A high-thermal-retention soft polyester blanket type textile fabric and a post-finishing preparation method thereof

Abstract

The application discloses a high-thermal-retention soft full-polyester blanket type textile fabric and a post-finishing preparation method thereof, and belongs to the technical field of textile fabrics. The fabric comprises a ground tissue layer and a pile layer connected to the surface of the ground tissue layer. The ground tissue layer is composed of full-draft polyester yarns, and the pile layer is composed of hollow polyester textured yarns. Single fibers have an axial through hollow cavity. The pile is erected on the surface of the ground tissue layer. The side of the ground tissue layer, which is away from the pile layer, is subjected to calendering finishing to form a dense surface. The pile is cut. The concentration of a softening agent is calculated according to the total surface area of the pile and the thickness of a single molecular film. The calendering setting is performed at a temperature determined according to the average value of the glass transition temperature and the melting point. The application realizes quantitative design of the thermal retention performance and structural parameters of the blanket type fabric. The hollow fibers and the dense base cloth are cooperated to improve the thermal retention performance and the light weight level. The product consistency and soft hand feeling are ensured through accurate calculation of the post-finishing process parameters.

Description

Technical Field

[0001] This invention relates to the field of textile fabric technology, and in particular to a high-insulation and soft all-polyester blanket-type textile fabric and its finishing preparation method. Background Technology

[0002] Blanket-type textile fabrics are widely used in home textiles, clothing linings, and outdoor thermal insulation. Their thermal insulation performance mainly depends on the loft of the pile layer and the heat insulation properties of the fiber material. Existing blanket-type fabrics typically use solid polyester fibers to weave the pile layer, resulting in limited static air content between the fibers and insufficient warmth retention. To achieve the same thermal insulation effect, the fabric thickness and weight per unit area need to be increased, leading to a heavy product and poor wearing comfort.

[0003] While existing hollow fiber blanket-type fabrics increase the static air content through the hollow structure inside the fibers, the hollow ratio is usually set empirically, without establishing a quantitative relationship between the hollow ratio and the fiber's apparent density, linear density, and outer diameter. When the hollow ratio is too high, the fiber wall thickness is too thin, resulting in insufficient bending stiffness, easy flattening and deformation of the pile, and loss of warmth retention; when the hollow ratio is too low, the thermal insulation advantage of the hollow structure is not obvious, and the product's lightweight effect is poor.

[0004] The pile height of existing blanket-type fabrics is usually set empirically based on hand feel or appearance requirements, without considering the self-folding and bending characteristics of the pile under gravity. When the pile height exceeds the critical height for self-folding and bending, the pile bends and collapses under its own weight, the porosity of the pile layer decreases, still air is squeezed out, and the warmth retention is significantly reduced; at the same time, the collapsed pile becomes entangled, the fabric feels stiff, and the softness decreases.

[0005] Existing blanket-type fabrics typically lack a quantitative correlation between thermal resistance design and ambient temperature and human body heat dissipation. Designers struggle to determine the required thermal resistance value based on the target usage scenario, and consequently, to deduce the structural parameters of the pile layer (height, porosity, fiber fineness, etc.). Product development relies on repeated trials, resulting in long development cycles and high costs.

[0006] The finishing process parameters for existing blanket-type fabrics are usually set based on experience. The water temperature and time for relaxation and pre-shrinking are not related to the glass transition temperature and thermal diffusivity of polyester, resulting in insufficient or excessive pre-shrinking; the number of napping passes is not calculated based on the target pile height and the increment per pass, resulting in insufficient napping or damage to the fabric; the amount of softener is not related to the total surface area of ​​the pile and the thickness of the monolayer, resulting in unstable softening effect; the calendering temperature and setting temperature are not related to the glass transition temperature and melting point of polyester, resulting in poor calendering effect if the temperature is too low and fiber damage if the temperature is too high.

[0007] The base fabric of existing blanket-type fabrics is usually not specially densified, and the porosity of the base fabric is high. Heat is lost from the base fabric through convection and radiation, the overall thermal resistance of the fabric is limited, and the warmth retention performance is difficult to improve further. Summary of the Invention

[0008] Therefore, embodiments of the present invention provide a high-insulation, soft, all-polyester blanket-type textile fabric and a method for preparing the same.

[0009] On one hand, a high-insulation, soft, all-polyester blanket-type textile fabric is provided, comprising a ground layer and a pile layer attached to the surface of the ground layer, characterized in that:

[0010] The ground structure layer is woven from a first polyester yarn, which is a fully drawn polyester yarn;

[0011] The fleece layer is composed of a second polyester yarn, which is a hollow polyester textured yarn. The single fiber cross-section of the hollow polyester textured yarn has a hollow cavity that runs through the fiber axis.

[0012] The fibers in the villous layer stand upright on the surface of the ground tissue layer, and the surface of the ground tissue layer facing away from the villous layer is calendered to form a dense surface.

[0013] The porosity of the villous layer is determined by the following formula:

[0014]

[0015] In the formula:

[0016] The porosity of the fluff layer;

[0017] The unit area mass of the fluff layer is expressed in grams per square meter.

[0018] The height of the fibers in the villous layer is expressed in millimeters.

[0019] This refers to the density of polyester material, expressed in grams per cubic centimeter.

[0020] On the other hand, a high-insulation and soft all-polyester blanket-type textile fabric and its finishing preparation method are also proposed, including the following steps:

[0021] S1. Relaxation and pre-shrinking: The woven fabric is placed in a water bath for relaxation treatment. The water temperature of the water bath and the relaxation treatment time are determined by the following two formulas:

[0022]

[0023]

[0024] S2. Pile Setting: The pre-shrinked fabric is napped at least once. The number of napping passes is calculated using the following formula. After each napping pass, the fabric is dried and set.

[0025]

[0026] S3. Combing and shearing: Combing and shearing are performed on the raised fabric in sequence to make the pile stand up and be of uniform height.

[0027] S4. Softening Padding: The sheared billet is placed in a padding solution containing a softener for padding treatment. The mass concentration of the softener in the padding solution is determined by the following formula. After padding, the billet is dehydrated.

[0028]

[0029] S5. Calendering and Setting: Calender the surface of the fabric away from the pile layer after impregnation. The surface temperature of the rollers and the hot air setting temperature are calculated and determined according to the following formula. Then, hot air baking and setting are performed. The setting time is determined according to the formula for the relaxation treatment time. After cooling, the fabric is unloaded.

[0030]

[0031] In the formula:

[0032] The water temperature of the water bath is expressed in degrees Celsius.

[0033] The glass transition temperature of polyester is expressed in degrees Celsius.

[0034] The boiling point of water is taken as 100 degrees Celsius.

[0035] Relaxation time or setting time, in seconds;

[0036] The thickness is half the thickness of the fabric, in millimeters. When substituting it into the cooling time formula, it should be converted to meters.

[0037] is the thermal diffusivity of polyester, expressed in square millimeters per second;

[0038] This represents the number of napping passes; the calculated result is rounded up.

[0039] The increment of pile height for a single pile raising process, in millimeters;

[0040] This refers to the mass concentration of the softener in the padding solution, expressed in grams per gram.

[0041] This refers to the amount of fabric softener applied per unit area, expressed in grams per square meter.

[0042] The rolling yield is the amount of liquid added during the immersion process.

[0043] The unit area mass of the raw fabric before rolling is expressed in grams per square meter.

