A dynamic sweat-wicking functional fabric and its preparation method

Abstract

This application discloses a dynamic perspiration-wicking functional fabric and its preparation method, belonging to the field of textile fabric technology. The functional fabric comprises a first fabric surface layer and a second fabric surface layer knitted from a dual-yarn system; the yarn count (D) of the first fabric surface layer is greater than that of the second fabric surface layer, and the yarn flow rate (F) of the first fabric surface layer is greater than that of the second fabric surface layer; the yarn system of the first fabric surface layer is hydrophilic, with a water contact angle of less than 90 degrees; the yarn system of the second fabric surface layer comprises a first base yarn, a second base yarn, and a moisture-wicking textured yarn spaced apart; the first base yarn has higher hydrophilicity than the second base yarn, and the second base yarn is a water-repellent yarn. This invention synergistically combines differential capillary effect, wetting gradient effect, and moisture-wicking textured effect to achieve dynamic perspiration wicking.

Description

Technical Field

[0001] This application belongs to the field of textile fabric technology, and in particular relates to a dynamic sweat-wicking functional fabric and its preparation method. Background Technology

[0002] The human body produces a large amount of sweat during exercise or in hot and humid environments. Its main function is to maintain a constant body temperature through evaporation. If sweat is not promptly wicked away from the skin and evaporates, it accumulates in the microclimate between the skin and clothing, causing the fabric to stick to the skin and resulting in discomfort such as dampness, coldness, and stickiness. This severely impacts thermal comfort and athletic performance. Furthermore, the humid environment provides favorable conditions for microbial growth, easily leading to odor and skin health problems. Therefore, developing fabrics that can quickly guide sweat from the inside of the skin to the outside of the fabric and accelerate evaporation has been a long-term goal in the sports, outdoor, and casual wear industries.

[0003] Currently, achieving the moisture-wicking and quick-drying function of fabrics mainly relies on three technical pathways: fiber material modification, fabric structure design, and functional finishing. Fiber modification improves the hydrophilicity and moisture-wicking properties of materials through physical or chemical means, such as using irregular cross-sections, hollow porous structures, or blending / composite spinning with hydrophilic polymers, thus improving the basic raw materials of the fabric. Some existing moisture-wicking fabrics consist of moisture-wicking warp and weft fibers, with the warp fibers having an X-shaped cross-section and the weft fibers having an O-shaped cross-section; there are also moisture-wicking and quick-drying fiber materials with irregular cross-sections such as cross-shaped and Y-shaped cross-sections. However, such methods often face problems such as complex processes, high costs, and difficulty in balancing large-scale production with cost-effectiveness. Creating moisture-wicking fabrics through specific fabric structure design mainly utilizes knitting or weaving processes to construct different pores, loops, or yarn configurations on the front and back of the fabric, combined with capillary effect for water wicking. Many functional fabric products rely on the finishing stage to apply a hydrophilic or hydrophobic coating or printing treatment to one side of the fabric to create a wetting gradient and achieve unidirectional moisture transfer. This method is relatively simple, but such functional coatings and printed layers have certain durability limitations. After repeated washing, they are prone to wear and peeling, resulting in a significant reduction in their moisture-wicking and quick-drying properties.

[0004] A more critical common limitation lies in the fact that the moisture-wicking and quick-drying mechanisms of existing technologies are mostly static. That is, the moisture-wicking capacity of the fabric remains fixed after it is manufactured. However, the human body's sweating process is dynamic, creating a contradiction between the static moisture-wicking and quick-drying functions of clothing fabrics and the dynamic need for perspiration wicking. During low-intensity activity (light sweating), excessive static moisture wicking may draw too much moisture from the skin's surface, leading to dryness and itching. Conversely, during high-intensity exercise or in high-temperature environments (profuse sweating), a fixed moisture-wicking rate is insufficient to cope with the rapid increase in sweat volume, ultimately causing sweat to remain on the skin's surface. Therefore, developing a "dynamic perspiration-wicking" fabric that can respond to changes in the amount of sweat produced and adaptively adjust its moisture-wicking rate has been a long-standing technical challenge. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a dynamic moisture-wicking functional fabric and its preparation method. The functional fabric has the ability to respond to changes in humidity and adaptively adjust its moisture-wicking performance, and can dynamically wick away sweat, which is beneficial for application.

[0006] This application provides a dynamic moisture-wicking functional fabric, comprising a first fabric surface layer and a second fabric surface layer formed by knitting a dual yarn system.

[0007] The number of yarns D in the first fabric surface layer is greater than the number of yarns D in the second fabric surface layer, and the number of yarns F in the first fabric surface layer is greater than the number of yarns F in the second fabric surface layer.

[0008] The yarn system of the first fabric surface layer is hydrophilic, with a water contact angle of less than 90 degrees; the yarn system of the second fabric surface layer includes a first base yarn, a second base yarn, and a moisture-absorbing textured yarn arranged at intervals; the first base yarn is more hydrophilic than the second base yarn, and the second base yarn is a water-repellent yarn.

[0009] In some embodiments, the yarn of the first fabric surface layer is a 75-100D / 72F hydrophilic filament, and the yarn of the second fabric surface layer is a 30-50D / 24F filament.

[0010] In some embodiments, the water contact angle of the first fabric surface layer is less than 30 degrees; the first base yarn is hydrophilic polyester filament or hydrophilic nylon filament; and the second base yarn is fluorine-free water-repellent yarn.

[0011] In some embodiments, the functional fabric has a double rib knit cross weave with a weight of 180-200 g / m². 2 .

