A six-layer structure hollow wool aerogel elastic warm flannel fabric and a manufacturing method thereof

Abstract

The present application relates to a kind of six-layer structure hollow wool aerogel elastic warm flannel fabric and its manufacturing method, the fabric includes first layer, second layer, third layer, fourth layer, fifth layer, sixth layer from front to back, wherein first layer, second layer, third layer are plain weave structure, fourth layer is hollow structure, fifth layer, sixth layer are three-dimensional texture structure;One weaving cycle of the fabric includes ten lines of body.The aerogel polyester filament of hollow structure is completely wrapped in the inside of fabric, so that it does not contact any friction surface, fundamentally avoids exposure and pilling risk, while retaining excellent hollow warm effect.

Description

Technical Field

[0001] This invention belongs to the field of textile fabric technology, specifically relating to a six-layer hollow wool aerogel elastic thermal fleece fabric and its manufacturing method. Background Technology

[0002] With the upgrading of consumption, the market's requirements for winter clothing fabrics are increasing. They not only need excellent warmth retention but also lightweight, comfortable, smooth appearance, and a good feel. Aerogel materials, due to their extremely high porosity and ultra-low thermal conductivity, are considered ideal insulation materials.

[0003] In recent years, there have been attempts to apply aerogel fibers or yarns to thermal insulation fabrics. For example, Chinese invention patent application CN115891307A discloses a heat-generating and heat-insulating fabric, including a skin-contact inner fabric and an outer fabric, wherein the outer fabric contains 30% to 40% aerogel fibers; the inner and outer fabrics are knitted separately and then sewn together using a quilting method to form a double-layer structure. However, the heat-generating and heat-insulating fabrics in the above-mentioned prior art do not effectively constrain the position of the aerogel fibers. Because the surface of aerogel fibers is relatively smooth and fluffy, they are easily exposed to the fabric surface during wear and washing, leading to severe pilling, snagging, and other problems, which seriously affect the appearance and durability of the fabric.

[0004] Therefore, there is considerable room for improvement in the existing technology. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a six-layer hollow wool aerogel elastic thermal fleece fabric and its manufacturing method. By completely wrapping the aerogel polyester filaments that form the hollow structure inside the fabric, so that they do not come into contact with any friction surface, the risk of exposure and pilling is fundamentally avoided, while retaining the excellent hollow thermal insulation effect.

[0006] To achieve the above objectives, the present invention proposes a six-layer hollow wool aerogel elastic warm fleece fabric, which includes a first layer, a second layer, a third layer, a fourth layer, a fifth layer, and a sixth layer from the front to the back. The first, second, and third layers are plain weave structures, the fourth layer is a hollow structure, and the fifth and sixth layers are three-dimensional texture structures. One weave cycle of the fabric comprises ten yarns, wherein... The first and sixth routes are located in the third layer, with the yarn being low-elasticity polyester yarn and an outer full-needle loop structure. The second and seventh routes are located in the first and second layers, respectively. The yarns are cotton / wool blended yarn + spandex elastic yarn and are full-needle loop weave. The cotton / wool blended yarn is located in the first layer and the spandex elastic yarn is located in the second layer. The third and eighth routes are located in the fourth layer, and the yarn is aerogel polyester filament. The third and eighth routes are a looped structure that interweaves the first, second, sixth, and seventh routes. The fourth and ninth routes are located in the fifth layer, and the yarn is aerogel polyester filament with an inner half-needle loop structure that is staggered vertically. The fifth and tenth routes are located in the sixth layer, with cotton-polyester blended yarn and an inner full-needle loop structure. The third and eighth routes are also interwoven with the fourth, fifth, ninth, and tenth routes.

[0007] In the above scheme, the first and sixth yarns are formed by looping polyester low-elasticity yarn in the third layer (inner layer of plain weave structure). This polyester low-elasticity yarn effectively binds and completely wraps the aerogel polyester filaments from the third and eighth yarns (the fourth layer hollow structure) inside the fabric through its looped structure. At the same time, the cotton / wool blended yarn and spandex elastic yarn from the second and seventh yarns are formed by looping in the first and second layers, forming a smooth outer front layer, further preventing the aerogel fibers from moving to the surface. The fourth layer is formed by the aerogel polyester filaments from the third and eighth yarns through a looped structure that connects the first, second, sixth, and seventh yarns, creating a hollow structure that supports a stable layer of still air inside the fabric. Simultaneously, the aerogel polyester filaments themselves have a porous honeycomb structure, which can trap a large amount of still air, significantly reducing the thermal conductivity of the fabric. This structural design ensures that the aerogel polyester filaments do not come into contact with any friction surfaces, fundamentally avoiding the risks of exposure, pilling, and snagging, while retaining excellent hollow insulation properties.

[0008] In one possible implementation, the polyester low-elasticity yarn has a count of 30D; the cotton / wool blended yarn has a count of 26-50 English count, wherein the wool content is 20-40% by weight; the spandex elastic yarn has a count of 20-30D; the aerogel polyester filament has a count of 50-100D; and the cotton-polyester blended yarn has a count of 20-30 English count, wherein the polyester content is 40% by weight.

