Preparation method of high-breathability anti-drilling down feather composite fabric

Abstract

The application discloses a preparation method of high-breathability anti-drilling down composite fabric, and belongs to the technical field of functional textile composite materials. The application takes high-melting-index TPU particles as raw materials, and prepares a porous elastic film with a honeycomb multi-layer fiber structure through low-temperature dehumidification drying, segmented melting and air spinning process. Then, the porous elastic film is compounded with the glued polyester fabric through pressure gluing. After moisture curing, the finished product composite fabric is prepared. The application solves the technical problems that the traditional down fabric cannot be compatible with breathability and moisture permeability, has poor washing resistance, slow rebound and wet and stuffy movement, and prepares the composite fabric with a breathability of 22-88 mm / s, a moisture permeability of greater than or equal to 14900 gm2 / d, and excellent anti-drilling down performance and composite fastness after multiple washing. The method has a coherent process flow, high equipment versatility, and can be produced on a large scale. The finished product is widely applicable to products such as sports down jackets, outdoor warm-keeping clothes, workwear inner liners and the like.

Description

Technical Field

[0001] This invention relates to a method for preparing a highly breathable and down-proof composite fabric, belonging to the field of functional textile composite material preparation technology. Background Technology

[0002] Currently, down jackets have become the mainstream clothing for winter outdoor and everyday wear due to their lightweight and warmth. To solve the problem of down leakage, traditional down fabrics generally undergo processes such as calendering, coating, and overall lamination. However, these processes seal the internal fiber pores of the fabric, directly leading to a significant reduction in the fabric's breathability and moisture permeability. This fails to meet the breathability, sweat-wicking, and moisture-wicking needs of the human body during outdoor activities such as running, hiking, and cycling, easily causing the wearer to experience a strong feeling of stuffiness and dampness, which can even affect athletic performance and body temperature regulation in severe cases.

[0003] Meanwhile, existing down-proof fabrics generally suffer from a trade-off between down-proof performance and breathability / moisture permeability, making it difficult to meet both core requirements. Furthermore, the bonding strength between the film layer and the base fabric of conventional laminated fabrics is insufficient, and the film layer is prone to peeling and cracking after repeated washing or friction, resulting in a rapid decline in down-proof performance. In addition, traditional down fabrics also have problems with poor flexibility and resilience, making it difficult for down jackets to expand quickly after folding and storage, and the rebound speed is slow, affecting the user experience and warmth retention.

[0004] Therefore, there is an urgent need for a composite fabric manufacturing process that can simultaneously achieve high air permeability, high moisture permeability, and durable down-proofing through the structure of the film layer itself, without the need for subsequent coating or calendering treatment, in order to solve the problems existing in the above-mentioned prior art. Summary of the Invention

[0005] To overcome the technical shortcomings of existing down fabrics, such as the incompatibility between down-proofness and breathability, poor washability and durability, weak resilience, and stuffiness during sportswear, this invention provides a method for preparing a highly breathable, down-proof composite fabric. This method uses high melt flow index TPU as a raw material to prepare a porous elastic membrane, which is then composited with a textile fabric. The resulting composite fabric possesses characteristics such as high breathability, high moisture permeability, down-proofness, washability, and rapid compression recovery, making it suitable for various sports down products and outdoor thermal apparel.

[0006] The present invention discloses a method for preparing a highly breathable and down-proof composite fabric, characterized in that the composite fabric is composed of an upper layer of polyester fabric with a basis weight of 20-40 g / m² and a lower layer of porous elastic membrane with a basis weight of 35-45 g / m². The porous elastic membrane is a TPU air-spun porous film, in which ultrafine elastic fibers are stacked in a honeycomb pattern to form a fiber structure of 5-15 layers, with a honeycomb unit diameter of 50-200 μm and an interlayer pore size of 10-50 μm. The present invention achieves down-proof honeycomb fiber structure down-proof locking at the structural level, rather than relying solely on post-processing, resulting in more durable down-proof performance and water resistance.