[0044] These are the surface temperature of the rolls and the hot air setting temperature, in degrees Celsius.

[0045] This is the melting point of polyester, expressed in degrees Celsius.

[0046] The meaning is the same as before.

[0047] Beneficial effects

[0048] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following:

[0049] This invention solves the technical problems of insufficient warmth retention caused by solid fibers and unoptimized hollow fiber ratio leading to an imbalance between mechanical properties and warmth retention in existing technologies. It achieves the technical effects of increasing static air content through hollow structure, achieving lightweight through all-polyester material, and reducing heat loss through dense base fabric. The ground layer is woven from a first polyester yarn, which is a fully drawn polyester yarn, and the pile layer is composed of a second polyester yarn, which is a hollow textured polyester yarn. The single fiber cross section has a hollow cavity that runs through the fiber axis. The pile layer in the pile layer stands upright on the surface of the ground layer. The surface of the ground layer away from the pile layer is calendered to form a dense surface.

[0050] This invention solves the technical problem in the prior art where porosity and hollowness are set based on experience, leading to uncontrollable thermal insulation performance. It achieves the technical effect of accurately designing the thermal insulation structure of the pile layer through the quantitative relationship between geometric parameters and material density.

[0051] This invention solves the technical problem in the prior art where the pile height does not exceed the critical height of the pile's self-bending. The critical height of the pile's self-bending is determined by the bending elastic modulus of polyester, the moment of inertia of the single fiber section, and the gravitational load per unit length of the pile. It achieves the technical effect of ensuring the pile stands upright for a long time, maintaining stable porosity, and a soft feel through mechanical constraints.

[0052] This invention addresses the technical problem in existing technologies where thermal resistance of the fabric satisfies the difference between the comfortable temperature of human skin and the design temperature of the usage environment, as well as the effective coverage area and the resting heat dissipation power of the human body. The equivalent thermal conductivity of the pile layer is calculated and determined based on the thermal conductivity of static air, the thermal conductivity of polyester, and porosity. The pile height is calculated and determined based on thermal resistance, equivalent thermal conductivity, and the thickness of the dense surface. This invention solves the technical problem that thermal resistance design does not establish a quantitative relationship with the usage scenario and that product development relies on repeated experiments. It achieves the technical effect of accurately designing the target thermal insulation performance by inferring structural parameters through thermal resistance verification relationships.

[0053] This invention addresses the technical problem in existing technologies where post-processing parameters are set based on experience, leading to unstable finishing results. It achieves the technical effect of determining process conditions through calculation of polyester thermophysical property parameters, improving post-processing stability and product consistency. The post-processing preparation method includes relaxation pre-shrinking, napping and setting, combing and shearing, softening padding, and calendering and setting. The water temperature for relaxation pre-shrinking is calculated based on the average glass transition temperature of polyester and the boiling point of water. The relaxation treatment time is calculated based on the half-thickness of the fabric and the thermal diffusivity of polyester. The number of napping passes is calculated based on the nap height and the napping increment per pass. Attached Figure Description

[0054] Figure 1 A flowchart provided for an embodiment of this application. Detailed Implementation

[0055] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0056] like Figure 1 As shown, a high-insulation, soft, all-polyester blanket-type textile fabric includes a ground layer and a pile layer attached to the surface of the ground layer, characterized in that:

[0057] The ground structure layer is woven from a first polyester yarn, which is a fully drawn polyester yarn;

[0058] The fleece layer is composed of a second polyester yarn, which is a hollow polyester textured yarn. The single fiber cross-section of the hollow polyester textured yarn has a hollow cavity that runs through the fiber axis.

[0059] The fibers in the villous layer stand upright on the surface of the ground tissue layer, and the surface of the ground tissue layer facing away from the villous layer is calendered to form a dense surface.

[0060] The porosity of the villous layer is determined by the following formula:

[0061]

[0062] In the formula:

[0063] The porosity of the fluff layer;

[0064] The unit area mass of the fluff layer is expressed in grams per square meter.

[0065] The height of the fibers in the villous layer is expressed in millimeters.

[0066] This refers to the density of polyester material, expressed in grams per cubic centimeter.

[0067] It should be noted that the pile layer is formed by raising, combing, and shearing the second polyester yarn, with the pile standing upright on the surface of the fabric layer. The unit area mass of the pile layer is the ratio of the dry mass of the pile cut off during the shearing process to the sampled area, or it can be obtained from the difference in unit area mass of the greige fabric before and after shearing; the pile height is set by the distance between the shearing blade and the fabric surface, and verified by measuring the difference in total thickness before and after shearing with a fabric thickness gauge. The porosity calculation process is as follows: take a pile layer with an area of ​​one square meter, its geometric volume is equal to 1000 multiplied by the pile height, in cubic centimeters; the volume of the polyester solid within the pile layer is the unit area mass of the pile layer divided by the density of the polyester material; subtract the solid volume from the geometric volume and then divide by the geometric volume, and the result is the above formula. For example: the unit area mass of the pile layer is 745 grams per square meter, the polyester material density is 1.38 grams per cubic centimeter, and the pile height is 13.5 millimeters. Substituting these values ​​into the above formula, we get:

[0068]

[0069] This fabric is designed for single-person thermal insulation in high-altitude and cold-weather emergency rescue scenarios: at night, temperatures are low and winds are strong, so the blanket needs to be wrapped around the body to suppress heat loss; during the day, it needs to be packed into a backpack and taken away; it needs to be washed when dirty, dried, and reused. Ordinary all-polyester blankets have several problems under these conditions: the pile flattens out easily when pressed and washed, eliminating the air layer; the blanket surface is breathable, and heat is directly carried away by the wind; the fibers are coarse and stiff against the skin. The hollow cavities of hollow polyester textured yarn lock in some stagnant air inside the fiber, and the fiber itself is not a good conductor of heat; the upright pile creates a thicker air layer on the surface of the weave layer, resulting in high porosity; after calendering the side away from the body, the surface pores are compressed, preventing wind penetration and undisturbing the stagnant air layer; the porosity formula links the air content to a measurable quantity, making the thermal insulation design based on verifiable data. With the combination of these elements, warmth is no longer achieved by piling on materials. The material can be restored after being compressed or folded, and the heat dissipation channels in strong winds are cut off. The weight and feel are also preserved because the amount of fiber used is controlled.

[0070] As an optional embodiment, the hollow ratio of the hollow polyester textured yarn is calculated and determined according to the following formula:

[0071]

[0072] The apparent density of the hollow polyester textured yarn is determined by the following formula:

[0073]

[0074] In the formula:

[0075] The hollowness ratio of the hollow polyester textured yarn;

[0076] The apparent density of the hollow polyester textured yarn is expressed in grams per cubic centimeter.

[0077] The linear density of the hollow polyester textured yarn is expressed in decitex.

[0078] The outer diameter of a single fiber of the hollow polyester textured yarn is expressed in micrometers and converted to meters when substituted into other formulas.

[0079] The meaning is the same as before.