[0012] This application provides a method for preparing the aforementioned dynamic sweat-wicking functional fabric, comprising:

[0013] A double-sided circular knitting machine is used to knit the yarns of the first and second fabric face layers. The first base yarn, the second base yarn, and the moisture-wicking textured yarn are fed in a cyclical manner to form the second fabric face layer. The first base yarn has higher hydrophilicity than the second base yarn, and the second base yarn is a water-repellent yarn. The first fabric face layer formed by knitting is hydrophilic.

[0014] After being taken off the machine, the woven fabric is relaxed and then set to obtain the dynamic sweat-wicking functional fabric.

[0015] In some embodiments, the yarn of the first fabric surface layer is made by plasma hydrophilic modification or by adding hydrophilic masterbatch during spinning.

[0016] In some embodiments, the moisture-wicking textured yarn is made of polyester or nylon as the base material, and is obtained by introducing hydrophilic chips in parallel spinning through blending.

[0017] In some embodiments, the knitting process is controlled at a speed of 15-25 rpm and the tension is controlled between 3 and 5 mN.

[0018] In some embodiments, refining, primarily to remove oils, is also included between the relaxation and setting processes.

[0019] In some embodiments, the shaping temperature is 150-165°C.

[0020] The functional fabric provided by this invention is woven using a dual-yarn system, featuring a basic knitted structure consisting of a first fabric surface layer and a second fabric surface layer. The yarn count (D) of the first fabric surface layer is greater than that of the second fabric surface layer, and the yarn flow rate (F) of the first fabric surface layer is also greater than that of the second fabric surface layer. Simultaneously, the yarn system of the first fabric surface layer is hydrophilic, while the yarn system of the second fabric surface layer includes a first base yarn, a second base yarn (water-repellent yarn), and a moisture-wicking textured yarn arranged at intervals. The first base yarn has higher hydrophilicity than the second base yarn. Using the functional fabric described in this invention, under slightly sweaty conditions, the water-repellent yarn of the second fabric surface layer (inner layer) can inhibit excessive moisture loss, while the moisture-wicking textured yarn exhibits only minor deformation, maintaining a relatively loose fabric structure and ensuring breathability. Under conditions of intense sweating, high humidity simultaneously triggers two mechanisms: ① the water-repellent yarn areas are wetted, increasing the moisture-wicking pathways; ② the moisture-wicking textured yarns stretch, actively pulling on surrounding yarns, causing displacement of the inner layer coil structure and increasing the fabric's porosity. Increased porosity facilitates rapid evaporation of outer layer moisture, thereby improving peak moisture-wicking efficiency under conditions of intense sweating. This invention synergistically combines differential capillary effect, wetting gradient effect, and moisture-wicking textured effect to achieve dynamic perspiration wicking. Attached Figure Description

[0021] Figure 1This is a schematic diagram illustrating the double-layer principle of the dynamic sweat-wicking functional fabric described in an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram of the yarn spacing arrangement structure of the inner layer in Embodiment 1 of the present invention. Detailed Implementation

[0023] The technical solutions in the embodiments of this application are described clearly and completely below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0024] This application provides a dynamic moisture-wicking functional fabric, comprising a first fabric surface layer and a second fabric surface layer formed by knitting a dual yarn system.

[0025] The number of yarns D in the first fabric surface layer is greater than the number of yarns D in the second fabric surface layer, and the number of yarns F in the first fabric surface layer is greater than the number of yarns F in the second fabric surface layer.

[0026] The yarn system of the first fabric surface layer is hydrophilic, with a water contact angle of less than 90 degrees; the yarn system of the second fabric surface layer includes a first base yarn, a second base yarn, and a moisture-absorbing textured yarn arranged at intervals; the first base yarn is more hydrophilic than the second base yarn, and the second base yarn is a water-repellent yarn.

[0027] This application provides a method for preparing the aforementioned dynamic perspiration-wicking functional fabric, comprising:

[0028] A double-sided circular knitting machine is used to knit the yarns of the first and second fabric layers. The first base yarn, the second base yarn, and the moisture-wicking textured yarn are fed in a cyclical manner to form the second fabric layer. The first base yarn has higher hydrophilicity than the second base yarn, and the second base yarn is a water-repellent yarn. The first fabric layer formed by knitting is hydrophilic.

[0029] After being taken off the machine, the woven fabric is relaxed and then set to obtain the dynamic sweat-wicking functional fabric.

[0030] The functional fabric provided by this invention has the ability to respond to changes in humidity and adaptively adjust its moisture-wicking properties, enabling dynamic perspiration wicking and facilitating its application.

[0031] The embodiments of this invention first prepare yarn raw materials, including raw materials for a first fabric surface layer and a second fabric surface layer. The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate; this is merely a way of distinguishing objects with the same attributes in the embodiments of this application. Generally, in the embodiments of this invention, the first fabric surface layer is the front side of the fabric, that is, the outer layer, surface layer, etc., of the fabric away from the skin; the second fabric surface layer is the reverse side of the fabric, that is, the inner layer, back layer, bottom layer, etc., of the fabric close to the skin.

[0032] In embodiments of the present invention, to achieve differential capillary effect, the denier (D) of the outer layer yarn is greater than that of the inner layer yarn, and the filament number (F) of the outer layer yarn is greater than that of the inner layer yarn. This configuration allows the inner layer yarn to form a finer microporous structure with higher capillary pressure, while the outer layer yarn forms a coarser macroscopic channel with lower capillary pressure. This establishes a stable capillary pressure difference from the inner layer to the outside, serving as the basic driving force for directional moisture transport. In a preferred embodiment of the present invention, 75-100D / 72F hydrophilic filaments are used as the outer layer yarn, and 30-50D / 24F filaments are used as the inner layer yarn. For example, the outer layer yarn is selected as 75D / 72F fine denier hydrophilic polyester FDY filament (fully oriented filament); the inner layer yarn can be selected as 50D / 24F chemical filament.