[0009] In the above scheme, by limiting the cotton / wool blend yarn count to 26-50 English count and the wool content to 20-40%, the front fabric has both a smooth appearance and natural warmth, while avoiding itchiness. 20-30D spandex elastic yarn gives the fabric comfortable elasticity and close-fitting recovery. Aerogel polyester filaments are made of 50-100D, which can both support a stable hollow air layer to lock in still air and avoid the risk of the fabric being too heavy or the aerogel being exposed due to excessively thick yarn; combined with 30D polyester low elastic yarn, a "fine-bound-coarse" optimized match is formed, which firmly wraps the aerogel yarn inside the fabric and effectively improves the anti-pilling performance. The reverse cotton-polyester blend yarn is made of 20-30 English count and polyester content of 40%, which not only ensures that the pile is dense and uniform after brushing and does not shed, but also uses the high strength of polyester to maintain the stability of the base fabric. The above parameter combination also ensures smooth weaving of the ten-way weave and strong dyeing consistency, achieving a synergistic improvement in warmth retention, pilling resistance, fleece feel, and process feasibility.

[0010] In one possible implementation, the yarn length for the first and sixth yarn feeds is 8.5-10.5cm / 50 stitches; the yarn length for the second yarn feed is 15.0cm / 50 stitches; the yarn length for the seventh yarn feed is 5.0cm / 50 stitches; the yarn length for the third and eighth yarn feeds is 26.0-28.0cm / 50 stitches; the yarn length for the fourth and ninth yarn feeds is 10.5cm / 50 stitches; and the yarn length for the fifth and tenth yarn feeds is 14.0-16.0cm / 50 stitches.

[0011] In the above scheme, by controlling the yarn length of the first and sixth yarns to 8.5-10.5cm / 50 stitches, the polyester low-elasticity yarn is tightly wrapped and bound to the aerogel yarn, preventing pilling and snagging; the second yarn length is 15cm / 50 stitches, which allows the cotton / wool blended yarn and spandex to form a full and smooth outer layer on the front side; the seventh yarn length is only 5cm / 50 stitches, which uses ultra-short loops to generate strong shrinkage force, making the corresponding area of ​​the seventh yarn tightly bound, forming an asymmetrical tension balance with the second yarn, effectively preventing wrinkles on the fabric surface and enhancing the stability of the front structure; the third and eighth yarns are enlarged to 26.0-28.0cm / 50 stitches, supporting a thick hollow air layer to lock in still air, significantly improving the warmth retention performance; the fourth and ninth yarns use a short yarn length of 10.5cm / 50 stitches to form a tight reverse base; the fifth and tenth yarns have a yarn length of 14.0-16.0cm / 50 stitches, which allows the cotton-polyester blended yarn to form a three-dimensional pique structure, and a dense and uniform pile layer is obtained through brushing.

[0012] In one possible implementation, the fabric has a weight of 280-400 g / m². 2Furthermore, the anti-pilling performance reaches level 3.5 or higher. By controlling the fabric weight within the range of 280-400g / m², the fabric maintains good warmth retention while also possessing a moderate thickness and fluffiness, avoiding being too thin and thus affecting warmth or too thick and thus affecting wearing comfort. At the same time, due to the complete wrapping and binding of aerogel polyester filaments by polyester low-elasticity yarn, the fabric's anti-pilling performance still reaches level 3.5 or higher under a friction test condition of 2500 revolutions.

[0013] This invention also proposes a method for manufacturing the above-mentioned six-layer hollow wool aerogel elastic thermal fleece fabric, including a knitting process and a finishing process. The knitting process uses a double-sided circular knitting machine to perform ten-way knitting, specifically: First way: upper needle plates 1 and 2 knit loops, lower needle cylinders 1 and 2 knit float yarn, with polyester low-elasticity yarn as the feed yarn; Second way: upper needle plates 1 and 2 knit loops, lower needle cylinders 1 and 2 knit float yarn, with a combination of cotton / wool blended yarn and spandex elastic yarn as the feed yarn; Third way: upper needle plates 1 and 2 knit tuck loops, lower needle cylinder #1 knits tuck loops, #2 knits float yarn, with aerogel polyester filament as the feed yarn; Fourth way: upper needle plates 1 and 2 knit float yarn, lower needle cylinder #1 knits loops, #2 knits float yarn, with aerogel polyester as the feed yarn. Filament; Fifth route: Upper needle plates 1 and 2 knit floats, lower needle cylinders 1 and 2 knit loops, feed yarn is cotton-polyester blended yarn; Sixth route: Upper needle plates 1 and 2 knit loops, lower needle cylinders 1 and 2 knit floats, feed yarn is polyester low-elasticity yarn; Seventh route: Upper needle plates 1 and 2 knit loops, lower needle cylinders 1 and 2 knit floats, feed yarn is a combination of cotton / wool blended yarn and spandex elastic yarn; Eighth route: Upper needle plates 1 and 2 knit tucks, lower needle cylinder #2 knits tucks, #1 knits floats, feed yarn is aerogel polyester filament; Ninth route: Upper needle plates 1 and 2 knit floats, lower needle cylinder #2 knits loops, #1 knits floats, feed yarn is aerogel polyester filament; Tenth route: Upper needle plates 1 and 2 knit floats, lower needle cylinders 1 and 2 knit loops, feed yarn is cotton-polyester blended yarn.

[0014] Preferably, the diameter of the needle plate of the double-sided circular knitting machine is 8-12 mm smaller than the diameter of the needle barrel. By designing the needle plate diameter to be 8-12 mm smaller than the needle barrel diameter, the radial dimensional difference allows the loop path of the aerogel polyester filament to be extended and tilted outward during tuck weaving, forming a full, arched hollow air layer, which is beneficial to improving heat insulation performance. At the same time, it allows the polyester low-elasticity yarn to form a ring-like binding with the aerogel yarn, preventing slippage and exposure, which is beneficial to improving anti-pilling performance. In addition, it also makes the three-dimensional pique texture on the reverse side clearer and more uniform, providing a good base for napping.