[0080] It should be noted that the calculation process for apparent density is as follows: Take a single fiber with a length of one meter; its mass is equal to the linear density of the single fiber multiplied by 10 to the power of -4, in grams. Calculate its geometric volume using the outer diameter of the single fiber. After unifying the units, divide the mass by the geometric volume to obtain the apparent density. The constant 400 is obtained through unit conversion and merging. The linear density of the single fiber is determined according to GB / T14343. The outer diameter of the single fiber is measured by photographing with a fiber cross-section microscope. The hollowness is calculated using the above two formulas and can be verified by actual measurement using a density gradient tube. For example: If the linear density of the single fiber is 1.11 decibels and the outer diameter of the single fiber is 13 micrometers, substituting the values, we get:

[0081]

[0082]

[0083] The hollow ratio directly corresponds to the proportion of still air inside a single fiber: the higher the hollow ratio, the lower the fiber's thermal conductivity, and the less fiber material is used in the same volume, resulting in simultaneous benefits in both warmth retention and weight reduction. The practical application of these two formulas is that the hollow ratio can be obtained using only two conventional instruments—linear density and outer diameter—which can be calculated batch by batch in the workshop and then verified using the actual measured values ​​from a density gradient tube. The degree of hollowness becomes a controllable and traceable indicator for material input, without relying on the fiber's nominal specifications, thus suppressing differences in warmth retention between batches.

[0084] As an optional embodiment, the pile height is not greater than the critical height of pile self-hanging, which is calculated and determined according to the following formula:

[0085]

[0086] The moment of inertia of the single fiber section is calculated and determined according to the following formula:

[0087]

[0088] The gravitational load per unit length of the fluff is calculated and determined according to the following formula:

[0089]

[0090] In the formula:

[0091] The critical height of the villi's self-adhesion, in meters;

[0092] The flexural modulus of polyester is expressed in Pascals (Pa).

[0093] The moment of inertia of a single fiber cross-section is expressed in fourth-order meters.

[0094] This represents the gravitational load per unit length of the down, expressed in Newtons per meter.

[0095] The acceleration due to gravity is taken as 9.8 meters per second squared.

[0096] . , The meaning is the same as before.

[0097] It should be noted that the upright fibers are equivalent to an elastic column fixed at the bottom and free at the top. The critical length at which it buckles under its own weight is given by the Greenhill formula, and the constant 7.837 is the cube of the solution to the transcendental equation of this formula. The formula for the moment of inertia of the cross section is derived from the formula for the moment of inertia of a hollow circular annulus. The inner diameter of the hollow part is equal to the product of the outer diameter of the single fiber and the square root of the hollowness ratio. Substituting these values ​​yields the form containing the square term of the hollowness ratio. The formula for the gravity load is obtained by multiplying the mass of the fiber per unit length by the acceleration due to gravity. In the calculation, the outer diameter of the single fiber is first converted from micrometers to meters and then substituted into the formula for the moment of inertia of the cross section. The apparent density is converted from grams per cubic centimeter to kilograms per cubic meter and then substituted into the formula for the load. The flexural modulus of elasticity is measured by a single fiber cantilever bending test. For example: the measured flexural modulus is 3.0 x 10^9 Pascals, the calculated moment of inertia is 1.18 x 10^-21 m^4, and the gravitational load is 1.09 x 10^-6 N / m. Substituting these values ​​into the critical height formula, we get:

[0098]

[0099] The critical height is approximately 29.5 mm, which is 13.5 mm greater than the pile height. This constraint addresses a direct problem: once the pile buckles and collapses under its own weight, the porosity is lost, and all the previously calculated insulation benefits are lost. By keeping the pile height within the critical height of self-buckling, the individual fibers maintain elastic stability under their own weight. After wrapping, folding, and washing, the pile can still spring back to an upright state, and the air layer remains throughout the entire service life. Furthermore, the constraint value is calculated based on the measured mechanical parameters of the fiber; the height is determined based on evidence, not just by taking pictures.

[0100] As an optional embodiment, the thermal resistance of the fabric satisfies the following verification relationship:

[0101]

[0102] In the formula:

[0103] The thermal resistance of the fabric is expressed in Kelvin per watt per square meter.

[0104] The difference between the comfortable temperature for human skin and the design temperature of the usage environment, expressed in Kelvin;

[0105] The effective area of ​​the human body covered by the fabric is in square meters.

[0106] The power of heat dissipation at rest for the human body is measured in watts.

[0107] It should be noted that this verification relationship is derived from the human body steady-state thermal balance equation: the resting heat dissipation power of the human body equals the coverage area multiplied by the temperature difference and then divided by the thermal resistance. To ensure that the heat dissipation of the human body does not exceed the resting heat dissipation power, the thermal resistance must be no less than the product of the temperature difference and the coverage area divided by the resting heat dissipation power. The comfortable temperature for human skin is taken as 33 degrees Celsius. The design temperature for the usage environment is taken as the low temperature limit of the application scenario. The coverage area is taken as the measured envelope area of ​​a single person in a wrapped posture. The resting heat dissipation power is taken as the average value of the measured values ​​in the resting state. The thermal resistance of the fabric is measured according to GB / T11048.1. For example, a single thermal blanket for emergency rescue in high-altitude and cold regions is designed for a nighttime environment temperature of -7 degrees Celsius, a skin comfort temperature of 33 degrees Celsius, a temperature difference of 40 Kelvin, a coverage area of ​​1.2 square meters, and a resting heat dissipation power of 100 watts. Substituting these values ​​into the calibration relationship, the thermal resistance is found to be no less than 0.48 Kelvin per watt. The fabric, measured according to GB / T11048.1, has a thermal resistance of 0.53 Kelvin per watt, meeting the calibration requirements. The purpose of the calibration is to change the warmth target from relying on experience to increase thickness to a quantitative approach based on human body thermal balance: the temperature difference, coverage area, and heat dissipation power correspond to the usage environment, wrapping method, and human body needs, respectively. The lower limit is recalculated for each different scenario, and the fabric is always designed for real-world usage conditions. Insufficient thermal resistance will lead to heat loss, while blindly increasing thickness will only add unnecessary weight. Both extremes are avoided.

[0108] As an optional embodiment, the equivalent thermal conductivity of the fluff layer is calculated and determined according to the following formula:

[0109]

[0110] The height of the fluff is determined by the following formula:

[0111]

[0112] In the formula:

[0113] The equivalent thermal conductivity of the fluff layer is expressed in watts per meter Kelvin.

[0114] The thermal conductivity of still air is taken as 0.026 W / m Kelvin;

[0115] The thermal conductivity of polyester is expressed in watts per meter (Kelvin).

[0116] The lower limit of the value for the thermal resistance of the fabric is taken from the value calculated by the aforementioned verification relationship;

[0117] The thickness of the dense surface is expressed in millimeters.

[0118] The meaning is the same as before.

[0119] It should be noted that the formula for the equivalent thermal conductivity is derived from a model of parallel heat conduction between still air and the polyester solid along the thickness direction. The equivalent thermal conductivity equals the air thermal conductivity multiplied by the porosity plus the polyester thermal conductivity multiplied by the solid fraction. The formula for the pile height is derived from the formula for the total thermal resistance of the fabric, which equals the pile layer thickness divided by the equivalent thermal conductivity plus the dense surface thermal resistance. The dense surface thermal resistance is obtained by dividing the dense surface thickness by the polyester thermal conductivity. The constant 1000 in the formula is obtained by converting meters to millimeters. The polyester thermal conductivity is measured by steady-state heat flow method, and the dense surface thickness is measured by a fabric thickness gauge on the calendered surface. For example, the thermal conductivity of polyester is measured to be 0.20 W / m Kelvin, and the porosity is taken as 0.96, resulting in an equivalent thermal conductivity of 0.0330 W / m Kelvin. The thermal resistance is taken as 0.48 square meters Kelvin per watt, and the dense surface thickness is 2.5 mm. Therefore, the pile height is calculated to be 13.3 mm, and we take 13.5 mm. This height is also less than the critical height of 29.5 mm calculated based on buckling conditions. This determined pile height satisfies the lower limit of the thermal resistance check: the still air layer is just sufficient, the fiber usage is reduced to the minimum level required for warmth, the blanket is light, folds easily, and is easy for rescuers to carry; moreover, the lower the height, the easier it is to meet the upright stability constraint. Warmth, uprightness, and lightness are all determined by the same calculation chain, without conflicting with each other.