[0007] This invention employs an air-jet spinning process to form a 5-15 layer honeycomb fiber structure, achieving a balance between high air permeability and high moisture permeability, thus resolving the technical contradiction between being down-proof but not breathable, and breathable but not down-proof.

[0008] The method for preparing the highly breathable and down-proof composite fabric includes the following steps: S1. Drying of TPU raw materials: Put high melt index TPU particles into a dryer with a dew point temperature of less than -45℃ and dry at a constant temperature of 90℃ for 4 to 6 hours. S2. Porous elastic film air-jet spinning: The dried TPU granules are fed into a screw extruder and melted sequentially through a 185°C feeding section, a 200°C melting section, and a 230°C metering section. The melt is then transported to the spinning die by a metering pump, and a porous film of 35-45 g / m² is prepared by air-jet spinning. The natural porous structure formed by the air-jet spinning process in this invention can achieve high air permeability and better elasticity without chemical modification.

[0009] S3, Gluing of polyester fabric Polyester fabric with a weight of 20-40 g / m² is selected as the face fabric, and glue is applied using a glue dotting machine; S4, double-layer fabric hot-pressed composite The glued polyester fabric and the porous elastic membrane are unwound simultaneously, keeping the polyester fabric on top and the porous elastic membrane on the bottom, ensuring that the two layers of fabric are aligned without misalignment or wrinkles; a double-roller hot press laminating machine is used for glue-free hot press lamination, and after hot pressing, the roll is placed in a curing workshop for moisture curing; the invention adopts a simple and lightweight two-layer composite structure with a total weight of 55-85g / m², while achieving excellent air and moisture permeability. S5, Moisture Curing The laminated fabric is placed in an aging room, and after the polyurethane adhesive has cured, it can be rolled up for inspection.

[0010] Furthermore, in S3, the adhesive used for the polyester fabric is a moisture-curing polyurethane hot melt adhesive with a melting point of 90–100°C and a dot density of 2500–3500 dots / m². 2 The amount of adhesive applied is 10-15 g / m². 2 This invention employs specifically defined adhesive dot density and moisture curing process parameters, resulting in higher composite strength, a film peel strength ≥8.0 N, excellent washability, and ≤10 down fibers after 3 washes. Furthermore, the controlled adhesive dot density avoids the problem of compacted honeycomb pores affecting breathability during hot-pressing, thus balancing fabric breathability and bonding strength.

[0011] Furthermore, in S4, the hot-pressing composite temperature is 95–120℃, the composite pressure is 0.3–0.6MPa, and the equipment travel speed is 5–10m / min.

[0012] Furthermore, in S5, the conditions for moisture curing are a temperature of 25–35°C and a relative humidity of 65%–80%, with a placement time of 12–15 hours.

[0013] Furthermore, the porous elastic membrane has an elastic elongation greater than 60%, an air permeability greater than 200 mm / s, and a moisture permeability greater than 15000 gm² / d.

[0014] By means of the above-described solution, the present invention has at least the following advantages: (1) The present invention uses air-jet spinning process to prepare TPU porous elastic membrane. The ultra-fine elastic fibers inside the membrane form a honeycomb stacked structure of 5 to 10 layers. The multi-layer fiber interlacing structure can strongly lock down, achieving high breathability and preventing down leakage. At the same time, the honeycomb three-dimensional pores are completely preserved. The air permeability of the composite fabric can reach 88.9 mm / s, and the moisture permeability exceeds 14900 gm² / d. This completely solves the technical contradiction of traditional down jacket fabrics being "down-proof but not breathable, breathable but not down-proof" and eliminates the stuffy feeling during outdoor sports.

[0015] (2) The present invention adopts a glue-free hot-pressing composite process, the polyester fabric and the porous elastic membrane are tightly bonded, and the membrane peel strength can reach more than 8.0N; after three standard water washing and friction tests, the membrane layer does not peel off or crack, the anti-down leakage performance decreases by a very small amount, greatly extending the service life of the fabric and meeting the needs of repeated washing of clothing.