[0015] Preferably, the double-sided circular knitting machine is equipped with an auxiliary pressing device, which includes an upper pressing plate and a lower pressing plate; the upper pressing plate is used to prevent the loops of the third and eighth paths from floating up with the needle track, and the lower pressing plate is used to provide tension for the looping yarns of the second and seventh paths.

[0016] Preferably, the finishing process includes opening the width, preparing the fabric, pre-setting, pretreatment, depilation, dyeing, wringing, loose drying, brushing, combing, shearing, setting, and final inspection; wherein, The predetermined process has a temperature and time of 185℃ × 24m / min and an effective air volume of 65% in the oven. The pretreatment process includes enzyme washing and bio-enzyme treatment. Specifically, the enzyme washing agent is used to treat at 95℃ for 45 minutes with a bath ratio of 1:5-10; the bio-enzyme treatment agent is used to treat at 45-65℃ for 45-60 minutes with a bath ratio of 1:5-10. The enzyme washing agent consists of 2 g / L degreasing agent, 3 g / L soda ash, 0.25 g / L penetrant SKS, 1.5 g / L dispersant, 3 g / L H2O2 (27.5%), and the balance being water. The bio-enzyme treatment agent consists of a pH of 4.5-6, 1.5-2.5 g / L neutral enzyme, 1-1.5 g / L sodium acetate, 0.1-0.2 g / L acetic acid, and the balance being water. The dyeing process includes dyeing polyester, reduction washing, dyeing cotton, dyeing wool, soaping, softening, and color fixing treatments. The dye formulation for dyeing polyester consists of 1-2 g / L of dispersing and leveling agent, pH adjusted to 4-5 with glacial acetic acid or a buffer acid, and the remainder being water, treated at 110-130℃ for 90 minutes. The detergent used for reduction washing includes 1.5 g / L of soda ash and sodium hydrosulfite (Na2S2O4). 2.25 g / L, balance water, 80℃ for 10 min, repeated twice, liquor ratio 1:5-10; For cotton dyeing, the dye formula is 65 g / L sodium sulfate, 20 g / L soda ash, balance water, 45-60℃ for 30-60 min, liquor ratio 1:6; For soaping, the detergent formula is 2 g / L soaping agent, balance water, 90℃ for 20 min; For color fixing, the treatment agent formula is 1 g / L color fixing agent, balance water, 45℃ for 15 min; For softening, the treatment agent formula is 1 g / L softener, balance water, 45℃ for 10 min; For color fixing, the treatment agent formula is 1 g / L color fixing agent, balance water, 45℃ for 15 min. The described brushing process is as follows: using a 36-roller brushing machine, brushing continuously for 7 times under the conditions of a fabric speed of 23-25m / min, 10-12% of the guide roller tension, a clockwise roller speed of 8-10r / min, and a counterclockwise roller speed of 8-12r / min. The shaping process is carried out at a temperature of 155℃, a machine speed of 16m / min, a width of 185CM, an overfeed of 35%, and an effective air volume of 60% in the oven.

[0017] Preferably, the degreasing agent in the enzymatic wash is selected from one or more of fatty alcohol polyoxyethylene ether, isomeric alcohol ether, and fatty alcohol phosphate; the dispersant is selected from one or more of naphthalene sulfonate, sodium lignosulfonate, and polyacrylate.

[0018] Preferably, the soaping agent used in the soaping process is selected from one or more of fatty acid methyl ester ethoxylate, modified polyacrylate, and polyepoxysuccinate.

[0019] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention involves a special modification to a double-sided circular knitting machine, including a special modification to the needle plate size, a modification to the triangular trajectory, and the preparation of special auxiliary devices. This reduces the needle plate diameter by 8-12mm compared to the conventional method, making it possible to achieve a strong hollow feel in the fabric. The yarn loop length is significantly enlarged, and the fabric face is designed with a three-layer structure: a cotton-over-polyester weave plus spandex. The aerogel polyester yarn in the middle is bound to another fine denier polyester yarn, while the face yarn and spandex do not need to be in direct contact with the aerogel polyester. The fabric reverse side is designed with a three-dimensional texture structure, which can be achieved through a special finishing process to create a fine and dense nap effect.

[0020] 2. This invention utilizes a six-layer hollow design. Through the design of process parameters and the combination of raw materials, the fabric achieves a good hollow feel and thickness. The surface has the warmth and smoothness of wool, while the middle layer uses aerogel material to lock in heat. The reverse side presents a three-dimensional effect. Through special finishing processes such as brushing, combing, and shearing, a six-layer hollow wool aerogel elastic warm fleece fabric is formed, avoiding the risk of pilling, snagging, and other issues when the garment is worn.

[0021] 3. Aerogel polyester filament is made by adding porous honeycomb-structured aerogel powder to molten polyester. During the spinning process, an irregular cross-section is used to make the yarn fluffy, trapping a large amount of still air, increasing its insulation performance, mitigating heat loss, and achieving a warming effect. Wool yarn also has good warmth retention. The combination of these raw materials results in a fabric with even better warmth retention.

[0022] 4. After being treated with napping, the fabric can achieve a delicate velvet effect.

