, and its down-proofness is tested by the friction method in GB / T 12705.1-2024. Both warp and weft down-proofness meet the requirement of ≤15 threads.