[0120] As an optional embodiment, the outer diameter of a single fiber of the hollow polyester textured yarn is calculated and determined according to the following formula, and the bending stiffness of a single fiber is verified and determined according to the following formula:

[0121]

[0122]

[0123] In the formula:

[0124] The bending stiffness of a single fiber is expressed in millinewtons per centimeter.

[0125] The mass per unit area of ​​the fabric is expressed in grams per square meter.

[0126] The exposed length of the tuft of hairs, in centimeters;

[0127] , , The meaning is the same as before.

[0128] It should be noted that the formula for single fiber outer diameter is obtained by simultaneously solving the formulas for apparent density and hollowness, eliminating the apparent density, and then rearranging. Its physical meaning is: under given linear density and hollowness, the outer diameter of a single fiber is uniquely determined by the conservation of the fiber's volume. The verification formula for bending stiffness is obtained from a cantilever beam model: considering the tuft as a cantilever beam with a uniformly distributed self-weight load, the bending stiffness equals the linear density multiplied by the gravitational acceleration and then multiplied by the cube of the exposed length. The constant 9.8 multiplied by 10 to the power of -4 is obtained through unit conversion between grams per square meter, centimeters, and millinewtons per centimeter. For example: with a single fiber linear density of 1.11 dBTx and a hollowness of 0.394, the calculated single fiber outer diameter is 13.0 micrometers, consistent with the microscopic measurement; with a fabric unit area mass of 1200 grams per square meter and a tuft exposed length of 1.35 centimeters, the verified single fiber bending stiffness is 2.9 millinewtons per centimeter. The considerations behind these two formulas are as follows: the bending stiffness of a single fiber changes with the fourth power of the outer diameter; a larger outer diameter results in a doubling of stiffness, immediately making the fabric feel harder. The outer diameter formula locks the outer diameter, linear density, and hollowness into the same conservation relationship, ensuring that a fine outer diameter and a high hollowness are achieved at the spinning specification stage, resulting in a soft, skin-friendly pile layer. The stiffness verification formula then uses the finished product weight and pile length to confirm that the softness is not achieved by sacrificing fiber strength, but rather by matching the outer diameter with the structure, ensuring that both softness and durability are achieved.

[0129] As an optional embodiment, the method for preparing the high-insulation, soft, all-polyester blanket-type textile fabric according to any one of claims 1 to 6 is characterized by comprising the following steps:

[0130] S1. Relaxation and pre-shrinking: The woven fabric is placed in a water bath for relaxation treatment. The water temperature of the water bath and the relaxation treatment time are determined by the following two formulas:

[0131]

[0132]

[0133] S2. Pile Setting: The pre-shrinked fabric is napped at least once. The number of napping passes is calculated using the following formula. After each napping pass, the fabric is dried and set.

[0134]

[0135] S3. Combing and shearing: Combing and shearing are performed on the raised fabric in sequence to make the pile stand up and be of uniform height.

[0136] S4. Softening Padding: The sheared billet is placed in a padding solution containing a softener for padding treatment. The mass concentration of the softener in the padding solution is determined by the following formula. After padding, the billet is dehydrated.

[0137]

[0138] S5. Calendering and Setting: Calender the surface of the fabric away from the pile layer after impregnation. The surface temperature of the rollers and the hot air setting temperature are calculated and determined according to the following formula. Then, hot air baking and setting are performed. The setting time is determined according to the formula for the relaxation treatment time. After cooling, the fabric is unloaded.

[0139]

[0140] In the formula:

[0141] The water temperature of the water bath is expressed in degrees Celsius.

[0142] The glass transition temperature of polyester is expressed in degrees Celsius.

[0143] The boiling point of water is taken as 100 degrees Celsius.

[0144] Relaxation time or setting time, in seconds;

[0145] The thickness is half the thickness of the fabric, in millimeters. When substituting it into the cooling time formula, it should be converted to meters.

[0146] is the thermal diffusivity of polyester, expressed in square millimeters per second;

[0147] This represents the number of napping passes; the calculated result is rounded up.

[0148] The increment in pile height for a single pile pass, in millimeters;

[0149] This refers to the mass concentration of the softener in the padding solution, expressed in grams per gram.

[0150] This refers to the amount of fabric softener applied per unit area, expressed in grams per square meter.

[0151] The rolling yield is the amount of liquid added during the immersion process.

[0152] The unit area mass of the raw fabric before rolling is expressed in grams per square meter.

[0153] These are the surface temperature of the rolls and the hot air setting temperature, in degrees Celsius.

[0154] This is the melting point of polyester, expressed in degrees Celsius.

[0155] The meaning is the same as before.

[0156] It should be noted that the glass transition temperature and melting point were measured using a differential scanning calorimeter on polyester chips; the thermal diffusivity is equal to the thermal conductivity divided by the product of density and specific heat capacity, and all three values ​​were taken from actual measurements. The water temperature was taken as the median of the glass transition temperature and the boiling point of water, based on the following: the water temperature must be higher than the glass transition temperature for the macromolecular chain segments to move and for the internal stress of the weaving to be released; the water temperature must be lower than the boiling point for the water bath to maintain a normal pressure liquid state. The median of these two values ​​ensures that the relaxation rate and operational safety are both at a moderate level. The formulas for relaxation time and setting time are derived from the condition that the Fourier number equals one in unsteady-state heat conduction, which is the characteristic time required for heat to penetrate half the thickness of the fabric and make the internal and external temperatures tend to be uniform. The increase in pile height for a single pass of napping was measured from the first pass of trial napping, and the result of the pass number calculation was rounded up. The formula for mass concentration is derived from the mass conservation principle before and after padding: the liquid-laden ratio is the ratio of the liquid-laden mass after padding to the dry mass before padding, determined by actual measurement; the amount of softener adhering is equal to the mass concentration multiplied by the liquid-laden ratio and then multiplied by the mass per unit area of ​​the fabric, which is obtained by inverse solution. The roll surface temperature and the hot air setting temperature are taken to be the same intermediate value, based on the following: the setting temperature must be higher than the glass transition temperature to allow chain segment rearrangement, and lower than the melting point to avoid fiber agglomeration. The intermediate value ensures sufficient setting and prevents heat damage to the pile. The two processes share the same temperature to avoid setting it separately. For example: The measured glass transition temperature is 75 degrees Celsius, and the melting point is 254 degrees Celsius. Substituting these into the water temperature formula yields 87.5 degrees Celsius. Substituting these into the temperature formula, the roll surface temperature and hot air setting temperature are both 164.5 degrees Celsius. The fabric half-thickness is 5.8 mm, the thermal conductivity is 0.20 W / m Kelvin, the density is 1380 kg / m³, and the specific heat capacity is 1250 J / kg Kelvin. The calculated thermal diffusivity is 0.116 mm² / s. Substituting these into the time formula, the relaxation time and setting time are both approximately 290 seconds. The target pile height is 13.5 mm, and the measured single-pass height increment is 3.0 mm, so the number of pile passes is calculated to be 5. The target softener adhesion amount is 0.193 g / m², the measured liquid yield is 0.60, and the fabric unit area mass is 890 g / m², so the calculated mass concentration is 3.61 x 10^-4 g / g.