[0023] 5. This product combines the hollow feel of an air layer with the fleece feel of a fleece sweatshirt, as well as the warmth of wool and aerogel. It is the first product of its kind in the industry and has great innovation and market potential. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the fabric described in this invention; wherein the labels are: 1, first layer; 2, second layer; 3, third layer; 4, fourth layer; 5, fifth layer; 6, sixth layer; Figure 2 This is a schematic diagram of the upper triangle of the ten-way knitting of the fabric of the present invention; Figure 3 This is a diagram showing the weaving structure of the fabric of the present invention; Figure 4 This is a schematic diagram illustrating the modification of the needle plate on a circular knitting machine according to the present invention; Figure 5 This is a schematic diagram of the auxiliary pressing plate set on the circular knitting machine according to the present invention. Detailed Implementation

[0025] The present invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are only for explaining the present invention and are not intended to limit the present invention.

[0026] Example 1, such as Figures 1-3 As shown, this invention provides a six-layer hollow wool gel elastic warm fleece fabric, which, from front to back, comprises a first layer 1, a second layer 2, a third layer 3, a fourth layer 4, a fifth layer 5, and a sixth layer 6. The first layer 1, second layer 2, and third layer 3 have a plain weave structure, the fourth layer 4 has a hollow structure, and the fifth layer 5 and sixth layer 6 have a three-dimensional texture structure. The sixth layer 6 has a fleece layer formed by a brushing process. One weaving cycle of the fabric includes ten yarns. The first and sixth yarns are located in the third layer 3, with polyester low-elasticity yarn as the feed yarn and a full-needle loop weave. The second and seventh yarns are located in the first and second layers 1 and 2, respectively, with cotton / wool blend yarn and spandex as the feed yarn. The structure consists of elastic yarn with an outer full-needle loop weave, with cotton / wool blended yarn in the first layer 1 and spandex elastic yarn in the second layer 2; the third and eighth lines are located in the fourth layer 4, with aerogel polyester filament as the feed yarn, and the third and eighth lines are interlaced loop weaves connecting the first, second, sixth, and seventh lines; the fourth and ninth lines are located in the fifth layer 5, with aerogel polyester filament as the feed yarn and an inner half-needle loop weave structure with staggered upper and lower sections; the fifth and tenth lines are located in the sixth layer 6, with cotton-polyester blended yarn as the feed yarn and an inner full-needle loop weave structure; the third and eighth lines are also interlaced with the fourth, fifth, ninth, and tenth lines.

[0027] The method for preparing the fabric includes the following steps: 1. Raw material preparation Cotton / wool blended yarn: 40 count, with wool accounting for 30% and cotton accounting for 70%; Spandex elastic yarn: 30D; Polyester low elastic yarn: 30D DTY semi-dull low elastic yarn; Aerogel polyester filament: 50D; Cotton-polyester blended yarn: 26 count, with polyester accounting for 40% of the weight.

[0028] 2. Knitting process The knitting process uses a 20G34" double-sided circular knitting machine, such as... Figure 4 As shown, the large circular knitting machine has been specially modified to make the needle plate diameter 10mm smaller than the syringe diameter; for example... Figure 5 As shown, the double-sided circular knitting machine is equipped with an auxiliary pressing device: the upper pressing plate presses the loops of the third and eighth paths to prevent them from floating up with the needle track; the lower pressing plate provides tension for the looping yarns of the second and seventh paths.

[0029] like Figure 2-3 As shown, the weaving is performed according to the ten-way weaving method, as detailed below: First route: Upper needles 1 and 2 knit in loops, lower needles 1 and 2 knit float yarn, with polyester low-elasticity yarn as the feed yarn; Second route: Upper needles 1 and 2 knit in loops, lower needles 1 and 2 knit float yarn, with cotton / wool blended yarn and spandex elastic yarn as the feed yarn; Third route: Upper needles 1 and 2 knit in tucked loops, lower needle 1 knits in tucked loops, needle 2 knits float yarn, with aerogel polyester filament yarn as the feed yarn; Fourth route: Upper needles 1 and 2 knit float yarn, lower needle 1 knits in loops, needle 2 knits float yarn, with aerogel polyester filament yarn as the feed yarn; Fifth route: Upper needles 1 and 2 knit float yarn, lower needles 1 and 2 knit in loops, with cotton-polyester blended yarn as the feed yarn; Row 6: Upper needle plates 1 and 2 knit in loops, lower needle cylinders 1 and 2 knit float yarn, with polyester low-elasticity yarn as the feed yarn; Row 7: Upper needle plates 1 and 2 knit in loops, lower needle cylinders 1 and 2 knit float yarn, with cotton / wool blended yarn and spandex elastic yarn as the feed yarn; Row 8: Upper needle plates 1 and 2 knit in tucked loops, lower needle cylinder #2 knits in tucked loops, #1 knits float yarn, with aerogel polyester filament yarn as the feed yarn; Row 9: Upper needle plates 1 and 2 knit float yarn, lower needle cylinder #2 knits in loops, #1 knits float yarn, with aerogel polyester filament yarn as the feed yarn; Row 10: Upper needle plates 1 and 2 knit float yarn, lower needle cylinders 1 and 2 knit in loops, with cotton-polyester blended yarn as the feed yarn.

[0030] The yarn lengths for the first and sixth rows are 10.5cm / 50 stitches; for the second row, it is 15cm / 50 stitches; for the seventh row, it is 5cm / 50 stitches; for the third and eighth rows, it is 26.5cm / 50 stitches; for the fourth and ninth rows, it is 10.5cm / 50 stitches; and for the fifth and tenth rows, it is 15.5cm / 50 stitches.