[0033] "D number" indicates yarn thickness; the higher the D number, the thicker the yarn. "F number" indicates the number of filaments in a single yarn; the higher the F number, the more finer filaments make up the same thickness of yarn, resulting in a larger specific surface area, a denser capillary structure, and higher capillary pressure. Therefore, the configuration of "high D and high F in the surface layer yarn" and "low D and low F in the bottom layer yarn" in this embodiment of the invention is to make the filaments in the bottom layer of the fabric finer and denser, thereby generating higher capillary pressure than the surface layer, which is beneficial for achieving differential capillary effect.

[0034] The hydrophilic yarns of the first fabric surface layer (fabric front and outer layers) impart hydrophilicity to the fabric front (outer layer); this can be called face yarn, and can be commercially available or made by plasma hydrophilic modification or by adding hydrophilic masterbatch during spinning. Typically, the water contact angle of the hydrophilic surface is less than 90 degrees.

[0035] The yarns of the second fabric surface layer (the reverse side of the fabric, the inner layer) have a certain proportion of first base yarn and second base yarn. The first base yarn is preferably hydrophilic polyester filament or hydrophilic nylon filament; the second base yarn is preferably a fluorine-free water-repellent yarn, and its fiber material type is polyester or nylon. To further enhance the dynamic response capability, in this embodiment of the invention, moisture-absorbing textured yarns are also intermittently combined and arranged in the yarn system on the reverse side of the fabric.

[0036] In a preferred embodiment of the present invention, the fluorine-free water-repellent yarn can be obtained by treating ordinary yarn with plasma modification and ultraviolet curing technology, or by directly adding fluorine-free water-repellent agent chips during the spinning process. Preferably, the hydrophilicity of the first base yarn is higher than that of the second base yarn fluorine-free water-repellent yarn.

[0037] Fluorine-free water repellents typically refer to environmentally friendly water-repellent finishing agents based on substances such as organosilicon (silicone), long-chain alkanes (such as paraffin), and their derivatives. Their water-repellent principle primarily involves reducing surface energy, rather than simultaneously reducing surface energy and solid-liquid interfacial tension like fluorine-containing water repellents. Therefore, their water-repellent performance (especially hydrostatic pressure resistance) is usually slightly weaker than fluorine-containing products. However, this invention utilizes its "weaker and reversible" characteristics to construct a "dynamic gate."

[0038] In a specific embodiment of the present invention, the moisture-absorbing textured yarn is mainly made of polyester or nylon as the base material, and is obtained by introducing hydrophilic chips through blending and parallel spinning; it can be circular or irregularly shaped. The principle is as follows: after absorbing moisture, the hydrophilic segments absorb water and stretch, resulting in significant longitudinal elongation deformation of the fiber macroscopically (polyester or nylon with added highly hydrophilic polymers or copolymer / grafted highly hydrophilic structures, which have high hydrophilicity, can stretch their macromolecular segments after absorbing water / water vapor, causing morphological changes and swelling, thereby generating significant internal stress), driving the coil structure displacement to increase the fabric porosity; during drying, due to the entropy elasticity-driven retraction and curling of the polymer chains, the cohesive force between the chain segments is enhanced, squeezing and expelling bound water, restoring the fiber macroscopic length to its initial state. This process is a reversible physical deformation, not involving the breaking and recombination of chemical bonds. The fiber restoration to its original length described in the embodiments of the present invention provides the mechanical force driving the change in fabric structure.

[0039] This moisture-wicking deformation principle utilizes the helical deformation or longitudinal elongation mechanism caused by the difference in moisture absorption between the two components in eccentric / parallel composite fibers, and reversible shrinkage occurs during drying. However, in synthetic fibers, this is achieved through molecular design. After absorbing water, the hydrophilic segments extend, macroscopically manifested as longitudinal elongation of the yarn and deformation of the loops, thereby changing the fabric structure. This is a physical change process that is reversible. Moisture-wicking textured yarns are not limited to a "peanut-shaped" cross-section; they can also be concentric, as long as they can satisfy the deformation characteristics of moisture absorption elongation and drying recovery.

[0040] In embodiments of the present invention, the moisture-wicking textured yarn is either a commercially available product or a self-made product. Commercially available products may include Toray T-400 moisture-wicking textured yarn (Japan) or Hyosung TMT FTET parallel composite moisture-wicking textured yarn, etc., with a longitudinal elongation ≥12% under saturated water absorption and an elongation recovery rate ≥95% after drying. The self-made method involves using PET as the base material, blending 15-25 wt% of polyetherketone-type hydrophilic copolyester chips, and then melt-spinning (spinning temperature 280-290℃, spinning speed 3500-4500 m / min) to obtain 50D / 24F yarn.

[0041] In some embodiments of the present invention, ordinary yarn and fluorine-free water-repellent yarn can be interspersed in a ratio of 4 ordinary yarns interspersed with 1 fluorine-free water-repellent yarn, and woven in alternately; or hydrophilic yarn and fluorine-free water-repellent yarn can be interspersed. The "4 ordinary yarns interspersed with 1 fluorine-free water-repellent yarn" is only an example, and the ratio can be adjusted to 6:1, 5:1, 3:1, 2:1, 1:1, etc., or a more complex non-uniform distribution pattern (such as gradient distribution, stripe distribution) can be used to precisely control the "barrier-moisture wicking" balance in different areas.

[0042] In some specific embodiments of the present invention, three ordinary hydrophilic yarns, one fluorine-free water-repellent yarn, and one moisture-absorbing textured yarn are sequentially fed in a cyclical ratio (i.e., 3:1:1) to form an alternately arranged base yarn structure. The base yarn is then cyclically fed into a double-sided circular knitting machine. The face yarn is woven to form the outer layer of the fabric, and the base yarn is woven to form the inner layer (the skin-contacting surface), thus creating a standard double-sided knitted structure. The functional fabric described in the embodiments of the present invention can be a double rib knit structure. Specifically, the knitting needles are arranged in a rib pattern. During the knitting process, the face yarn and base yarn alternately form loops and tufts according to a certain pattern, forming a structure with air gaps.