[0157] The division of labor in each step of the entire process chain is as follows: relaxation pre-shrinking releases the internal stress of weaving at a temperature where the chain segments can move, so that the finished product will not shrink back in subsequent processing and use, and the blanket surface dimensions remain stable; pile raising is evenly distributed according to the number of passes to avoid fiber breakage and uneven pile caused by strong pulling in a single pass; combing and shearing make the pile neat and upright, so that the porosity design value has a geometric basis; the amount of soft padding is controlled by back-calculation of mass concentration, and the lubricating film is applied quantitatively, so that the pile has a smooth feel and will not be stuck and crushed by excessive auxiliaries; calendering only presses the side away from the pile layer, so that ventilation is blocked but the air content of the pile layer is not damaged; the setting temperature is taken as the median value of the glass transition temperature and the melting point, combined with the Fourier number time, and the chain segment rearrangement is completed simultaneously inside and outside in the thickness direction of the blanket body, so that the upright shape of the pile and the dense surface are locked together and will not spring back after cooling. By completing this process, the product's porosity, pile height, softness, and windproofness are all achieved through design, thus solving the problem that it is difficult to simultaneously achieve warmth, softness, uprightness, and windproofness in low-temperature and windy environments.

[0158] As an optional embodiment, the softener is an amino-modified polysiloxane;

[0159] The amount of fabric softener adhering per unit area is determined by the following formula:

[0160]

[0161] The thickness of the softener monolayer is determined by the following formula:

[0162]

[0163] The total surface area of ​​the fibers in the villous layer is determined by the following formula:

[0164]

[0165] The average diameter of the fluff is determined by the following formula:

[0166]

[0167] In the formula:

[0168] The thickness of the softener monolayer is expressed in meters.

[0169] This refers to the molar mass of the fabric softener, expressed in kilograms per mole.

[0170] This refers to the density of the fabric softener, expressed in kilograms per cubic meter.

[0171] Let Avogadro's constant be 6.02 multiplied by 10 to the power of 23 per mole;

[0172] The total surface area of ​​the fibers in the pile layer is expressed in square meters per square meter.

[0173] The average diameter of the fibers is given in meters.

[0174] The diameter of a single fiber of the first polyester yarn is in meters;

[0175] q. , , , The meaning is the same as before.

[0176] It should be noted that the film thickness is taken as the cube root of the monomolecular volume, which is equal to the molar mass divided by the product of density and Avogadro's constant. The total surface area is calculated by summing the lateral surface area of ​​the cylindrical fibers over all fibers, with the constant 4 derived from the ratio of the circumference to the cross-sectional area of ​​the circle. The average diameter is calculated as the weighted average of the monofibrils in the ground tissue layer and the single fibers in the pile layer according to their respective mass fractions. All quantities are substituted into SI units during calculation, and the adhesion amount is finally converted from kilograms per square meter to grams per square meter, i.e., the coefficient 1000 in the adhesion amount formula. The softener used is an amino-modified polysiloxane emulsion, whose aminoethylaminopropyl side chains impart a smooth surface to the fibers. The molar mass and density are obtained from the product quality inspection report and can also be verified by actual measurement with a densitometer. For example: With a fabric softener molar mass of 25 kg / mol and a density of 980 kg / m³, the film thickness is calculated to be 3.5 nm. The diameter of a single fiber in the ground layer is 20 μm, and the outer diameter of a single fiber in the pile layer is 13 μm. The fabric's unit area mass is 1200 g / m², and the pile layer's unit area mass is 745 g / m², resulting in an average diameter of 15.7 μm. This leads to a total surface area of ​​55.4 m² / m², and ultimately, an adhesion weight of 0.193 g / m². The quantitative consideration of using a single-molecule film is as follows: After amino-modified polysiloxane is directionally spread to form a film on the fiber surface, the coefficient of friction between fibers immediately decreases; covering one molecular layer is sufficient. Adding more will not improve the feel; instead, the softener will accumulate at fiber intersections, sticking to the pile and compressing the air layer. Adding too little will result in incomplete lubrication. This set of formulas establishes the amount of adhesion based on molecular size and the geometric surface area of ​​the pile. The softening finish changes from adding materials based on experience to quantitatively determining the amount needed for coverage. The smooth feel and the upright and fluffy pile are achieved simultaneously.

[0177] As an optional embodiment, in the napping and raising process of step S2, the speed ratio of the linear velocity of the napping roller needle tip to the fabric feeding speed is calculated and determined according to the following formula:

[0178]

[0179] The speed ratio calibration coefficient is calculated and determined according to the following formula:

[0180]

[0181] In the formula:

[0182] This is the speed ratio of the linear velocity of the napping roller needle tip to the fabric feeding speed;

[0183] This is the speed ratio calibration coefficient, in millimeters;

[0184] The increment of pile height is used to calibrate the pile height; the unit is millimeters.

[0185] The speed ratio used for calibrating napping;

[0186] The meaning is the same as before.

[0187] It should be noted that the speed ratio calibration coefficient is obtained from the actual measurement of one calibrated napping pass: the sliding distance of the napping roller needle tip relative to the fabric surface is directly proportional to the speed ratio minus one, and the increase in nap height is directly proportional to the sliding distance. These two proportional relationships are combined into the calibration coefficient formula. After obtaining the calibration coefficient, the target speed ratio for each napping pass is then directly calculated from the speed ratio formula. For example: if the calibrated napping speed ratio is 1.30, and the measured nap height increase is 2.4 mm, the calculated calibration coefficient is 8.0 mm; the target height increase for a single pass is 3.0 mm, and the target speed ratio is 1.375. The significance of calibration is that the speed ratio determines the relative travel distance of the needle tip to the fiber, which in turn determines the increase in nap height for a single pass; without calibration, the speed ratio can only be determined by the operator through trial and error on each machine, and the height increase immediately becomes uncontrollable after changing machines or product types. The speed ratio and height increment are fixed as the calibration coefficient for this type of equipment by using a calibration pile raising process. After that, the speed ratio can be directly calculated back for any target increment. The height increment of each pile raising process is uniform and controllable, the pile height of the whole piece of fabric is consistent, and the porosity design value is uniformly realized in the width and length directions.

[0188] As an optional embodiment, in the calendering process of step S5, the contact time at the calendering point is calculated and determined according to the following formula:

[0189]

[0190] The width of the rolling point is determined by the following formula:

[0191]

[0192] The thermal diffusivity is determined by the following formula:

[0193]

[0194] The cooling time is calculated and determined according to the following formula:

[0195]

[0196] In the formula:

[0197] The contact time at the rolling point is in seconds.

[0198] The width of the rolling point is in millimeters.

[0199] This refers to the calendering speed, measured in millimeters per second.

[0200] The diameter of the finishing roll is in millimeters.

[0201] The thickness of the raw fabric before calendering is in millimeters.

[0202] The thickness of the calendered fabric is in millimeters.

[0203] This refers to the specific heat capacity of polyester, expressed in joules per kilogram (Kelvin).

[0204] Cooling time, in seconds;

[0205] The coefficient of heat transfer from natural convection to the surface of the fabric is given in Kelvin per watt per square meter.