[0031] 3. Post-processing Fabric preparation - pre-sizing - pre-treatment - depilation - dyeing - wringing - loose drying - brushing - combing - shearing - setting - final inspection; among which, The predetermined process has a temperature and time of 185℃ × 24m / min and an effective air volume of 65% in the oven.

[0032] The pretreatment process includes enzymatic washing and biological enzyme treatment. Specifically, the enzymatic washing agent is used to treat at 95°C for 45 minutes with a bath ratio of 1:6; and the biological enzyme treatment agent is used to treat at 60°C for 60 minutes with a bath ratio of 1:6. The enzymatic washing agent consists of 2 g / L degreasing agent, 3 g / L soda ash, 0.25 g / L penetrant SKS, 1.5 g / L dispersant, 3 g / L H2O2 (27.5%), and the balance being water. The biological enzyme treatment agent consists of 2 g / L neutral enzyme with a pH of 5, 1.5 g / L sodium acetate, 0.15 g / L acetic acid, and the balance being water.

[0033] The dyeing process includes dyeing polyester, reduction washing, dyeing cotton, dyeing wool, soaping, softening, and color fixing treatments. The dye formulation for dyeing polyester is 1.5 g / L of dispersing and leveling agent, pH adjusted to 4.5 with glacial acetic acid or a buffer acid, and the remainder is water, treated at 120°C for 90 minutes. The detergent used for reduction washing includes 1.5 g / L of soda ash and sodium hydrosulfite (Na2S2O4). 2.25 g / L, balance water, 80℃ for 10 min, repeated twice, liquor ratio 1:5; Dye formulation for cotton dyeing: 65 g / L sodium sulfate, 20 g / L soda ash, balance water, 50℃ for 45 min, liquor ratio 1:6; Detergent formulation for soaping: 2 g / L soaping agent, balance water, 90℃ for 20 min; Fixing agent formulation: 1 g / L fixing agent, balance water, 45℃ for 15 min; Softening process formulation: 1 g / L softener, balance water, 45℃ for 10 min; Fixing process formulation: 1 g / L fixing agent, balance water, 45℃ for 15 min.

[0034] The brushing process is as follows: using a 36-roller brushing machine, brushing the fibers continuously for 7 times at a fabric speed of 23m / min, 11% of the guide roller tension, a clockwise roller speed of 10r / min, and a counterclockwise roller speed of 12r / min; then brushing the fibers with a combing machine to ensure that the short broken fibers are combed clean and the fibers are raised, and then shearing the fibers with a shearing machine. Combing and shearing process: The combing process is the same as the conventional process. The shearing process is as follows: Shearing speed 18 m / min Spiral cutter speed 1600 r / min Shear blade distance 3.5mm Spiral cutter adjustment rod height 6 squares (0 indicates the furthest from the side of the supporting triangle, 8 indicates the closest to the side of the supporting triangle) The shaping process is carried out at a temperature of 155℃, a machine speed of 16m / min, a width of 185CM, an overfeed of 35%, and an effective air volume of 60% in the oven.

[0035] The degreasing agent used in the enzyme wash is selected from fatty alcohol polyoxyethylene ether; the dispersant is selected from naphthalene sulfonate; and the soaping agent used in the soaping is selected from fatty acid methyl ester ethoxylate. Other finishing processes are standard operating procedures.

[0036] The resulting fabric exhibits good warmth retention properties and has passed relevant warmth retention tests, including thermal resistance and temperature rise performance tests. It also demonstrates excellent pilling resistance, achieving a pilling resistance rating of 3.5 or higher according to GB4802.1. The fabric's weight is 300 g / m². 2 .