[0043] This design creates a dynamic wetting gradient system: in low-humidity environments, the water-repellent effect of the fluorine-free water-repellent yarn dominates, effectively reducing the overall hydrophilicity and moisture-wicking efficiency of the inner layer, mitigating excessive absorption during light perspiration, and preventing excessive dryness of the skin during light perspiration; in high-humidity (excessive sweating) environments, a large amount of liquid water will locally break through the barrier of the fluorine-free water-repellent yarn, be quickly captured by the large number of surrounding hydrophilic / ordinary yarns, and rapidly discharged using differential capillary effect. The fluorine-free water-repellent yarn plays a selective blocking role in this process; its water-repellent properties are partially lost upon impact with liquid water, and can be restored after the humidity decreases, achieving dynamic adjustment.

[0044] Preferably, the knitting speed in the embodiments of the present invention is controlled at 15-25 rpm, and the tension is controlled between 3 and 5 mN.

[0045] After finishing, in this embodiment of the invention, the woven fabric (grey fabric) is subjected to a flat-width relaxation treatment at room temperature for 4-6 hours, or in a warm water bath at 40-50°C for 30-60 minutes, to eliminate internal stress generated during spinning and weaving. Additionally, a non-ionic refining agent (such as fatty alcohol polyoxyethylene ethers) at 2-4 g / L, a liquor ratio of 1:10-1:15, a temperature of 60-80°C, and a treatment time of 20-40 minutes can be used to remove spinning oils from the yarn surface and impurities such as wax and oil introduced during weaving. After refining, the fabric is rinsed 2-3 times with clean water until the pH value is neutral. Subsequently, a heat setting machine is used for dry heat setting at a setting temperature of 150-165°C, a machine speed controlled at 15-25 m / min, an overfeed rate controlled at +5%-+10%, and a width expansion controlled within ±2% of the target width of the finished product. High-temperature over-setting should be avoided during the setting process to preserve the water-repellent properties of the fluorine-free water-repellent yarn and the potential deformation ability of the moisture-wicking textured yarn. After setting, the fabric width should be controlled at 180cm, and the weight at 180~200g / m². 2 Ultimately, a dynamic sweat-wicking functional fabric with a triple synergistic effect was obtained.

[0046] For example, the weight of the functional fabric may be 180-200 g / m². 2 The fabric width is controlled at 180cm. In addition, the longitudinal density of the fabric is approximately 90-95 threads / 5cm, and the transverse density is approximately 120-130 threads / 5cm.

[0047] Research has found that most existing technologies rely on differential capillary effects determined by fixed differences in fiber cross-sectional shape. Once the fabric is woven, the capillary pressure difference between its two sides is a constant value, unable to change with variations in external humidity conditions, and therefore unsuitable for dynamic perspiration scenarios. At low perspiration rates, its fixed and strong capillary suction may lead to excessive loss of necessary moisture from the skin surface, causing dryness and discomfort; at high perspiration rates, its fixed moisture-wicking capacity easily reaches saturation, failing to meet peak demands, resulting in moisture wicking lag and sweat accumulation. Its static properties are the fundamental reason why it cannot provide optimal comfort in all scenarios.

[0048] One-way moisture wicking technology is a key solution to the problem of moisture absorption and perspiration. Its basic principle is to create a humidity or capillary pressure gradient from the inner layer of the fabric (in contact with the skin) to the outer layer (in contact with the air), driving liquid water to spontaneously travel in one direction. Because this invention incorporates water-repellent yarns as barrier units and dynamically responsive moisture-wicking textured yarns, the fabric's moisture-wicking properties become dynamic. The double-knitted fabric woven from this yarn system automatically adapts to the full range of perspiration intensities, from light sweating to heavy sweating, avoiding excessive dryness at low intensity and insufficient moisture wicking at high intensity, providing an extremely dry wearing experience at any stage of exercise.

[0049] like Figure 1 As shown, Figure 1 The outer layer of yarn is hydrophilic yarn (hydrophilic polyester filament), while the inner layer is composed of three types of yarn in a specific ratio: hydrophilic yarn, fluorine-free water-repellent yarn, and moisture-absorbing textured yarn. Moisture on the skin side is absorbed and diffused through the inner layer and evaporates to the outer layer.

[0050] During peak sweating periods, the active deformation mechanism of the introduced moisture-wicking textured yarn instantly increases the fabric's porosity, accelerating evaporation. This provides the fabric with a peak performance boost that is distributed on demand, surpassing all static materials, effectively handling extreme sweating scenarios and completely solving the problem of sweat accumulation and clinging to the skin.

[0051] This invention innovatively combines differential capillary effect, wetting gradient effect, and moisture absorption deformation effect to produce a synergistic effect, endowing the fabric with the ability to respond to changes in humidity and adaptively adjust its moisture-wicking properties. This dynamic intelligent perspiration-wicking function can comprehensively improve the comfort of the fabric, especially achieving excellent perspiration-wicking capabilities.

[0052] Furthermore, in the embodiments of this invention, the hydrophilic, water-repellent, and deformable functions are achieved through fiber chemical modification or structural design, rather than through post-treatment coatings. The functionality and durability of this invention are significantly improved: the functionality is integrated with the fiber itself, resulting in wash resistance and abrasion resistance far superior to post-treated functional fabrics, leading to a longer product lifespan and stable, long-lasting functionality.