[0206] The difference between the fabric temperature and room temperature during calendering and finishing, expressed in Kelvin;

[0207] The difference between the fabric temperature and room temperature at the end of cooling is expressed in Kelvin.

[0208] , , The meaning is the same as before.

[0209] It should be noted that the formula for the nip width is derived from the geometric relationship between the roll and the fabric. The nip width is equal to the square root of the difference between the product of the roll diameter and the thickness before rolling and the product of the roll diameter and the thickness after rolling. Higher-order small quantities of the square of the thickness difference are omitted in the derivation. The formula for the thermal diffusivity is its definition, and the thermal conductivity, density, and specific heat capacity are all based on measured values. The formula for the cooling time is derived from the lumped heat capacity model. The cooling time is equal to the heat capacity per unit area divided by the natural convection heat transfer coefficient and multiplied by the natural logarithm of the initial and final temperature difference ratio. The model holds true only if the Biwo number is much less than one, and the thermal conductivity in the thickness direction of the polyester fabric is much faster than the surface convection heat dissipation, which is naturally satisfied. The natural convection heat transfer coefficient is calculated from the fabric width and temperature difference according to the vertical plate natural convection correlation formula, or verified by actual measurements in a heat dissipation experiment with a covered heat flow meter. The cooling termination temperature is taken to be lower than the glass transition temperature, i.e., the temperature difference is not less than the difference between the hot air setting temperature and room temperature minus the difference between the glass transition temperature and room temperature. For example: with a roll diameter of 300 mm, a pre-roll thickness of 8.0 mm, and a post-roll thickness of 6.5 mm, the calculated roll width is 21.2 mm, the machine speed is 600 mm / s, and the contact time is 0.035 seconds; the thermal conductivity is 0.20 W / m Kelvin, the density is 1380 kg / m³, the specific heat capacity is 1250 J / kg Kelvin, and the thermal diffusivity is 1.16 x 10^-7 m² / s; the half-thickness of the fabric is converted to 3.25 mm, the natural convection heat transfer coefficient is calculated to be 8.5 W / m Kelvin, the hot air setting temperature is 164.5 degrees Celsius, the room temperature is 25 degrees Celsius, the cooling termination temperature is 70 degrees Celsius, the initial temperature difference is 139.5 Kelvin, the final temperature difference is 45 Kelvin, and the cooling time is approximately 1637 seconds. The control logic for calendering and cooling is as follows: the contact time at the calendering point determines the heat transferred to the fabric by the rolls. If the contact time is too long, the heat penetrates the blanket, causing the pile to flatten due to heat; if it is too short, the dense surface is not fully formed, and airflow is blocked. The formulas for contact time and calendering width establish the heat transfer window based on measurable parameters such as roll diameter, compression amount, and machine speed, ensuring that the densification heat acts precisely on the surface. The cooling time is calculated using the lumped heat capacity model until the fabric temperature is below the glass transition temperature. The chain segment rearrangement is frozen during the cooling process, and the dense surface and upright pile shape do not spring back after the fabric is dropped. The effects of calendering and setting are maintained across the entire width and length of the fabric, thus avoiding secondary deformation and quality differences within the roll caused by residual heat after dropping.

[0210] Example 1;

[0211] I. Raw Materials and Measured Physical Properties

[0212] The first polyester yarn is a fully drawn polyester filament with a single fiber diameter of 20 micrometers. The second polyester yarn is a hollow textured polyester filament with a hollow cavity running along the fiber axis within the cross-section of each fiber. The single fiber linear density is 1.11 dBTx, the single fiber outer diameter is 13 micrometers, and the apparent density calculated using the apparent density formula is 0.836 g / cm³. The hollowness ratio is 0.394, which is consistent with the actual measurement using a density gradient tube. The polyester material density is 1.38 g / cm³, the flexural modulus of elasticity measured by the single fiber cantilever bending test is 3.0 x 10^9 Pascals, the thermal conductivity measured by the steady-state heat flow method is 0.20 W / m Kelvin, the density is 1380 kg / m³, the specific heat capacity is 1250 J / kg Kelvin, the glass transition temperature is 75°C, and the melting point is 254°C. The softener is an amino-modified polysiloxane emulsion with a molar mass of 25 kg / mol and a density of 980 kg / m³.

[0213] II. Parameter Calculation;

[0214] The skin comfort temperature is set at 33 degrees Celsius, the designed environmental temperature is -7 degrees Celsius, and the temperature difference is 40 Kelvin; the measured envelope area for a single person in a wrapped posture is 1.2 square meters, and the resting heat dissipation power is taken as the measured average of 100 watts. The lower limit of thermal resistance is:

[0215]

[0216] The design value for the porosity of the fluff layer is 0.96, and the equivalent thermal conductivity is:

[0217]

[0218] The measured thickness of the dense surface is 2.5 mm, and the lower limit of the pile height is:

[0219]

[0220] The pile height is taken as 13.5 mm. According to the Greenhill buckling condition, the moment of inertia of the section is 1.18 x 10^-21 m, the gravity load is 1.09 x 10^-6 N / m, the critical height of self-clinching buckling is 29.5 mm, which is greater than 13.5 mm, so the pile height is feasible.

[0221] The water temperature and relaxation time are as follows:

[0222]

[0223]

[0224]

[0225] The actual measured half-thickness of the fabric is 5.8 mm, and the thermal diffusivity is 0.116 mm² / s.

[0226] The speed ratio calibration factor, speed ratio, and number of raising passes are as follows:

[0227]

[0228]

[0229]

[0230] The calibrated pile raising speed ratio was 1.30, and the actual measured pile height increase was 2.4 mm; the target height increase per pass was 3.0 mm.

[0231] The softener film thickness is 3.5 nanometers, the average pile diameter is 15.7 micrometers, the total pile surface area is 55.4 square meters per square meter, and the adhesion amount is 0.193 grams per square meter; the measured unit area mass of the fabric before padding is 890 grams per square meter, the measured padding rate is 0.60, and the padding solution concentration is:

[0232]

[0233] The surface temperature of the rolls and the hot air setting temperature are:

[0234]

[0235] The calendering roll diameter is 300 mm, the pre-calender fabric thickness is 8.0 mm, the post-calender fabric thickness is 6.5 mm, and the calendering point width and contact time are:

[0236]

[0237]

[0238] The calendering speed is 600 mm / s. The hot air setting time is calculated as 290 seconds based on the relaxation time formula. Cooling stage: hot air setting temperature 164.5 degrees Celsius, room temperature 25 degrees Celsius, initial temperature difference 139.5 Kelvin; cooling termination temperature is 70 degrees Celsius, below the glass transition temperature, final temperature difference 45 Kelvin; the natural convection heat transfer coefficient is calculated as 8.5 W / m² Kelvin based on the vertical plate natural convection correlation formula; substituting into the cooling time formula, the cooling time is approximately 1637 seconds.

[0239] III. Preparation steps;

[0240] S1. Relaxation and pre-shrinking: Place the woven fabric in a water bath at 87.5 degrees Celsius for relaxation treatment for 290 seconds, then remove it, dehydrate and air dry.

[0241] S2. Pile setting: The pre-shrinked fabric is piled in 5 stages, with a speed ratio of 1.375 for each stage. After each pile setting, the fabric is dried and set.

