Preparation method of high-breathability anti-ultraviolet fabric

Abstract

This invention discloses a method for preparing a highly breathable and UV-protective fabric, belonging to the field of textile fabric technology. The invention uses a combination of 20D-75D nylon / PU yarn and water-soluble PE yarn in a weaving process, followed by refining, pre-setting at 180℃-195℃, weight reduction treatment with 60-100g / L NaOH solution to remove water-soluble PE yarn, dyeing at 90℃-95℃ with simultaneous addition of an anti-nylon type UV-protective finishing agent, washing and drying, processing with non-fluorinated water-repellent resin, and finishing and setting at 160℃-170℃. This invention combines alkali reduction and pore-forming of water-soluble PE yarn with simultaneous UV protection treatment in the dyeing bath, resulting in a fabric with an air transmittance ≥4.0cc, UPF ≥50, UVA ≤5%, and UVB ≤5%, simultaneously satisfying both high breathability and high UV protection properties. This significantly improves wearing comfort and has excellent washability, making it suitable for sun-protective clothing, outdoor sportswear, and other fields.

Description

Technical Field

[0001] This invention belongs to the field of textile fabric technology, specifically relating to a method for preparing a highly breathable and UV-resistant fabric. Background Technology

[0002] Currently, achieving both high breathability and excellent UV protection in fabrics is a pressing technical challenge in the field of functional fabrics. To this end, those skilled in the art have made various attempts.

[0003] Existing technologies are mainly researched from the following directions: I. Optimization of Weave Structure: This method balances breathability and sun protection performance by designing special weave structures. For example, Toray Fiber Research Institute (China) disclosed a UV-protective knitted fabric in patent application No. 202380075205.3, employing a double-sided weave process. By controlling the ratio of the depth of the concave portions on side A and side B of the fabric cross-section, a UPF value exceeding 30 and an air permeability exceeding 200 cm³ / (cm²·s) were achieved. Bosideng Down Apparel Co., Ltd., in its patent application No. 202410134022.0, used a specific combination of weave structures to improve the breathability and UV protection performance of the fabric. However, while these methods can improve breathability to some extent, the increase in air permeability is limited by the tight arrangement of the yarns themselves, making it difficult to achieve a significantly high breathability effect.

[0004] II. Multi-layer Composite Structure Method: This method combines different functional layers through a lamination process. Zhejiang Wanlihong Textile Technology Co., Ltd. disclosed a production process for waterproof, breathable, and UV-resistant warp-knitted composite fabrics in its patent application CN202311234011.1. This process involves treating the fabric with sodium hydroxide and a chelating agent in the pretreatment solution before dyeing and UV-resistant finishing. However, while this type of multi-layer structure offers strong functionality, the interlayer bonding affects overall breathability, and the composite process increases production costs and complexity.

[0005] III. Chemical Finishing Method: This involves adding UV-resistant finishing agents during the dyeing or setting process. Chinese patent application number 201810123557.2 uses phenyl phthalate (o-hydroxybenzoate) in combination with titanium dioxide to prepare a UV-resistant finishing agent, which is then laminated with PTFE garment film to create fabric, claiming a UPF ≥ 70 and high breathability. Another approach uses all-polyester fabrics that undergo alkali reduction and digital printing followed by UV-resistant finishing. However, traditional alkali reduction processes are mainly for polyester fibers, limiting their applicability to nylon / PU fabrics; furthermore, conventional UV-resistant finishing agents have insufficient bonding strength with fibers, resulting in poor wash resistance.

[0006] IV. Physical Perforation Method: This method creates breathable pores in the fabric through mechanical punching or laser cutting. Wujiang Yili Textile Co., Ltd. disclosed a sun-protective and breathable synthetic fiber fabric in its utility model patent application (application number 202420266780.3). The fabric features an I-shaped slit in the inner layer with a blocking sheet, achieving a dynamic balance between breathability and sun protection through the opening and closing of the slit under external force. While this method offers significant breathability, the location and size of the pores are difficult to control precisely, allowing ultraviolet rays to still penetrate directly through the pores, affecting the overall protective effect.

[0007] A comprehensive analysis of the above technical solutions reveals the following common shortcomings in existing technologies: 1. Difficulty in achieving both functions: When improving breathability through optimized fabric structure or physical openings, the UV transmittance increases accordingly; while when enhancing UV protection (such as by using multi-layer composites or high-density weaving), the air transmittance often drops below 2.0cc, resulting in a noticeable stuffy feeling when wearing it.

[0008] 2. Complex processes or high costs: Although solutions such as rare earth functional yarns and multi-layer composites can achieve certain effects, the cost of raw materials or the complexity of processes are significantly increased, which is not conducive to industrialization and promotion.