[0037] The obtained fabric underwent routine physicochemical and functional tests, and the results are shown in the table below: Color fastness of textiles to sunlight GB / T 8427 ≥4.0 level 4.5 Color fastness to perspiration in textiles GB / T 3922 ≥4.0 level (color change) ≥3.0 level (staining) 4 Color fastness to water stains of textiles GB / T 5713 ≥3-4.0 level (color change) ≥3-4.0 level (staining) 4 Color fastness to rubbing of textiles GB / T 3920 4.0 grade (dry grinding) ≥ 3.0 grade (wet grinding, dark color 2.0) Grade 4 (dry grinding) Grade 3.5 (wet grinding) Color fastness to washing of textiles GB / T 3921 A1 ≥4.0 level 4.5 Dimensional stability GB / T 8629-5A -5.0~+2.0% Vertical: -4.8% Horizontal: -3.7% pilling GB / T 4802.1 3 4 Breaking through the powerful GB / T 19976 ≥250N 356N Formaldehyde content GB / T 2912.1 ≤75PPM Not detected pH value of textiles GB / T 7573 4.5-6.5 5.8 Thermal resistance test ISO 11092:2014 >0.03m2·K / W 0.051 Maximum temperature rise performance FZ / T 73036-2010, Annex A; ≥4.0 ºC 5.5 ºC Average temperature rise performance FZ / T 73036-2010, Annex A; ≥3.0 ºC 3.6ºC Example 2 is basically the same as Example 1, except that: the diameter of the needle plate is 8mm smaller than the diameter of the needle barrel; the yarn count of the cotton / wool blended yarn is 32 English count (30% wool, 70% cotton); the yarn count of the spandex elastic yarn is 20D; the yarn count of the aerogel polyester filament is 80D; and the yarn count of the cotton-polyester blended yarn is 20 English count (40% polyester, 60% cotton). The yarn length for the first and sixth rows is 10.5cm / 50 stitches; the yarn length for the second row is 15.0cm / 50 stitches; the yarn length for the seventh row is 5.0cm / 50 stitches; the yarn length for the third and eighth rows is 28.0cm / 50 stitches; the yarn length for the fourth and ninth rows is 10.5cm / 50 stitches; and the yarn length for the fifth and tenth rows is 16.0cm / 50 stitches. In the pretreatment process, an enzyme washing agent is used to treat at 95℃ for 45 minutes with a bath ratio of 1:5; a biological enzyme washing agent is used to treat at 60℃ for 60 minutes with a bath ratio of 1:6. The enzyme washing agent consists of 2 g / L degreasing agent, 3 g / L soda ash, 0.25 g / L penetrant SKS, 1.5 g / L dispersant, 4 g / L H2O2 (27.5%), and the balance being water. The biological enzyme washing agent consists of pH 5, 2.5 g / L neutral enzyme, 1.5 g / L sodium acetate, 0.15 g / L acetic acid, and the balance being water. The degreasing agent is selected from isomeric alcohol ethers; the dispersant is selected from sodium lignosulfonate. In the dyeing process, the dye formulation for dyeing polyester is 1.5 g / L of dispersing and leveling agent, pH adjusted to 4.5 with glacial acetic acid or buffered acid, and the remainder is water, treated at 130℃ for 90 min; the washing agent for reduction cleaning includes 2 g / L of soda ash, 2.25 g / L of sodium hydrosulfite (Na2S2O4), and the remainder is water, treated at 80℃ for 12 min, repeated twice, with a liquor ratio of 1:6; the dye formulation for dyeing cotton is 70 g / L of sodium sulfate, 25 g / L of soda ash, and the remainder is water, treated at 55℃ for 45 min, with a liquor ratio of 1:6; the washing agent formulation for soaping is 2 g / L of soaping agent, and the remainder is water, treated at 90℃ for 20 min; the soaping agent is selected from modified polyacrylate. In the softening treatment, the softener is 1 g / L, treated at 45℃ for 10 min. In the color-fixing treatment, the color-fixing agent is 1 g / L, treated at 45℃ for 15 min.

[0038] The brushing process is as follows: using a 36-roller brushing machine, brushing the fibers continuously for 7 times at a fabric speed of 25m / min, 10% guide roller tension, clockwise roller speed of 10r / min, and counterclockwise roller speed of 12r / min; then brushing the fibers with a combing machine to ensure that short broken fibers are combed clean and the fibers are raised, and then shearing the fibers with a shearing machine. Combing and shearing process: The combing process is the same as the conventional process. The shearing process is as follows: Shearing speed 19 m / min Spiral cutter speed 1600 r / min Shear blade distance 3.3mm Spiral cutter adjustment rod height 6 squares (0 indicates the furthest from the side of the supporting triangle, 8 indicates the closest to the side of the supporting triangle) Example 3 is basically the same as Example 1, except that: the diameter of the needle plate is 12mm smaller than the diameter of the needle barrel; the yarn count of the cotton / wool blended yarn is 50 English count (20% wool, 80% cotton); the yarn count of the spandex elastic yarn is 25D; the yarn count of the aerogel polyester filament is 100D; and the yarn count of the cotton-polyester blended yarn is 30 English count (40% polyester, 60% cotton). The yarn length for the first and sixth rows is 8.5cm / 50 stitches; the yarn length for the second row is 15cm / 50 stitches; the yarn length for the seventh row is 5cm / 50 stitches; the yarn length for the third and eighth rows is 28.0cm / 50 stitches; the yarn length for the fourth and ninth rows is 10.5cm / 50 stitches; and the yarn length for the fifth and tenth rows is 14.0cm / 50 stitches. In the pretreatment process, an enzyme washing agent is used to treat at 95℃ for 45 min with a bath ratio of 1:10; a biological enzyme treatment agent is used to treat at 65℃ for 60 min with a bath ratio of 1:10. The enzyme washing agent consists of 2 g / L degreasing agent, 3 g / L soda ash, 0.25 g / L penetrant SKS, 1.5 g / L dispersant, 3 g / L H2O2 (27.5%), and the balance being water. The biological enzyme treatment agent consists of pH 6, 2.5 g / L neutral enzyme, 1.5 g / L sodium acetate, 0.2 g / L acetic acid, and the balance being water. The degreasing agent is selected from fatty alcohol phosphates; the dispersant is selected from polyacrylates.

[0039] In the dyeing process, the dye formulation for dyeing polyester is 2 g / L of dispersing and leveling agent, pH adjusted to 5 with glacial acetic acid or buffer acid, and the remainder is water, treated at 130℃ for 90 min; the detergent for reduction washing includes 1.5 g / L of soda ash, 2.25 g / L of sodium hydrosulfite (Na2S2O4), and the remainder is water, treated at 80℃ for 10 min, repeated twice, with a liquor ratio of 1:10; the dye formulation for dyeing cotton is 65 g / L of sodium sulfate, 20 g / L of soda ash, and the remainder is water, treated at 60℃ for 60 min, with a liquor ratio of 1:6; the detergent formulation for soap washing is 2 g / L of soaping agent, and the remainder is water, treated at 90℃ for 20 min; the soaping agent is selected from polyepoxysuccinate.