[0053] Furthermore, the embodiments of the present invention are environmentally friendly and comply with environmental regulations. The preferred technical solution of the present invention completely eliminates environmentally controversial fluorinated compounds (PFCs), adopts a fluorine-free chemical system and physical modification technology; the product is safe and non-toxic, meets increasingly stringent global environmental regulations (such as restrictions on PFAS), and has higher market access and social acceptance.

[0054] To better understand the technical content of this application, specific embodiments are provided below for further explanation. The substances used in these embodiments may be commercially available.

[0055] Example 1:

[0056] First, raw material preparation is carried out. The outer layer yarn is made of 75D / 72F hydrophilic polyester filament (purchased from Sheng Hong Group Co., Ltd., 75D / 72F hydrophilic polyester FDY, water contact angle <30 degrees). This filament is prepared by adding hydrophilic masterbatch to the spinning melt.

[0057] The inner bottom yarn is composed of three types of yarn in a specific ratio. The first type is 50D / 24F ordinary hydrophilic polyester FDY filament (purchased from Sheng Hong Group Co., Ltd.). It is also prepared by adding hydrophilic masterbatch to the spinning melt. Its hydrophilicity is between that of the outer hydrophilic yarn and the water-repellent yarn, and the water contact angle is between 40 degrees and 60 degrees.

[0058] The second type is a self-made fluorine-free water-repellent yarn. The preparation method is to add silicone-based fluorine-free water-repellent masterbatch (5wt%) to the spinning melt and melt-spin it into 50D / 24F polyester filament. Its single filament diameter is also about 3.3μm, and the water contact angle is about 140 degrees.

[0059] The third type is moisture-wicking textured yarn (T-400 moisture-wicking textured yarn, Toray Industries, Japan, 50D / 24F), which can achieve a longitudinal elongation of more than 12% under water-saturated conditions and can reversibly recover after drying.

[0060] The ratio of the number of yarns in these three types of yarns is 3:1:1, which is the ratio of ordinary hydrophilic yarn to non-fluorine water-repellent yarn to moisture-wicking textured yarn. Figure 2 As shown.

[0061] The weaving process then proceeds using a 30-inch diameter, 24G double-sided circular knitting machine, employing a double rib cross-stitch structure. The needles of the double-sided circular knitting machine are arranged in a rib pattern (i.e., the needles on the upper needle plate and lower needle cylinder are alternately configured). During weaving, the face yarn and base yarn alternate according to a specific loop-forming and tucking pattern. The outer layer is uniformly fed with 75D / 72F hydrophilic polyester filament to form the outer surface of the fabric. The inner layer is formed by cyclically feeding ordinary hydrophilic yarn, fluorine-free water-repellent yarn, and moisture-wicking textured yarn in a 3:1:1 ratio. The base yarn forms the inner layer of the fabric, the surface in contact with the skin. Through the alternating loop-forming and tucking of the needles on the upper needle plate and lower needle cylinder, the loops of the outer and inner layers interlock in the fabric thickness direction, forming a double rib cross-stitch structure with an air-layered structure. The weaving speed is controlled at 20 rpm, and the tension is controlled between 3 and 5 mN.

[0062] After weaving, the fabric undergoes finishing treatment: the greige fabric is relaxed at room temperature (25±2℃) for 5 hours, followed by relaxation in a 45℃ water bath for 60 minutes to eliminate internal stress generated during spinning and weaving. A non-ionic refining agent, fatty alcohol polyoxyethylene ether (AEO-9), is used at a dosage of 2-4 g / L, a liquor ratio of 1:12, a temperature of 60℃, and a treatment time of 30 minutes. This primarily removes spinning oils from the yarn surface and impurities such as waxes and oils introduced during weaving. After refining, the fabric is rinsed 2-3 times with clean water until the pH value is neutral. It is then set at 160℃ for 40 seconds, with the overfeed rate controlled at +5% to +8%, the machine speed controlled at 20 m / min, the width controlled at 180 cm, and the weight controlled at 200 g / m².2 The result is a dynamic sweat-wicking fabric with a triple synergistic effect, with a longitudinal density of approximately 90 threads / 5cm and a transverse density of approximately 120 threads / 5cm.

[0063] Example 2:

[0064] First, raw material preparation is carried out. The outer layer yarn is made of 100D / 96F hydrophilic polyester filament (purchased from Sheng Hong Group Co., Ltd., 100D / 96F hydrophilic polyester FDY, water contact angle <25 degrees). This filament is prepared by adding hydrophilic masterbatch to the spinning melt.

[0065] The inner layer yarn is composed of three types of yarn in a specific ratio. The first type is a 30D / 24F ordinary hydrophilic polyester FDY filament (purchased from Sheng Hong Group Co., Ltd.), which is also prepared by adding hydrophilic masterbatch to the spinning melt. Its hydrophilicity is between that of the outer hydrophilic yarn and the water-repellent yarn, and the water contact angle is between 40 degrees and 60 degrees. The second type is a self-made fluorine-free water-repellent yarn, which is prepared by adding silicone-based fluorine-free water-repellent masterbatch (5wt%) to the spinning melt and then melt spinning it into 30D / 24F polyester filament. Its single filament diameter is about 2.5μm and the water contact angle is about 140 degrees. The third type is a moisture-wicking textured yarn (Korean Hyosung TMT FTET parallel composite moisture-wicking textured yarn, 30D / 24F), which can achieve a longitudinal elongation of more than 15% under water saturation and can reversibly recover after drying.

[0066] The ratio of the number of yarns in these three types of yarns is 4:1:2, which is different from the ratio in Example 1.