[0009] 3. Insufficient wash resistance: Conventional UV-resistant finishing agents are mostly applied by padding, and their binding with fibers is mainly through physical adsorption. After repeated washing, their function is significantly reduced.

[0010] 4. Poor compatibility with nylon / PU substrates: Existing alkali reduction pore-forming technology is mainly developed for polyester fibers. When applied to nylon / PU fabrics, it suffers from problems such as mismatched process parameters and fiber damage.

[0011] Therefore, developing a process that is controllable, cost-effective, and capable of simultaneously achieving high breathability (≥4.0 cc) and high UV resistance (UPF≥50) on nylon / PU fabrics remains a pressing technical problem to be solved in this field. Summary of the Invention

[0012] Purpose of the invention: The present invention aims to provide a method for preparing a highly breathable and UV-protective fabric, in order to solve the problem that existing fabrics cannot simultaneously meet the dual performance requirements of air transmittance ≥4.0 cc and UPF ≥50 (UVA and UVB both ≤5%), thereby significantly improving the wearing comfort of the fabric while ensuring excellent UV protection capabilities.

[0013] Technical solution: On one hand, the present invention provides a method for preparing a highly breathable and UV-protective fabric, comprising the following steps: Step S1. Fabric weaving: Water-soluble PE yarn and nylon / PU yarn are arranged and woven to obtain a composite structure fabric; Step S2. Fabric refining: Remove the sizing agent from the fabric weaving process to allow the fabric to shrink evenly; Step S3. Pre-setting: Perform high-temperature setting to stretch the fabric evenly; Step S4. Weight reduction processing: NaOH solution is used to perform weight reduction processing to remove water-soluble PE yarn; Step S5. Dyeing: High-temperature dyeing is carried out in an overflow dyeing machine, while anti-nylon type UV-resistant finishing agent, dye and auxiliaries are added to make the fabric colored and have UV-resistant function; Step S6. Washing and drying: After dyeing, the water is removed by a dryer; Step S7. Water-repellent treatment: The fabric is impregnated in water-repellent resin using a resin processing machine, and excess water is dried to ensure that the water-repellent substance is evenly coated on the fabric surface, while protecting the UV-resistant finishing agent from being washed off. Step S8. Finishing and shaping: Stretch the fabric evenly to stabilize yarn shrinkage.

[0014] Furthermore, in step S1, the fineness of the nylon / PU yarn is 20D-75D.

[0015] Furthermore, in step S3, the pre-forming temperature is 180℃-195℃.

[0016] Furthermore, in step S4, the concentration of the NaOH solution is 60 g / L-100 g / L, and the treatment temperature is 100 °C.

[0017] Furthermore, in step S5, the staining temperature is 90℃-95℃.

[0018] Furthermore, in step S7, the water-repellent resin is a non-fluorinated water-repellent resin.

[0019] Furthermore, in step S8, the finishing and shaping temperature is 160℃-170℃.

[0020] Furthermore, the finished fabric has an air transmittance of ≥4.0cc, a UPF of ≥50, a UVA of ≤5%, and a UVB of ≤5%.

[0021] On the other hand, the present invention provides a highly breathable and UV-protective fabric, which is prepared by the above-described method.

[0022] Furthermore, after washing, the fabric has UVA≤5%, UVB≤5%, UPF≥50, and air transmittance≥4.0cc.

[0023] Beneficial effects: Compared with the prior art, the present invention has the following beneficial effects: 1. Achieving both high breathability and high UV protection performance. In existing technologies, conventional methods for improving fabric breathability (such as reducing warp and weft density, mechanical punching, etc.) lead to ultraviolet rays penetrating the fabric surface more easily, making it impossible to meet the national standard GB / T 18830 requirements for UV protection: UPF ≥ 50, UVA ≤ 5%, UVB ≤ 5%. While conventional UV-protective fabrics block UV rays by increasing yarn density and weave tightness, this results in air transmittance dropping below 2.0cc, leading to significant stuffiness and extremely poor comfort. This invention uses a combination of water-soluble PE yarn and nylon / PU yarn in a weaving process, followed by a selective alkali reduction process to dissolve and remove the water-soluble PE yarn, forming uniform microporous channels within the fabric. Simultaneously, an anti-nylon type UV-protective finishing agent is added during the dyeing process, ensuring the UV-protective components are evenly adhered to the fiber surface and interior. Testing shows that the fabric of this invention has an air transmittance ≥ 4.0cc, while maintaining UPF ≥ 50, UVA ≤ 5%, and UVB ≤ 5%, simultaneously meeting the national standard's dual requirements for high breathability and high UV protection performance on the same fabric, solving a long-standing technical problem in this field.