[0040] Comparative Example 1 provides a heat-generating and heat-insulating fabric (referencing the teachings of CN115891307A), comprising a skin-contact inner fabric and an outer fabric, by weight percentage; the skin-contact inner fabric is knitted from a first yarn and a second yarn; the first yarn comprises 50% light-generating fibers and 50% antibacterial fibers, blended and Z-twisted; the second yarn comprises 30% moisture-absorbing and heat-generating fibers, 30% protein cellulose fibers, and 40% polylactic acid fibers, blended and S-twisted; the outer fabric is knitted from a third yarn and a fourth yarn; the third yarn comprises 30% light-generating fibers, 30% aerogel fibers, and 40% nylon fibers, blended and Z-twisted; the fourth yarn comprises 50% light-generating fibers, 40% aerogel fibers, and 10% cellulose fibers, blended and S-twisted; the skin-contact inner fabric and the outer fabric are composited by quilting.

[0041] The conventional physicochemical properties of the fabrics prepared in Examples 1-3 and Comparative Example 1 were compared, and the results are shown in the table below: gram / / 300g / m² 280g / m² 400g / m² 310g / m² pilling GB / T 4802.1 ≥3 4 3.5 3.5 2 Thermal resistance test ISO 11092:2014 <![CDATA[>0.03m 2 ·K / W]]> 0.051 0.048 0.055 0.032 Maximum temperature rise performance FZ / T 73036-2010, Annex A ≥4.0℃ 5.5℃ 5.1℃ 5.8℃ 4.3℃ Average temperature rise performance FZ / T 73036-2010, Annex A ≥3.0℃ 3.6℃ 3.4℃ 3.8℃ 2.8℃ The test results above demonstrate that this invention, employing a six-layer fabric structure combined with a specific weaving process, completely encapsulates the aerogel polyester filaments within the fabric, preventing them from contacting friction surfaces. This achieves an anti-pilling rating of 3.5 or higher. Simultaneously, the hollow air layer, working in conjunction with the aerogel material, traps still air, resulting in a thermal resistance value exceeding 0.048 m²·K / W, significantly outperforming existing technologies in terms of warmth retention. This invention effectively overcomes the technical shortcomings of existing aerogel materials, such as easy exposure and pilling.

[0042] The above description is only a preferred embodiment of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of this patent application are included in the scope of this patent application.

Claims

1. A six-layer hollow wool aerogel elastic thermal fleece fabric, characterized in that, From front to back, the layers are: first layer (1), second layer (2), third layer (3), fourth layer (4), fifth layer (5), and sixth layer (6). The first layer (1), second layer (2), and third layer (3) are plain weave structures, the fourth layer (4) is a hollow structure, and the fifth layer (5) and sixth layer (6) are three-dimensional texture structures. One weaving cycle of the fabric includes ten lines, wherein the first line and the sixth line are located in the third layer (3), and the yarn is polyester low elasticity yarn and is an outer full needle loop structure; The second and seventh routes are located in the first layer (1) and the second layer (2), respectively. The yarn is cotton / wool blended yarn + spandex elastic yarn and is an outer full needle loop structure. The cotton / wool blended yarn is located in the first layer (1) and the spandex elastic yarn is located in the second layer (2). The third and eighth routes are located in the fourth layer (4), and the yarn is aerogel polyester filament. The third and eighth routes are interlocked loop structures that connect the first, second, sixth, and seventh routes. The fourth and ninth routes are located in the fifth layer (5), and the yarn is aerogel polyester filament and is an inner half-needle loop structure with staggered upper and lower parts; The fifth and tenth routes are located in the sixth layer (6), and the yarn is a cotton-polyester blended yarn with an inner full needle loop structure; The third and eighth routes are also interwoven with the fourth, fifth, ninth, and tenth routes.

2. The six-layer hollow wool aerogel elastic thermal fleece fabric according to claim 1, characterized in that, The polyester low-elastic yarn has a count of 30D; the cotton / wool blended yarn has a count of 26-50 English count, of which wool accounts for 20-40% by weight; the spandex elastic yarn has a count of 20-30D; the aerogel polyester filament has a count of 50-100D; and the cotton-polyester blended yarn has a count of 20-30 English count, of which polyester accounts for 40% by weight.

3. The six-layer hollow wool aerogel elastic thermal fleece fabric according to claim 1 or 2, characterized in that, The yarn length for the first and sixth rows is 8.5-10.5cm / 50 stitches; the yarn length for the second row is 15.0cm / 50 stitches; the yarn length for the seventh row is 5.0cm / 50 stitches; the yarn length for the third and eighth rows is 26.0-28.0cm / 50 stitches; the yarn length for the fourth and ninth rows is 10.5cm / 50 stitches; and the yarn length for the fifth and tenth rows is 14.0-16.0cm / 50 stitches.

4. The six-layer hollow wool aerogel elastic thermal fleece fabric according to claim 1, characterized in that, The fabric has a weight of 280-400 g / m². 2 Furthermore, its anti-pilling and anti-fuzzing performance reaches level 3.5 or above.