[0016] (3) The porous elastic membrane is made of high elastic TPU. The membrane has an elastic elongation rate of more than 60%, and the composite fabric has strong overall flexibility. After the fabric is compressed and folded, it can quickly expand and recover without having to wait a long time to recover its fluffiness. It perfectly matches the use scenario of self-packing and quick wearing of sports down jackets. At the same time, the down can quickly release moisture after absorbing moisture, and can still maintain stable warmth after long-term use.

[0017] (4) The entire preparation process mainly consists of raw material drying, air-jet spinning, and hot-pressing composite. No additional processes such as gluing or chemical coating are required. The process is simple, the equipment is versatile, and continuous production line production can be achieved. Production energy consumption is low, and production costs are effectively controlled.

[0018] (5) The finished composite fabric is soft and skin-friendly and can be used as an outer layer or inner lining fabric. In addition to sports down jackets and down vests, it can also be used in outdoor hiking clothing, cycling clothing, workwear thermal lining and other products, with strong scene adaptability.

[0019] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show a certain embodiment of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the layered structure of the high-breathability down-proof composite fabric of the present invention; In the figure: 1. Polyester fabric; 2. Adhesive dot layer; 3. Porous elastic membrane. Detailed Implementation

[0022] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0023] See Figure 1 A highly breathable and down-proof composite surface is described, the final product consisting of an upper layer of 20-40 g / m² polyester fabric 1 and an inner layer of 35-45 g / m² porous elastic membrane 3. An adhesive dot layer 2 is provided between the porous elastic membrane 3 and the polyester fabric 1. This adhesive dot layer 2 is formed by applying adhesive dots to the surface of the polyester fabric 1 using an adhesive dot roller to create an array of adhesive dots for bonding the polyester fabric 1 and the porous elastic membrane 3. The porous elastic membrane 3 is composed of 5-15 layers of ultrafine elastic fibers stacked in a honeycomb pattern, possessing high elasticity, high breathability, high moisture permeability, and strong down-locking ability. The overall preparation process includes TPU raw material drying, air-jet spinning, applying adhesive to the polyester fabric, hot-pressing lamination, and moisture curing.

[0024] Specific preparation steps Step 1: Drying of TPU raw materials High melt flow index TPU particles were selected as the raw material for preparing porous elastic membranes. The TPU particles were put into a special dryer with a dew point temperature of less than ~45℃, and the drying temperature was set to 90℃. The dryer was kept at a constant temperature for 4 to 6 hours to completely remove the internal moisture of the raw material and prevent defects such as bubbles and broken fibers during melt spinning. After drying, the material was discharged for use.

[0025] Step 2: Air-jet spinning of porous elastic membrane The dried TPU granules are fed into a screw extruder, and the temperature of each zone of the screw is controlled in stages: the temperature of the feeding zone is 185℃, the temperature of the melting zone is 200℃, and the temperature of the metering zone is 230℃, so that the TPU granules are fully melted to form a uniform melt. The molten melt is quantitatively delivered to the spinning die by a metering pump at a speed of 10-20 rpm, and a porous film with uniform width is prepared by air-jet spinning process. The specific process parameters are as follows: hot air flow temperature 240-280℃, air flow velocity 50-100m / s, and TPU fines are drawn from both sides of the spinneret at a blowing angle of 30-45℃ to form ultrafine elastic fibers; the fiber deposition trajectory is controlled by linearly controlling the moving speed of the receiving screen (5-10m / min) and the vibration frequency (45-65Hz) of the oscillating mechanism; when the ratio of the screen moving speed to the oscillating frequency is in the range of 0.12-0.18, the ultrafine fibers are randomly and disorderly laid out on the screen surface. By controlling the cumulative deposition thickness, they are naturally stacked to form a honeycomb structure of 5-15 layers, with a honeycomb unit diameter of 50-200μm and an interlayer pore size of 10-50μm, finally producing a porous elastic membrane with a basis weight of 35-45g / m².