[0242] S3. Combing and shearing: Combing and shearing are performed on the raised fabric in sequence. The distance between the shearing blade and the fabric surface is set to 13.5 mm to make the pile stand up and have a uniform height. The difference in total thickness before and after shearing is measured with a fabric thickness gauge to verify the pile height.

[0243] S4. Softening padding: The sheared blank is placed in a padding solution containing amino-modified polysiloxane for padding treatment. The mass concentration of softener in the padding solution is 3.61 x 10^-4 grams per gram. After padding, the solution is removed.

[0244] S5. Calendering and Setting: Calender the surface of the fabric away from the pile layer after impregnation. The surface temperature of the rollers is 164.5 degrees Celsius and the calendering speed is 600 mm / s. Then, hot air baking and setting are performed at a temperature of 164.5 degrees Celsius for 290 seconds. After that, the fabric is naturally cooled for 1637 seconds. The fabric is then unloaded after the temperature drops to 70 degrees Celsius.

[0245] IV. Product Specifications and Test Results

[0246] The resulting thermal insulation blanket has a ground layer woven from fully drawn polyester yarn, and a pile layer made of hollow textured polyester yarn. The pile stands upright on the surface of the ground layer, with a dense surface formed by calendering on the side facing away from the pile layer. The finished product has a unit area mass of 1200 grams per square meter, of which the pile layer has a unit area mass of 745 grams per square meter, a pile height of 13.5 mm, and a porosity of 0.96. The thermal resistance, measured according to GB / T 11048.1, is 0.53 Kelvin per watt, with a lower limit of not less than 0.48; the air permeability, measured according to GB / T 5453, is 12.3 mm / s; the bending length, measured according to GB / T 18318.1, is 29.5 mm; after washing five times and drying according to GB / T 8629, the pile remains upright, and the measured thermal resistance is 0.51 Kelvin per watt. The sample was covered with a hot plate and placed in a wind tunnel with a wind speed of 10 meters per second. The wind-induced thermal resistance was measured to be 0.50 square kelvin per watt.

[0247] Example 2;

[0248] This embodiment prepares a thermal insulation blanket for the same purpose, with a design temperature of -15 degrees Celsius for the environment in which it is used. The raw materials and measured properties are the same as in Example 1.

[0249] I. Parameter Recalculation

[0250] Temperature difference 48 Kelvin, coverage area and resting heat dissipation power are the same as in Example 1, lower limit of thermal resistance is:

[0251]

[0252] The lower limit of the pile height is:

[0253]

[0254] The pile height is set at 16.5 mm, which is still less than the critical height for self-hanging and flexing at 29.5 mm. The number of pile rows is:

[0255]

[0256] The remaining process parameters are the same as in Example 1.

[0257] II. Product Specifications and Test Results

[0258] The finished product has a unit area mass of 1366 grams per square meter, of which the unit area mass of the pile layer is 911 grams per square meter, the pile height is 16.5 mm, and the porosity is 0.96. The bending stiffness of the single fiber is calculated to be 6.0 millinewtons based on the composite method. The measured thermal resistance is 0.61 Kelvin per watt, which is not less than the lower limit of 0.576. The measured air permeability is 11.8 mm / s. The measured bending length is 33.1 mm. After washing and drying 5 times, the pile remains upright, and the measured thermal resistance is 0.59 Kelvin per watt.

[0259] Comparative Example 1;

[0260] The only difference from Example 1 is that the second polyester yarn uses solid polyester textured yarn with a single fiber outer diameter of 13 micrometers, while the other raw materials and processes are the same as in Example 1.

[0261] Solid fibers contain no hollow cavities and have an apparent density equal to the material density of 1.38 g / cm³. Under the same conditions as in Example 1, the mass per unit area of ​​the pile layer is:

[0262]

[0263] Porosity is:

[0264]

[0265] The equivalent thermal conductivity is:

[0266]

[0267] The corresponding total thermal resistance is:

[0268]

[0269] The value of 0.43 is less than the lower limit of 0.48, and the measured value of thermal resistance is 0.42 Kelvin per watt, which does not meet the insulation requirements for a -7 degree Celsius scenario; the unit area mass of the finished product increased from 1200 grams per square meter to 1684 grams per square meter, and the carrying burden increased accordingly; the measured bending length is 34.8 mm, and it feels harder than in Example 1; after 5 washes, the measured thermal resistance is 0.33 Kelvin per watt, and the pile shows obvious flattening.

[0270] Comparative Example 2;

[0271] The only difference from Example 1 is that the calendering in step S5 is omitted, and the fabric is directly baked and shaped by hot air after impregnation and dehydration. All other raw materials and processes are the same as in Example 1.

[0272] The resulting blanket did not form a dense surface on the side away from the pile layer. The measured static thermal resistance was 0.49 Kelvin per watt, close to that of Example 1; the measured air permeability according to GB / T 5453 was 156 mm / s, much higher than the 12.3 mm / s of Example 1; the wind resistance measured in a wind tunnel with a wind speed of 10 m / s was only 0.21 Kelvin per watt, indicating that the still air layer was penetrated and disturbed by the airflow, resulting in the loss of heat preservation capacity in high wind conditions, which does not meet the requirements for use in high-altitude and cold-weather emergency rescue scenarios.

[0273] Summary of test results;

[0274] Example 1 has a thermal resistance of 0.53 square Kelvin per watt, an air permeability of 12.3 mm / s, a bending length of 29.5 mm, a post-wash thermal resistance of 0.51 square Kelvin per watt, and a wind-resistant thermal resistance of 0.50 square Kelvin per watt. Example 2 has a thermal resistance of 0.61 square Kelvin per watt, an air permeability of 11.8 mm / s, a bending length of 33.1 mm, and a post-wash thermal resistance of 0.59 square Kelvin per watt. Comparative Example 1 has a thermal resistance of 0.42 square Kelvin per watt, which decreases to 0.33 square Kelvin per watt after washing, and both the basis weight and bending length increase. Comparative Example 2 has a static thermal resistance close to that of Example 1, but its air permeability reaches 156 mm / s, and its wind-resistant thermal resistance decreases to 0.21 square Kelvin per watt. The comparison shows that: the hollow cavity traps the static air inside the fiber, which is a prerequisite for balancing warmth and weight under the same geometric volume; the dense surface provides wind protection, which is a prerequisite for maintaining static heat preservation in windy conditions; the constraint of pile height and the quantitative control of monomolecular film respectively ensure the uprightness of the pile and the feel. If any link is missing, the corresponding indicators will show a gap.

[0275] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it; any equivalent substitutions and modifications made by those skilled in the art to the above embodiments without departing from the concept of the present invention should fall within the protection scope of the present invention.

[0276] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A high-insulation, soft, all-polyester blanket-type textile fabric, characterized in that, It comprises a ground tissue layer and a villous layer connected to the surface of the ground tissue layer, characterized in that: The ground structure layer is woven from a first polyester yarn, which is a fully drawn polyester yarn; The fleece layer is composed of a second polyester yarn, which is a hollow polyester textured yarn. The single fiber cross-section of the hollow polyester textured yarn has a hollow cavity that runs through the fiber axis. The fibers in the villous layer stand upright on the surface of the ground tissue layer, and the surface of the ground tissue layer facing away from the villous layer is calendered to form a dense surface. The porosity of the villous layer is determined by the following formula: In the formula: The porosity of the fluff layer; The unit area mass of the fluff layer is expressed in grams per square meter. The height of the fibers in the villous layer is expressed in millimeters. This refers to the density of polyester material, expressed in grams per cubic centimeter.