[0067] The weaving process then proceeds using a 34-inch diameter, 28G double-sided circular knitting machine, employing a double rib cross-stitch structure. The needles of the double-sided circular knitting machine are arranged in a rib pattern (i.e., the needles on the upper needle plate and lower cylinder are alternately configured). During each pass, the outer layer is uniformly fed with 100D / 96F hydrophilic polyester filament to form the outer surface of the fabric, while the inner layer, which is the skin-contacting surface, is formed by cyclically feeding ordinary hydrophilic yarn, fluorine-free water-repellent yarn, and moisture-wicking textured yarn in a 4:1:2 ratio. Through the alternating looping and tucking of the needles on the upper needle plate and lower cylinder, the loops of the outer and inner layers interlock in the fabric thickness direction, forming a double rib cross-stitch structure with an air-layered structure. The weaving speed is controlled at 18 rpm, and the tension is controlled between 3 and 5 mN.

[0068] After the fabric comes off the machine, finishing is performed: the greige fabric is relaxed at room temperature (25±2℃) for 4 hours, followed by relaxation in a 45℃ water bath for 45 minutes to eliminate internal stress generated during spinning and weaving; a non-ionic refining agent, fatty alcohol polyoxyethylene ether (AEO-9), is used at a dosage of 2.5~3.5g / L, a liquor ratio of 1:12, a temperature of 70℃, and a treatment time of 30 minutes, mainly to remove spinning oils and impurities such as wax and oil introduced during weaving from the yarn surface. After refining, the fabric is rinsed 2~3 times with clean water until the pH value is neutral. Then, it is set at 155℃ for 40s, during which the overfeed rate is controlled at +5%~+8%, the machine speed is controlled at 20m / min, the width is controlled at 170cm, and the weight is controlled at 185g / m², finally obtaining a dynamic moisture-wicking fabric with a triple synergistic effect. The fabric has a longitudinal density of approximately 95 threads / 5cm and a transverse density of approximately 130 threads / 5cm.

[0069] Comparative Example 1:

[0070] One-way moisture-wicking fabrics are commonly found on the market today.

[0071] Comparative Example 2:

[0072] Basic differential capillary effect fabric

[0073] Step 1: Prepare raw materials: The outer layer yarn is made of 75D / 72F fine denier polyester FDY filament. The inner layer bottom yarn is made of 50D / 24F regular polyester FDY filament.

[0074] Step 2: Perform routine refining and hydrophilic finishing on all yarns (using hydrophilic auxiliaries) to make their surfaces hydrophilic with a contact angle of less than 30 degrees.

[0075] Step 3: Using a double-sided circular knitting machine, knit a standard double-sided knitted structure (rib knit air layer structure), in which the face yarn is knitted to form the outer layer of the fabric, and the back yarn is knitted to form the inner layer of the fabric (the side in contact with the skin).

[0076] Step 4: After the fabric is woven, it is relaxed, refined, dyed (as needed), and hydrophilic treated, and finally shaped.

[0077] The capillary pressure of the inner layer (50D / 24F) of this fabric is significantly higher than that of the outer layer (75D / 72F). Therefore, once sweat is absorbed by the inner layer, it is spontaneously transferred from the high-pressure zone to the low-pressure zone through the capillaries between the fibers, i.e., transported from the skin side to the outside. However, the moisture-wicking capacity of this structure is static. The differential capillary effect of this fabric is determined by the fixed difference in linear density between the inner and outer layers, and its capillary pressure difference is a constant value, which cannot adaptively adjust with changes in the perspiration rate. Therefore, at low perspiration rates, the capillary suction force is relatively too strong, resulting in excessively rapid moisture wicking; at high perspiration rates, the transport flux reaches saturation, resulting in hygroscopic lag.

[0078] Comparative Example 3:

[0079] Step 1: Add fluorine-free water-repellent masterbatch based on organosilicon polymer to the spinning melt, and melt spin to produce 50D / 24F fluorine-free water-repellent polyester filament with a water contact angle of about 140 degrees.

[0080] Step 2: The outer layer yarn is made of 75D / 72F hydrophilic polyester filament. The inner layer yarn is composed of a combination of two functional yarns in a certain proportion: ordinary hydrophilic yarn (50D / 24F hydrophilic polyester FDY filament) and the fluorine-free water-repellent yarn obtained in Step 1.

[0081] Step 3: Using a ratio of 4 ordinary hydrophilic yarns to 1 fluorine-free water-repellent yarn, feed the base yarns into the double-sided circular knitting machine in a cyclical manner. The face yarns are knitted to form the outer layer of the fabric, and the base yarns are knitted to form the inner layer of the fabric (the side in contact with the skin), thus knitting a standard double-sided knitted structure.

[0082] Step 4: After weaving, only relaxation, refining and setting are performed, without overall hydrophilic finishing, in order to retain the inherent water-repellent properties of the fluorine-free water-repellent yarn.

[0083] The preparation process is similar to that of Example 1, except that the inner layer yarn does not contain moisture-absorbing and deformable yarn. Specifically, the outer layer yarn also uses 75D / 72F hydrophilic polyester filament with a fiber diameter of approximately 20μm and a single filament diameter of approximately 2.3μm. The inner layer yarn is composed of 50D / 24F ordinary hydrophilic yarn and 50D / 24F fluorine-free water-repellent yarn in a 4:1 ratio, where the single filament diameter of both the ordinary hydrophilic yarn and the water-repellent yarn is approximately 3.3μm. Weaving is also performed using a 30-inch diameter, 24G double-sided circular knitting machine, weaving a rib air layer structure. The weaving speed, tension control, and finishing conditions are consistent with those of Example 1. After setting, the width is controlled at 180cm and the weight at 195g / m². 2 The longitudinal density is approximately 88 threads / 5cm, and the transverse density is approximately 118 threads / 5cm, resulting in a comparative fabric that exhibits only differential capillary effect and dynamic wetting gradient effect.

[0084] Comparative Example 4:

[0085] Step 1: A certain proportion of hydrophilic chips were introduced into the PET polymerization process using a copolymerization method to prepare hygroscopic deformable filaments with a peanut-shaped cross section.