[0024] 2. Significantly improves wearing comfort Conventional UV-protective fabrics, due to their tight weave and high yarn density, typically have an air permeability of less than 2.0cc. This makes it difficult for heat and moisture generated by the body to escape, resulting in a stuffy feeling when worn in hot environments and severely impacting the wearing experience. This invention, through a reduced-weight processing method that creates a uniform microporous structure, achieves an air permeability of over 4.0cc, more than twice that of conventional UV-protective fabrics. This enables highly efficient air exchange, promptly releasing heat and moisture from the skin, significantly reducing stuffiness, and improving wearing comfort in summer or outdoor sports scenarios.

[0025] 3. Excellent UV resistance and durability Conventional UV-resistant finishing methods typically employ padding, resulting in a weak bond between the UV-resistant agent and the fiber, which is primarily a physical adsorption process. This leads to a significant decrease in UV resistance after repeated washing. This invention, however, incorporates a nylon-type UV-resistant finishing agent during the dyeing process. High-temperature dyeing conditions allow the UV-resistant components to bond more firmly with the nylon / PU fibers. Simultaneously, in subsequent processes, a non-fluorinated water-repellent resin forms a uniform coating layer on the fabric surface. This coating layer not only imparts water repellency but also effectively protects the internal UV-resistant finishing agent, reducing its loss during washing. After multiple washes, the UVA and UVB levels of the fabric from this invention remain below 5%, and the UPF remains above 50, demonstrating excellent wash resistance.

[0026] 4. The process is environmentally friendly and the cost is controllable. In existing technologies, to achieve a combination of high breathability and UV resistance, some solutions employ rare-earth functional yarns or multi-layer composite structures, significantly increasing raw material costs; others utilize complex finishing processes, resulting in long production cycles and high energy consumption. This invention, however, can be achieved using conventional textile equipment. Both water-soluble PE yarn and nylon / PU yarn are readily available commercial raw materials. The alkali reduction process is mild (NaOH concentration 60-100 g / L, treatment temperature 100℃), and the non-fluorinated water-repellent resin aligns with current environmental trends. Overall, this invention features a simple process route, controllable raw material costs, and good production reproducibility, making it suitable for large-scale industrial application.

[0027] 5. Excellent compatibility with nylon / PU substrates. Existing alkali reduction and pore-forming technologies are mainly developed for polyester fibers. When applied to nylon / PU fabrics, they suffer from problems such as difficulty in matching process parameters and easy fiber damage. This invention, specifically targeting the characteristics of nylon / PU fibers, systematically optimizes the parameter ranges of each process, including refining, pre-setting, alkali reduction, dyeing, and setting (e.g., pre-setting 180-195℃, dyeing 90-95℃, finishing and setting 160-170℃). This ensures complete dissolution of water-soluble PE yarn while avoiding excessive damage to nylon / PU fibers, thus maintaining the fabric's mechanical properties and hand feel.

[0028] 6. Excellent overall performance indicators According to third-party testing standards, the specific performance indicators of the fabric of this invention are as follows: UV protection factor (UPF) ≥ 50 (national standard requires ≥ 50); UVA transmittance ≤ 5% (national standard requires ≤ 5%); UVB transmittance ≤ 5% (national standard requires ≤ 5%); air transmittance ≥ 4.0 cc (conventional UV-protective fabrics are usually < 2.0 cc); after washing (referring to the washing procedure of GB / T 8629 standard), UVA and UVB are still ≤ 5%, UPF ≥ 50, and the UV protection performance retention rate is ≥ 85%; the washing shrinkage rate and ironing shrinkage rate of the fabric meet the requirements of the apparel standard.

[0029] In summary, this invention solves the contradiction between high breathability and high UV protection in existing technologies by combining "water-soluble PE yarn + alkali reduction and pore-forming" with "dyeing and UV protection treatment in the same bath + water-repellent coating protection". It also takes into account durability, comfort, environmental protection and economy, and can be widely used in sun protection clothing, outdoor sportswear, summer fashion, sunshade products and other fields, with significant social and economic benefits. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall technical solution of the present invention. Detailed Implementation

[0031] This invention uses 20D-75D nylon / PU fabric, and its process flow is as follows: fabric weaving - fabric refining - pre-setting - weight reduction - dyeing - washing and drying - water-repellent treatment - finishing and setting.