[0026] The porous elastic membrane has ultrafine elastic fibers stacked in a honeycomb pattern to form 5 to 10 fiber layers. The membrane has an elastic elongation greater than 60%, an air permeability greater than 200 mm / s, and a moisture permeability greater than 15,000 gm² / d. The formed porous elastic membrane is then wound up and temporarily stored.

[0027] Step 3: Applying adhesive to the polyester fabric Polyester fabric with a weight of 20-40 g / m² was selected as the face fabric. Adhesive was applied using a dotting machine. Specific process parameters were: moisture-curing polyurethane hot melt adhesive with a melting point of 90-100℃ and a dot density of 2500-3500 dots / m². 2 The amount of adhesive applied is 10-15 g / m². 2 .

[0028] Step 4: Hot-pressing and laminating of double-layer fabric The glued polyester fabric and the porous elastic film are unwound simultaneously, keeping the polyester fabric on top and the porous elastic film on the bottom, ensuring that the two layers of fabric are aligned without misalignment or wrinkles; a double-roller hot press laminating machine is used for glue-free hot pressing lamination, with a lamination temperature of 95-120℃, a lamination pressure of 0.3-0.6MPa, and a machine travel speed of 5-10m / min; after hot pressing, the fabric is rolled up and placed in a curing workshop for moisture curing.

[0029] Step 5: Moisture Curing The laminated fabric is placed in an aging room with the following environmental conditions: temperature 25–35℃, relative humidity 65%–80%. The aging time is 12–15 hours. Once the polyurethane adhesive has cured, it can be rolled up for inspection.

[0030] Preferred process parameters 1) Drying of TPU raw materials: Dew point temperature ~50℃, drying temperature 90℃, drying time 4h; 2) Screw extruder zone temperatures: feeding section 185℃, melting section 200℃, metering section 230℃; 3) Hot-press lamination: The adhesive used is a moisture-curing polyurethane hot melt adhesive with a dot density of 3000 dots / m. 2 Adhesive application rate: 10g / m 2 The composite temperature is 105℃, the composite pressure is 0.4MPa, and the travel speed is 6m / min. 4) Moisture curing: Ambient temperature 25℃, relative humidity 65%, aging time 12h.

[0031] Core performance indicators of finished products The composite fabric prepared by this method was tested according to the corresponding national standards, and the performance parameters are as follows: 1) Air permeability: 22~88.9mm / s (Testing standard: GB / T5453~1997); 2) Moisture permeability: ≥14900gm² / d (Test standard: GB / T12704.2~2009 Method B, condition a); 3) Membrane peel strength: ≥8.0N (Reference standard: FZ / T80007.1~2006); 4) Down-proof performance: The number of down feathers before washing is ≤4. After washing 3 times and drying, the number of down feathers is ≤10 (Testing standard: Appendix E of GB / T14272~2011, using 90% white duck down for testing).

[0032] Example Example 1 A method for preparing a highly breathable and down-proof composite fabric, comprising the following specific steps: TPU raw material drying: High melt flow index TPU granules were selected and placed in a dryer with a dew point temperature of ~50℃. They were then dried at a constant temperature of 90℃ for 4 hours to remove moisture from the raw materials.

[0033] Porous elastic membrane air-jet spinning: The dried TPU granules are fed into a screw extruder at 185°C in the feeding section, 200°C in the melting section, and 230°C in the metering section. After the TPU is fully melted, it is transported to the spinning die by a metering pump. A 45g / m² porous elastic membrane is prepared by air-jet spinning process. The fibers inside the membrane form a 10-15 layer honeycomb stacked structure and are then wound up for later use.

[0034] Applying adhesive to polyester checkered fabric: Take 20g / m² polyester checkered fabric and apply adhesive dots at a rate of 10g / m².2 Adhesive dot density 3000 dots / m 2 .

[0035] Hot pressing composite molding: The adhesive-coated polyester checkered fabric and the porous elastic film are simultaneously unwound and aligned, and then fed into a hot press laminating machine. The lamination temperature is 105℃, the pressure is 0.4MPa, and the travel speed is 9m / min.