2. The high-insulation, soft, all-polyester blanket-type textile fabric according to claim 1, characterized in that: The hollow ratio of the hollow polyester textured yarn is determined by the following formula: The apparent density of the hollow polyester textured yarn is determined by the following formula: In the formula: The hollowness ratio of the hollow polyester textured yarn; The apparent density of the hollow polyester textured yarn is expressed in grams per cubic centimeter. The linear density of the hollow polyester textured yarn is expressed in decitex. The outer diameter of a single fiber of the hollow polyester textured yarn is expressed in micrometers and converted to meters when substituted into other formulas. The meaning is the same as before.

3. The high-insulation, soft, all-polyester blanket-type textile fabric according to claim 2, characterized in that: The height of the fibers is not greater than the critical height for fiber self-adhesion, which is calculated and determined according to the following formula: The moment of inertia of the single fiber section is calculated and determined according to the following formula: The gravitational load per unit length of the fluff is calculated and determined according to the following formula: In the formula: The critical height of the villi's self-adhesion, in meters; This is the flexural modulus of polyester, expressed in Pascals (Pa). The moment of inertia of a single fiber cross-section is expressed in fourth-order meters. This represents the gravitational load per unit length of the down, expressed in Newtons per meter. The acceleration due to gravity is taken as 9.8 meters per second squared. , , The meaning is the same as before.

4. The high-insulation, soft, all-polyester blanket-type textile fabric according to claim 1, characterized in that: The thermal resistance of the fabric satisfies the following verification relationship: In the formula: The thermal resistance of the fabric is expressed in Kelvin per watt per square meter. The difference between the comfortable temperature for human skin and the design temperature of the usage environment, expressed in Kelvin; The effective area of ​​the human body covered by the fabric is in square meters. The power of heat dissipation at rest for the human body is measured in watts.

5. The high-insulation, soft, all-polyester blanket-type textile fabric according to claim 4, characterized in that: The equivalent thermal conductivity of the fluff layer is determined by the following formula: The height of the fluff is determined by the following formula: In the formula: The equivalent thermal conductivity of the fluff layer is expressed in watts per meter Kelvin. The thermal conductivity of still air is taken as 0.026 W / m Kelvin; The thermal conductivity of polyester is expressed in watts per meter (Kelvin). The lower limit of the value for the thermal resistance of the fabric is taken from the value calculated by the aforementioned verification relationship; The thickness of the dense surface is expressed in millimeters. The meaning is the same as before.

6. The high-insulation, soft, all-polyester blanket-type textile fabric according to claim 5, characterized in that: The outer diameter of a single fiber of the hollow polyester textured yarn is calculated using the following formula, and the bending stiffness of a single fiber is verified using the following formula: In the formula: The bending stiffness of a single fiber is expressed in millinewtons per centimeter. The mass per unit area of ​​the fabric is expressed in grams per square meter. The exposed length of the tuft of hairs, in centimeters; , , The meaning is the same as before.

7. A finishing process for a high-insulation, soft, all-polyester blanket-type textile fabric, used to prepare the high-insulation, soft, all-polyester blanket-type textile fabric according to any one of claims 1 to 6, characterized in that, Includes the following steps: S1. Relaxation and pre-shrinking: The woven fabric is placed in a water bath for relaxation treatment. The water temperature of the water bath and the relaxation treatment time are determined by the following two formulas: S2. Pile Setting: The pre-shrinked fabric is napped at least once. The number of napping passes is calculated using the following formula. After each napping pass, the fabric is dried and set. S3. Combing and shearing: Combing and shearing are performed on the raised fabric in sequence to make the pile stand up and be of uniform height. S4. Softening Padding: The sheared billet is placed in a padding solution containing a softener for padding treatment. The mass concentration of the softener in the padding solution is determined by the following formula. After padding, the billet is dehydrated. S5. Calendering and Setting: Calender the surface of the fabric away from the pile layer after impregnation. The surface temperature of the rollers and the hot air setting temperature are calculated and determined according to the following formula. Then, hot air baking and setting are performed. The setting time is determined according to the formula for the relaxation treatment time. After cooling, the fabric is unloaded. In the formula: The water temperature of the water bath is expressed in degrees Celsius. The glass transition temperature of polyester is expressed in degrees Celsius. The boiling point of water is taken as 100 degrees Celsius. Relaxation time or setting time, in seconds; The thickness is half the thickness of the fabric, in millimeters. When substituting it into the cooling time formula, it should be converted to meters. is the thermal diffusivity of polyester, expressed in square millimeters per second; This represents the number of napping passes; the calculated result is rounded up. The increment in pile height for a single pile pass, in millimeters; This refers to the mass concentration of the softener in the padding solution, expressed in grams per gram. This refers to the amount of fabric softener applied per unit area, expressed in grams per square meter. The rolling yield is the amount of liquid added during the immersion process. The unit area mass of the raw fabric before rolling is expressed in grams per square meter. These are the surface temperature of the rolls and the hot air setting temperature, in degrees Celsius. This is the melting point of polyester, expressed in degrees Celsius. The meaning is the same as before.

8. The post-treatment preparation method according to claim 7, characterized in that: The softener is an amino-modified polysiloxane; The amount of fabric softener adhering per unit area is determined by the following formula: The thickness of the softener monolayer is determined by the following formula: The total surface area of ​​the fibers in the villous layer is determined by the following formula: The average diameter of the fluff is determined by the following formula: In the formula: The thickness of the softener monolayer is expressed in meters. This refers to the molar mass of the fabric softener, expressed in kilograms per mole. This refers to the density of the fabric softener, expressed in kilograms per cubic meter. Let Avogadro's constant be 6.02 multiplied by 10 to the power of 23 per mole; The total surface area of ​​the fibers in the pile layer is expressed in square meters per square meter. The average diameter of the fibers is given in meters. The diameter of a single fiber of the first polyester yarn is in meters; , , , , The meaning is the same as before.

9. The post-treatment preparation method according to claim 7, characterized in that: In step S2, the ratio of the linear velocity of the napping roller needle tip to the fabric feeding speed is calculated and determined according to the following formula: The speed ratio calibration coefficient is calculated and determined according to the following formula: In the formula: This is the speed ratio of the linear velocity of the napping roller needle tip to the fabric feeding speed; This is the speed ratio calibration coefficient, in millimeters; The increment of pile height is used to calibrate the pile height; the unit is millimeters. The speed ratio used for calibrating napping; The meaning is the same as before.

10. The post-treatment preparation method according to claim 7, characterized in that: In the calendering process of step S5, the contact time at the calendering point is calculated and determined according to the following formula: The width of the rolling point is determined by the following formula: The thermal diffusivity is determined by the following formula: The cooling time is calculated and determined according to the following formula: In the formula: The contact time at the rolling point is in seconds. The width of the rolling point is in millimeters. This refers to the calendering speed, measured in millimeters per second. The diameter of the finishing roll is in millimeters. The thickness of the raw fabric before calendering is in millimeters. The thickness of the calendered fabric is in millimeters. This refers to the specific heat capacity of polyester, expressed in joules per kilogram (Kelvin). Cooling time, in seconds; The coefficient of heat transfer from natural convection to the surface of the fabric is given in Kelvin per watt per square meter. The difference between the fabric temperature and room temperature during calendering and finishing, expressed in Kelvin; The difference between the fabric temperature and room temperature at the end of cooling is expressed in Kelvin. , , The meaning is the same as before.

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