[0032] Example 1 like Figure 1 As shown, a method for preparing a highly breathable and UV-protective fabric includes the following steps: Step S1. Fabric weaving: Use water-soluble PE yarn to weave fabric with nylon / PU; Step S2. Fabric refining: Remove the sizing agent from the fabric weaving process, allowing the fabric to shrink evenly. Step S3. Pre-setting: After setting at 180℃, the fabric is stretched evenly, which improves the air permeability of the fabric; Step S4. Weight reduction processing: The fabric is treated with 60 g / L NaOH at 100°C to remove water-soluble PE yarn and improve the air permeability of the fabric. Step S5. Dyeing: In the overflow dyeing machine cylinder, the fabric is dyed at a high temperature of 90°C, with the addition of auxiliaries, dyes and anti-nylon type anti-UV agents, so that the fabric is colored and has anti-ultraviolet function. Step S6. Washing and drying: After dyeing, the fabric is dried in a dryer to remove moisture, making it easier for subsequent finishing processes. Step S7. Water-repellent treatment: The fabric is impregnated in non-fluorinated water-repellent resin through a resin processing machine, and excess water is dried to make the water-repellent material evenly coated on the fabric; at the same time, it protects the anti-UV agent from being easily washed away. Step S8. Finishing and Shaping: The last process before finishing the product. The fabric is stretched evenly at a high temperature of 160℃ to further improve air permeability and stabilize yarn shrinkage, so that the finished product can also meet the requirements for washing shrinkage and ironing shrinkage.

[0033] Example 2 like Figure 1 As shown, a method for preparing a highly breathable and UV-protective fabric includes the following steps: Step S1. Fabric weaving: Use water-soluble PE yarn to weave fabric with nylon / PU; Step S2. Fabric refining: Remove the sizing agent from the fabric weaving process, allowing the fabric to shrink evenly. Step S3. Pre-setting: After setting at a high temperature of 195℃, the fabric is stretched evenly, which improves the air permeability of the fabric; Step S4. Weight reduction processing: The fabric is treated with 100 g / L NaOH at 100°C to remove water-soluble PE yarn and improve the air permeability of the fabric. Step S5. Dyeing: In the overflow dyeing machine cylinder, the fabric is dyed at a high temperature of 95°C, with the addition of auxiliaries, dyes and anti-nylon type anti-UV agents, so that the fabric is colored and has anti-ultraviolet function. Step S6. Washing and drying: After dyeing, the fabric is dried in a dryer to remove moisture, making it easier for subsequent finishing processes. Step S7. Water-repellent treatment: The fabric is impregnated in non-fluorinated water-repellent resin through a resin processing machine, and excess water is dried to make the water-repellent material evenly coated on the fabric; at the same time, it protects the anti-UV agent from being easily washed away. Step S8. Finishing and Shaping: The last process before finishing the product. The fabric is stretched evenly at a high temperature of 170℃ to further improve air permeability and stabilize yarn shrinkage, so that the finished product can meet the requirements for washing shrinkage and ironing shrinkage.

[0034] Example 3 like Figure 1 As shown, a method for preparing a highly breathable and UV-protective fabric includes the following steps: Step S1. Fabric weaving: Use water-soluble PE yarn to weave fabric with nylon / PU; Step S2. Fabric refining: Remove the sizing agent from the fabric weaving process, allowing the fabric to shrink evenly. Step S3. Pre-setting: The fabric is set at a high temperature of 187℃ to stretch it evenly and improve its air permeability. Step S4. Weight reduction processing: The fabric is treated with 86 g / L NaOH at 100°C to remove water-soluble PE yarn and improve the air permeability of the fabric. Step S5. Dyeing: In the overflow dyeing machine cylinder, the fabric is dyed at a high temperature of 92°C, with the addition of auxiliaries, dyes and anti-nylon type anti-UV agents, so that the fabric is colored and has anti-ultraviolet function. Step S6. Washing and drying: After dyeing, the fabric is dried in a dryer to remove moisture, making it easier for subsequent finishing processes. Step S7. Water-repellent treatment: The fabric is impregnated in non-fluorinated water-repellent resin through a resin processing machine, and excess water is dried to make the water-repellent material evenly coated on the fabric; at the same time, it protects the anti-UV agent from being easily washed away. Step S8. Finishing and Shaping: The last process before finishing the product. The fabric is stretched evenly at a high temperature of 164℃ to further improve air permeability and stabilize yarn shrinkage, so that the finished product can meet the requirements for washing shrinkage and ironing shrinkage.

[0035] Example 4 (Impact of each process on performance) The fabric performance at each stage of the process was tested according to the technical solution of this invention, and the results are shown in Table 1 below: Table 1. Fabric performance of the technical solution of the present invention at each process stage.