[0036] Mature and solidify: The composite fabric is then placed in a curing workshop under the following conditions: temperature 25℃, relative humidity 65%, and curing time 15 hours.

[0037] Finished product test results: air permeability 88.9mm / s, moisture permeability 14900gm² / d, membrane peel strength 18.5N; 0 down leakage before washing, 4 down leakage after 3 washes, elastic elongation 65%, all indicators meet the highest usage standards for sports down fabrics.

[0038] Example 2 A method for preparing a highly breathable and down-proof composite fabric, wherein the parameters for each process are selected within the lower limit of the range, and the remaining operations are the same as in Example 1: TPU dryer dew point temperature ~45℃, dry at 90℃ for 4 hours; The temperature in each zone of the screw remains constant, the number of porous elastic membrane fiber stacks is 5 to 10 layers, and the basis weight is 35g / m2; Applying adhesive to polyester checkered fabric: Take 40g / m² polyester checkered fabric and apply adhesive dots at a rate of 15g / m². 2 Adhesive dot density 3000 dots / m 2 .

[0039] Hot pressing composite molding: The adhesive-coated polyester checkered fabric and the porous elastic film are simultaneously unwound and aligned, and then fed into a hot press laminating machine. The lamination temperature is 95℃, the pressure is 0.4MPa, and the travel speed is 9m / min.

[0040] Mature and solidify: The composite fabric is then placed in a curing workshop under the following conditions: temperature 25℃, relative humidity 65%, and curing time 15 hours.

[0041] Polyester checkered fabric adhesive application: 10g / m 2 Adhesive dot density 3000 dots / m 2 .

[0042] Hot-pressing composite temperature 95℃, pressure 0.3MPa, travel speed 6m / min; The curing conditions are: temperature 30℃, relative humidity 75%, and curing time 10h.

[0043] Finished product test results: air permeability 200mm / s, moisture permeability 15000gm² / d, membrane peel strength 8N; 4 down fibers escaped before washing, 10 down fibers escaped after 3 washes, elastic elongation 61%, which meets the requirements for use in regular thermal down jackets.

[0044] Example 3 A method for preparing a highly breathable and down-proof composite fabric, wherein the parameters for each process are selected within the upper limit of the range, and the remaining operations are the same as in Example 1: TPU dryer dew point temperature ~55℃, dry at 90℃ for 4 hours; The temperature in each zone of the screw remains constant, the porous elastic membrane fiber stack has 15 layers, and the basis weight is 45g / m2; Applying adhesive to polyester checkered fabric: Take 40g / m² polyester checkered fabric and apply adhesive dots at a rate of 15g / m². 2 Adhesive dot density 3000 dots / m 2 .

[0045] Hot pressing composite molding: The adhesive-coated polyester checkered fabric and the porous elastic film are simultaneously unwound and aligned, and then fed into a hot press laminating machine. The lamination temperature is 105℃, the pressure is 0.4MPa, and the travel speed is 9m / min.

[0046] Mature and solidify: The composite fabric is then placed in a curing workshop under the following conditions: temperature 35℃, relative humidity 85%, and curing time 15 hours.

[0047] Finished product test results: air permeability 60mm / s, moisture permeability 12000gm² / d, membrane peel strength 12.0N; 0 down leakage before washing, 3 down leakage after 3 washes, elastic elongation 63%, suitable for high-intensity outdoor sportswear.

[0048] Comparative Example: Traditional Coated Down Fabric Using traditional polyurethane coating technology to prepare down fabric of the same weight, the finished product has an air permeability of <5mm / s and a moisture permeability of <6000gm² / d. After one wash, the coating slightly peels off, and after three washes, the coating falls off and more than 20 down fibers escape. It has poor elasticity and slow rebound, and its overall performance is far inferior to the composite fabric prepared by this invention.