[0086] Step 2: Prepare raw materials: The outer layer yarn is made of 75D / 72F fine denier hydrophilic polyester filament. The inner layer yarn is composed of ordinary hydrophilic yarn (50D / 24F hydrophilic polyester FDY filament) and the moisture-absorbing and elongating polyester filament obtained in Step 1, in a certain proportion.

[0087] Step 3: Using a ratio of 4 ordinary hydrophilic yarns to 1 moisture-wicking textured yarn, feed the base yarns into the double-sided circular knitting machine in a cyclical manner. The face yarns are knitted to form the outer layer of the fabric, and the base yarns are knitted to form the inner layer of the fabric (the side in contact with the skin), thus knitting a standard double-sided knitted structure.

[0088] Step 4: After weaving, only relaxation, refining and setting are performed. No further overall hydrophilic finishing is done. Temperature and tension must be strictly controlled during the finishing process to avoid damaging the potential deformation ability of the moisture-wicking yarn.

[0089] The performance of four samples from Examples 1, 2 and the comparative example was systematically tested. All tests were conducted under standard atmospheric conditions. Before testing, the samples were conditioned for 24 hours in an environment with a temperature of 20±2℃ and a relative humidity of 65±4%.

[0090] Dynamic Liquid Moisture Transfer Test: This test aims to quantify the dynamic behavior of moisture transfer within fabrics. The test was conducted according to GB / T 21655.2-2019 "Evaluation of Moisture Absorption and Quick-Drying Properties of Textiles - Part 2: Dynamic Moisture Transfer Method" and AATCC™ 195 standard, using a Liquid Moisture Management Tester (MMT, Gellowen G290). This instrument is equipped with concentric ring sensors to monitor the real-time transfer of moisture between the inner and outer layers of the fabric. Before the test, the sample was cut to a size of 90mm × 90mm and conditioned for 24 hours under standard conditions of 20±2℃ and 65±4% relative humidity. The test solution used was a 0.9% NaCl solution with a conductivity of 16±0.2mS / cm, with a drop volume of 0.22±0.01g, added uniformly to the fabric surface over 20 seconds. The data acquisition frequency was no less than 10Hz, and the test lasted for 120 seconds. The key point is to record the unidirectional transfer index R, which quantifies the ability of moisture to be transferred unidirectionally from the inner layer of the fabric to the outer layer. The higher the value, the better the unidirectional moisture wicking effect.

[0091] Evaporation and Drying Performance Test: This test evaluates the rapid evaporation capacity of fabrics after moisture absorption. The test can be conducted using either the weighing method or the hot plate method. The weighing method follows GB / T 21655.1-2023 "Evaluation of Moisture Absorption and Quick-Drying Properties of Textiles - Part 1: Single-Item Combination Test Method," using an electronic balance (Shimadzu AUY220, Japan) with an accuracy of 0.001g, conducted in a constant temperature and humidity environment of 21±1℃ and 50±2% relative humidity. After weighing a 100mm×100mm sample, 0.2mL of distilled water is added to the fabric surface using a pipette. The weight change is recorded every 5 minutes until the fabric moisture content drops below 10%, at which point the timing is stopped, and the evaporation rate and drying time are calculated. The hot plate method is based on the AATCC 201 standard "Fabric drying rate: hot plate method". A fabric drying rate tester is used, the hot plate temperature is set to 37°C to simulate human skin temperature, 0.2 mL of deionized water is dropped onto the fabric surface, and the time required for the moisture to evaporate completely and the evaporation rate are recorded.

[0092] Thermal and Moisture Comfort Test: This test evaluates the heat and moisture transfer capacity of fabrics under steady-state conditions, providing a basic reference for dynamic perspiration performance. The test is conducted according to ISO 11092:2014 "Textiles – Physiological effects – Determination of thermal and moisture resistance under steady-state conditions (sweating hot plate method)" and GB / T 11048-2018 "Textiles – Physiological comfort – Determination of thermal and moisture resistance under steady-state conditions", using a sweating hot plate apparatus (Thermetrics). This instrument accurately measures the thermal and moisture resistance of fabrics by simulating the sweating and heat dissipation process of human skin. During the test, the hot plate temperature is set to 35℃, the ambient air temperature to 20℃, the relative humidity to 40%, and the wind speed to 1m / s. Thermal resistance reflects the fabric's heat insulation capacity, while moisture resistance reflects the fabric's resistance to moisture permeability; the lower the moisture resistance value, the better the moisture permeability.

[0093] Dynamic Dryness Index Test: The test was conducted according to the group standard T / SDTES 027-2025 "Determination of Dynamic Perspiration Performance of Textiles - Part 1: Dryness Index Method". The test used a programmable dynamic perspiration simulator, whose core components included a micro-injection pump for precise control of the perspiration rate; a high-precision temperature and humidity sensor for monitoring microclimate changes on the simulated skin surface; and an infrared thermal imager for recording the temperature distribution and evaporative heat dissipation process on the fabric surface. The test environment was set at a temperature of 25±2℃ and a relative humidity of 50±5%. To simulate the dynamic changes in sweating during human exercise, the test employed a three-stage programmed sweating mode: first, a low sweating rate of 0.5 g / min was maintained for 15 minutes, simulating rest or light activity; then, a moderate sweating rate of 2.0 g / min was maintained for 15 minutes, simulating moderate-intensity exercise; finally, a high sweating rate of 5.0 g / min was maintained for 15 minutes, simulating high-intensity exercise or profuse sweating. The cumulative change rate of relative humidity on the simulated skin surface was recorded throughout the process; the smaller this value, the stronger the fabric's ability to keep the skin dry during high-intensity sweating. A 0.9% NaCl solution was used in the test to simulate the composition of human sweat.