5. A method for manufacturing a six-layer hollow wool aerogel elastic thermal fleece fabric according to any one of claims 1-4, characterized in that, The process includes a knitting process and a finishing process. The knitting process uses a double-sided circular knitting machine to perform ten-way knitting, specifically: First row: upper needles 1 and 2 knit in circles, lower needles 1 and 2 knit float yarn, and the yarn fed in is polyester low elasticity yarn; Second course: upper needle plates 1 and 2 knit in circles, lower needle cylinders 1 and 2 knit float yarn, and the yarn fed in is a combination of cotton / wool blended yarn and spandex elastic yarn; Third row: Upper needle plate 1 and 2 knit tuck loops, lower needle cylinder 1 knits tuck loops, and needle cylinder 2 knits float yarn. The yarn fed in is aerogel polyester filament. Fourth route: upper needle plates 1 and 2 knit float yarn, lower needle cylinder 1 knits in loops, needle cylinder 2 knits float yarn, and the yarn feed is aerogel polyester filament; Fifth row: upper needle cylinders 1 and 2 knit float yarn, lower needle cylinders 1 and 2 knit loops, and the yarn fed in is cotton-polyester blended yarn; Sixth row: upper needles 1 and 2 knit in circles, lower needles 1 and 2 knit float yarn, and the yarn fed in is polyester low elasticity yarn; Seventh row: upper needle plates 1 and 2 knit in circles, lower needle cylinders 1 and 2 knit float yarn, and the yarn fed in is a combination of cotton / wool blended yarn and spandex elastic yarn; Eighth row: Upper needle plate 1 and 2 knit tuck loops, lower needle cylinder 2 knits tuck loops, and needle cylinder 1 knits float yarn. The yarn fed in is aerogel polyester filament. Ninth row: upper needle plate 1 and 2 knit float yarn, lower needle cylinder 2 knits in loops, needle cylinder 1 knits float yarn, and the yarn feed is aerogel polyester filament; Tenth row: Upper needle plates 1 and 2 knit float yarn, lower needle cylinders 1 and 2 knit loops, and the yarn fed in is cotton-polyester blended yarn.

6. In the manufacturing method according to claim 5, the diameter of the needle plate of the double-sided circular knitting machine is 8-12 mm smaller than the diameter of the needle cylinder.

7. The manufacturing method according to claim 5 or 6, wherein the double-sided large circular mill is provided with an auxiliary pressing device, the auxiliary pressing device comprising an upper pressing plate and a lower pressing plate; The upper pressure plate is used to prevent the loops of the third and eighth paths from floating up with the needle track, and the lower pressure plate is used to provide tension for the looped yarns of the second and seventh paths.

8. The manufacturing method according to claim 5, characterized in that, The finishing processes include: opening the fabric width, preparing the fabric, pre-shaping, pre-treatment, depilation, dyeing, wringing, loose drying, brushing, combing, shearing, setting, and final inspection; among which... The predetermined process has a temperature and time of 185℃ × 24m / min and an effective air volume of 65% in the oven. The pretreatment process includes enzyme washing and bio-enzyme treatment. Specifically, the enzyme washing agent is used to treat at 95℃ for 45 minutes with a bath ratio of 1:5-10; the bio-enzyme treatment agent is used to treat at 45-65℃ for 45-60 minutes with a bath ratio of 1:5-10. The enzyme washing agent consists of 2 g / L degreasing agent, 3 g / L soda ash, 0.25 g / L penetrant SKS, 1.5 g / L dispersant, 3 g / L H2O2 (27.5%), and the balance being water. The bio-enzyme treatment agent consists of a pH of 4.5-6, 1.5-2.5 g / L neutral enzyme, 1-1.5 g / L sodium acetate, 0.1-0.2 g / L acetic acid, and the balance being water. The dyeing process includes dyeing polyester, reduction washing, dyeing cotton, dyeing wool, soaping, softening, and color fixing treatments. The dye formulation for dyeing polyester consists of 1-2 g / L of dispersing and leveling agent, pH adjusted to 4-5 with glacial acetic acid or a buffer acid, and the remainder being water, treated at 110-130℃ for 90 minutes. The detergent used for reduction washing includes 1.5 g / L of soda ash and sodium hydrosulfite (Na2S2O4). 2.25 g / L, balance water, 80℃ for 10 min, repeated twice, liquor ratio 1:5-10; For cotton dyeing, the dye formula is 65 g / L sodium sulfate, 20 g / L soda ash, balance water, 45-60℃ for 30-60 min, liquor ratio 1:6; For soaping, the detergent formula is 2 g / L soaping agent, balance water, 90℃ for 20 min; For softening, the treatment agent formula is 1 g / L softener, balance water, 45℃ for 10 min; For color fixing, the treatment agent formula is 1 g / L color fixing agent, balance water, 45℃ for 15 min. The described brushing process is as follows: using a 36-roller brushing machine, brushing continuously for 7 times under the conditions of a fabric speed of 23-25m / min, 10-12% of the guide roller tension, a clockwise roller speed of 8-10r / min, and a counterclockwise roller speed of 8-12r / min. The shaping process is carried out at a temperature of 155℃, a machine speed of 16m / min, a width of 185CM, an overfeed of 35%, and an effective air volume of 60% in the oven.

9. The manufacturing method according to claim 8, characterized in that, The degreasing agent in the enzyme wash is selected from one or more of fatty alcohol polyoxyethylene ether, isomeric alcohol ether, and fatty alcohol phosphate; the dispersant is selected from one or more of naphthalene sulfonate, sodium lignosulfonate, and polyacrylate.

10. The manufacturing method according to claim 8, characterized in that, The soaping agent used in the soaping process is selected from one or more of fatty acid methyl ester ethoxylate, modified polyacrylate, and polyepoxysuccinate.

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