[0049] The final performance test results of the fabrics prepared in Examples 1-3 and the control example show that the present invention uses an air-jet spinning process to prepare a TPU porous elastic membrane. The membrane's internal ultrafine elastic fibers form a 5-10 layer honeycomb stacked structure. This multi-layered fiber interlacing structure strongly locks in down, achieving high breathability and preventing down leakage. Simultaneously, the honeycomb three-dimensional pores are completely preserved, resulting in a fabric air permeability of up to 88.9 mm / s and a moisture permeability exceeding 14900 gm² / d. This completely solves the technical contradiction of traditional fabrics being "down-proof but not breathable, breathable but not down-proof," eliminating the stuffy feeling during outdoor activities. The polyester fabric is tightly bonded to the porous elastic membrane, with a membrane peel strength exceeding 8.0 N. After three standard washes and friction tests, the membrane layer showed no peeling or cracking, and the down-proof performance decreased only slightly, significantly extending the fabric's lifespan and meeting the needs of repeated washing of clothing. The porous elastic membrane is made of high-elasticity TPU, with an elastic elongation rate of more than 60%, and the composite fabric has strong overall flexibility. The fabric can quickly expand and recover after being compressed and folded, without having to wait a long time to regain its fluffiness. It is perfectly matched to the usage scenario of self-packing and quick wearing of sports down jackets. At the same time, the down can quickly wick away moisture after absorbing it, and can still maintain stable warmth after long-term use.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for preparing a highly breathable, down-proof composite fabric, characterized in that, The composite fabric is composed of an upper layer of polyester fabric with a basis weight of 20-40 g / m² and a lower layer of porous elastic membrane with a basis weight of 35-45 g / m². The porous elastic membrane is a TPU air-spun porous film, in which ultra-fine elastic fibers are stacked in a honeycomb pattern to form a fiber structure of 5-15 layers. The honeycomb unit diameter is 50-200 μm, and the interlayer pore size is 10-50 μm. The preparation method of the high-breathability and down-proof composite fabric includes the following steps: S1. Drying of TPU raw materials: Put high melt index TPU particles into a dryer with a dew point temperature of less than -45℃ and dry at a constant temperature of 90℃ for 4 to 6 hours. S2. Porous elastic membrane air-jet spinning: The dried TPU granules are fed into a screw extruder and melted sequentially through a 185°C feeding section, a 200°C melting section, and a 230°C metering section. The melt is then transported to the spinning die by a metering pump and a porous film of 35-45 g / m² is prepared by air-jet spinning process. S3, Gluing of polyester fabric Polyester fabric with a weight of 20-40 g / m² is selected as the face fabric, and glue is applied using a glue dotting machine; S4, double-layer fabric hot-pressed composite The glued polyester fabric and the porous elastic film are unwound simultaneously, keeping the polyester fabric on top and the porous elastic film on the bottom, ensuring that the two layers of fabric are aligned without misalignment or wrinkles; a double-roller hot press laminating machine is used for glue-free hot press lamination, and after hot pressing, the roll is placed in the curing workshop for moisture curing. S5, Moisture Curing The laminated fabric is placed in an aging room, and after the polyurethane adhesive has cured, it can be rolled up for inspection.

2. The method for preparing a highly breathable, down-proof composite fabric according to claim 1, characterized in that, In S3, the adhesive used for the polyester fabric is a moisture-curing polyurethane hot melt adhesive with a melting point of 90–100℃ and a dot density of 2500–3500 dots / m. 2 The amount of adhesive applied is 10-15 g / m². 2 .

3. The method for preparing a highly breathable, down-proof composite fabric according to claim 1, characterized in that, In S4, the hot-pressing composite temperature is 95–120℃, the composite pressure is 0.3–0.6MPa, and the equipment travel speed is 5–10m / min.

4. The method for preparing a highly breathable, down-proof composite fabric according to claim 1, characterized in that, In S5, the conditions for moisture curing are a temperature of 25–35°C and a relative humidity of 65%–80%. The curing time is 12–15 hours.

5. The method for preparing a highly breathable, down-proof composite fabric according to claim 1, characterized in that, The porous elastic membrane has an elastic elongation greater than 60%, an air permeability greater than 200 mm / s, and a moisture permeability greater than 15000 gm² / d.

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