[0094] The results are as follows:

[0095] Table 1 Performance Comparison Table

[0096]

[0097] According to Table 1, Examples 1 and 2 achieved an ideal dynamic response of slow absorption in low humidity and rapid evaporation in high humidity. In the slight perspiration stage, the inner water-repellent yarn inhibits excessive absorption, thus preventing dry skin. In the heavy perspiration stage, the active deformation of the moisture-wicking yarn disrupts the water film and accelerates evaporation. Combined with the differential capillary effect, this results in the lowest rate of change in skin humidity (+1.9%), achieving optimal overall performance.

[0098] Comparative Example 1 (conventional unidirectional moisture-wicking fabric) exhibits moderate moisture wicking at low sweat rates, but insufficient wicking capacity at high sweat rates, resulting in noticeable surface dampness. Comparative Example 2 (basic differential capillary effect fabric) has its moisture wicking capacity determined by a fixed capillary pressure difference, unable to adaptively adjust with changes in sweat rate. At low sweat rates, excessively strong capillary suction leads to rapid moisture wicking, while at high sweat rates, saturation of the transport flux results in delayed wicking. Comparative Example 3 (no moisture-wicking textured yarn) has a wetting gradient adjustment, but lacks an "active opening" evaporation acceleration mechanism during heavy sweating, resulting in a significantly lower evaporation rate than the example, limiting perspiration efficiency in high humidity environments. Comparative Example 4 (no water-repellent yarn) demonstrates strong moisture wicking and evaporation capabilities during heavy sweating, but the lack of water-repellent yarn during light sweating poses a risk of excessive absorption, making it less comfortable to wear in low humidity environments compared to the embodiments of this invention.

[0099] In the embodiments of this invention, the differential capillary effect provides the basic driving force to ensure directional moisture transport; the dynamic wetting gradient effect inhibits moisture conduction during light sweating and opens channels during heavy sweating; the moisture-wicking deformation effect further increases porosity and improves evaporation efficiency during heavy sweating. In the light sweating state, the wetting gradient effect dominates, inhibiting excessive moisture conduction, and the deformation effect is almost not triggered, maintaining breathability; in the heavy sweating state, the wetting gradient effect fails, the water-repellent yarn is soaked, the differential capillary effect is fully activated, and the moisture-wicking deformation yarn absorbs water and elongates, actively stretching the fabric structure. The three work together to achieve a dual acceleration of "moisture conduction + evaporation," demonstrating the synergistic advantage of the combined effects, far exceeding the performance limits of a single mechanism.

[0100] The above embodiments are only for illustrating the technical concept and features of this application, and are intended to enable those skilled in the art to understand the content of this application and implement it accordingly. They should not be construed as limiting the scope of protection of this application. All equivalent changes or modifications made in accordance with the spirit and essence of this application should be included within the scope of protection of this application. The endpoints and any values ​​of the ranges disclosed herein are not limited to the precise ranges or values; these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of various ranges, the endpoint values ​​of various ranges and individual point values, and individual point values ​​can be combined to obtain one or more new numerical ranges, which should be considered as specifically disclosed herein.

Claims

1. A dynamic sweat-wicking functional fabric, characterized in that, It includes a first fabric surface layer and a second fabric surface layer formed by knitting with a dual yarn system; The number of yarns D in the first fabric surface layer is greater than the number of yarns D in the second fabric surface layer, and the number of yarns F in the first fabric surface layer is greater than the number of yarns F in the second fabric surface layer. The yarn system of the first fabric surface layer is hydrophilic, with a water contact angle of less than 90 degrees; the yarn system of the second fabric surface layer includes a first base yarn, a second base yarn, and a moisture-absorbing textured yarn arranged at intervals; the first base yarn is more hydrophilic than the second base yarn, and the second base yarn is a water-repellent yarn.

2. The dynamic sweat-wicking functional fabric according to claim 1, characterized in that, The yarn of the first fabric surface layer is 75-100D / 72F hydrophilic filament, and the yarn of the second fabric surface layer is 30-50D / 24F filament.

3. The dynamic sweat-wicking functional fabric according to claim 1, characterized in that, The water contact angle of the first fabric surface layer is less than 30 degrees; the first base yarn is hydrophilic polyester filament or hydrophilic nylon filament; the second base yarn is fluorine-free water-repellent yarn.

4. The dynamic sweat-wicking functional fabric according to any one of claims 1-3, characterized in that, The functional fabric has a double rib knit weave with a weight of 180-200 g / m². 2 .

5. A method for preparing the dynamic perspiration-wicking functional fabric according to any one of claims 1-4, characterized in that, include: A double-sided circular knitting machine is used to knit the yarns of the first and second fabric face layers. The first base yarn, the second base yarn, and the moisture-wicking textured yarn are fed in a cyclical manner to form the second fabric face layer. The first base yarn has higher hydrophilicity than the second base yarn, and the second base yarn is a water-repellent yarn. The first fabric face layer formed by knitting is hydrophilic. After being taken off the machine, the woven fabric is relaxed and then set to obtain the dynamic sweat-wicking functional fabric.

6. The preparation method according to claim 5, characterized in that, The yarn of the first fabric surface layer is made by plasma hydrophilic modification or by adding hydrophilic masterbatch during spinning.

7. The preparation method according to claim 5, characterized in that, The moisture-absorbing textured yarn is made of polyester or nylon as the base material, and is obtained by introducing hydrophilic chips in parallel spinning through blending.

8. The preparation method according to any one of claims 5-7, characterized in that, The knitting process is controlled at a speed of 15-25 rpm and a tension of 3 to 5 mN.

9. The preparation method according to any one of claims 5-7, characterized in that, The process between relaxation and setting also includes refining, primarily to remove oils.

10. The preparation method according to claim 9, characterized in that, The shaping temperature is 150-165℃.

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