[0036] Results analysis: After the reduction processing, the air permeability was significantly improved (from 1.89cc to 6.82cc); the UPF was greatly improved after the introduction of UV-resistant finishing agent in the dyeing process (from 49.8 to 99.2); subsequent finishing processes kept the performance stable.

[0037] Example 5 (Pre-set Temperature Comparison) According to the technical solution of this invention, different pre-forming temperatures were compared, and the fabric performance was tested. The results are shown in Table 2 below: Table 2. Fabric Performance Test Table

[0038] Results analysis: A suitable pre-forming temperature (180-195℃) can achieve an ideal air permeability (7.12cc) while ensuring UPF≥50. Among them, pre-forming condition 1 makes the fabric uniformly stretched, improving the air permeability of the fabric; pre-forming condition 2 improves the water repellency of the fabric surface and further enhances dimensional stability. Finally, the functional comparison of the present invention with existing products is shown in Table 3 below: Table 3 Performance Test Table of Existing Products and the Product of This Invention

[0039] Results analysis: Ordinary fabrics cannot simultaneously meet the requirements of high air permeability and high UV resistance; this invention patent can guarantee excellent UV resistance and excellent air permeability, achieving strong functionality and good comfort.

[0040] According to third-party testing standards, the specific performance indicators of the fabric of this invention are as follows: UV protection factor (UPF) ≥ 50 (national standard requires ≥ 50); UVA transmittance ≤ 5% (national standard requires ≤ 5%); UVB transmittance ≤ 5% (national standard requires ≤ 5%); air transmittance ≥ 4.0 cc (conventional UV-protective fabrics are usually < 2.0 cc); after washing (referring to the washing procedure of GB / T 8629 standard), UVA and UVB are still ≤ 5%, UPF ≥ 50, and the UV protection performance retention rate is ≥ 85%; the washing shrinkage rate and ironing shrinkage rate of the fabric meet the requirements of the apparel standard.

Claims

1. A method for preparing a highly breathable and UV-protective fabric, characterized in that: Includes the following steps: Step S1. Fabric weaving: Water-soluble PE yarn and nylon / PU yarn are arranged and woven to obtain a composite structure fabric; Step S2. Fabric refining: Remove the sizing agent from the fabric weaving process to allow the fabric to shrink evenly; Step S3. Pre-setting: Perform high-temperature setting to stretch the fabric evenly; Step S4. Weight reduction processing: NaOH solution is used to perform weight reduction processing to remove water-soluble PE yarn; Step S5. Dyeing: High-temperature dyeing is carried out in an overflow dyeing machine, while anti-nylon type UV-resistant finishing agent, dye and auxiliaries are added to make the fabric colored and have UV-resistant function; Step S6. Washing and drying: After dyeing, the water is removed by a dryer; Step S7. Water-repellent treatment: The fabric is impregnated in water-repellent resin using a resin processing machine, and excess water is dried to ensure that the water-repellent substance is evenly coated on the fabric surface, while protecting the UV-resistant finishing agent from being washed off. Step S8. Finishing and shaping: Stretch the fabric evenly to stabilize yarn shrinkage.

2. The method for preparing the highly breathable and UV-resistant fabric according to claim 1, characterized in that: In step S1, the fineness of the nylon / PU yarn is 20D-75D.

3. The method for preparing the highly breathable and UV-resistant fabric according to claim 1, characterized in that: In step S3, the pre-forming temperature is 180℃-195℃.

4. The method for preparing the highly breathable and UV-resistant fabric according to claim 1, characterized in that: In step S4, the concentration of the NaOH solution is 60 g / L-100 g / L, and the treatment temperature is 100 °C.

5. The method for preparing the highly breathable and UV-resistant fabric according to claim 1, characterized in that: In step S5, the staining temperature is 90℃-95℃.

6. The method for preparing the highly breathable and UV-resistant fabric according to claim 1, characterized in that: In step S7, the water-repellent resin is an acrylate-based water-repellent resin.

7. The method for preparing the highly breathable and UV-resistant fabric according to claim 1, characterized in that: In step S8, the finishing and shaping temperature is 160℃-170℃.

8. The method for preparing the highly breathable and UV-resistant fabric according to any one of claims 1 to 7, characterized in that: The finished fabric has an air permeability of ≥4.0cc, UPF ≥50, UVA ≤5%, and UVB ≤5%.

9. A highly breathable and UV-protective fabric, characterized in that: It is prepared by any one of claims 1 to 8.

10. The highly breathable and UV-resistant fabric according to claim 9, characterized in that: After washing, the fabric has UVA≤5%, UVB≤5%, UPF≥50, and air transmittance≥4.0cc.

Images