A high abrasion resistant cloth and a method of producing the same

Abstract

The application discloses high-wear-resistant cloth and a production method thereof, which is divided into two types of general wear-resistant and heavy-load wear-resistant fabrics, and sequentially passes through six processes of raw material compounding, spinning, warping weaving, grey cloth pretreatment, wear-resistant finishing and finished product setting. The application differentiates and sets fiber ratio: the general type adopts polyester, polyamide and viscose blended yarn, and the heavy-load type is matched with high-modulus polyester and aramid fiber; a multi-physical model of fiber sliding, friction and fatigue is established in the spinning stage, polyurethane wear-resistant liquid is prepared for finishing, and nano silicon dioxide powder is compounded for heavy-load fabric to build a rigid and flexible wear-resistant coating. The application is quantifiable and controllable in whole-process parameters, solves defects of poor wear resistance, single scene adaptation and easy yarn fatigue and fracture of traditional fabrics, and the finished product has advantages of high wear resistance, anti-pilling and size stability, and is suitable for workwear, outdoor and industrial heavy-load wear-resistant fabrics.

Description

Technical Field

[0001] This invention relates to the field of textile fabric technology, specifically to a high abrasion-resistant fabric and its production method. Background Technology

[0002] With the improvement of people's living standards and the increase in outdoor activities, especially with the rapid development of industries such as home upholstered furniture, functional workwear, and outdoor equipment, the market's requirements for the comprehensive performance of fabrics, such as wear resistance, anti-pilling, resistance to bending fatigue, and scratch resistance, are constantly being upgraded.

[0003] Existing conventional textile fabrics have limited abrasion resistance. Under long-term reciprocating friction, repeated stretching, and bending conditions, they are prone to problems such as pilling, yarn loosening and breakage, and fabric damage. They have a short service life and are difficult to adapt to high-intensity and high-frequency abrasion environments. The current manufacturing processes for abrasion-resistant fabrics generally suffer from several shortcomings: First, the fabric fiber formulations are often limited, failing to differentiate between ordinary abrasion-resistant scenarios and heavy-duty industrial abrasion-resistant scenarios, resulting in poor fabric adaptability and an inability to achieve graded applications. Second, spinning process parameters are rigid, relying solely on fixed twist to produce yarn without optimization based on the fiber slippage, frictional wear, and tensile fatigue damage patterns observed during actual yarn service, leading to poor fiber cohesion stability and a high risk of fatigue fracture. Third, the process control in weaving, pretreatment, functional finishing, and setting is often rudimentary, lacking precise range control of key process parameters, resulting in inconsistent density, uniformity, and dimensional stability of the finished fabric. Fourth, traditional abrasion-resistant finishing coatings have a simple structure, relying solely on a single polymer film to achieve abrasion resistance; under heavy-duty, high-intensity friction conditions, the coating is prone to wear, peeling, and failure, resulting in insufficient overall abrasion resistance and durability of the fabric. Summary of the Invention

[0004] In order to overcome the technical problem of low abrasion resistance of existing abrasion-resistant fabrics, the present invention provides a high abrasion-resistant fabric and its production method.

[0005] To solve the above problems, the present invention is implemented according to the following technical solution:

[0006] A method for producing a high abrasion-resistant fabric, characterized by comprising the following steps:

[0007] (1) Raw material compounding: Select general wear-resistant or heavy-duty wear-resistant fiber raw materials according to the application scenario, complete the fiber compounding according to the mass percentage, and add the corresponding spinning auxiliary agent;

[0008] (2) Raw material pretreatment and spinning: The mixed fibers are sequentially processed through opening and cleaning, carding, drawing, roving, spinning and winding to prepare yarn. The twist coefficient of the general-purpose yarn is set to 360-380, and the twist coefficient of the heavy-duty yarn is set to 400-420. The internal fiber slippage, reciprocating friction and tensile fatigue conditions of the yarn are simulated. The yarn wear rate and fiber breakage probability are calculated by combining the wear model. The fiber ratio and yarn twist are optimized according to the simulation results, and the spinning process parameters are solidified.

[0009] (3) Warping and weaving: The yarn is warped in sections, and the tension difference between the warping sections is controlled to be ≤5cN;

[0010] (4) Pretreatment of greige fabric: The greige fabric after weaving is subjected to desizing, scouring, bleaching and pre-setting treatment in sequence. The pre-setting temperature is controlled at 160-170℃.

[0011] (5) Abrasion-resistant finishing: Prepare abrasion-resistant finishing solution, and treat the fabric with a two-dip and two-roll process, with the roll-off rate controlled at 70%±5%; then carry out segmented drying and baking curing.

[0012] (6) Finished product shaping: The finished fabric is heat-shaped at 140-155℃.

[0013] Furthermore, in step (1), the general wear-resistant material composition is: 82% polyester staple fiber, 15% high-strength nylon 6 staple fiber, and 3% viscose filament, with 0.3% of spinning oil added to the total fiber mass. The polyester staple fiber has a specification of 1.56dtex×38mm and a breaking strength ≥5.5cN / dtex, and the nylon 6 staple fiber has a specification of 2.22dtex×40mm. The heavy-duty wear-resistant material composition is: 78% industrial high-modulus polyester filament, 12% aramid staple fiber, and 8% high-elastic nylon filament, with an additional 2% of nano-silica wear-resistant powder added to the total fiber mass in the finishing process.

[0014] Furthermore, the concentrations of each component in the general-purpose wear-resistant finishing liquid are as follows: 120 g / L of waterborne polyurethane wear-resistant finishing agent, 20 g / L of anti-pilling agent, and 3 g / L of penetrant; the heavy-duty wear-resistant finishing liquid is formulated with nano-silica dispersion and crosslinking agent based on the general-purpose formula.

[0015] Furthermore, in step (5), the segmented drying is divided into two temperature control levels: the first drying temperature is 80-90℃, and the second drying temperature is 90-100℃; the baking temperature is 150-165℃, and the baking and holding time is 3-5min.

[0016] Furthermore, in step (3), the general abrasion-resistant fabric adopts a twill weave with a warp density of 370-390 threads / 10cm and a weft density of 350-370 threads / 10cm; the heavy-duty abrasion-resistant fabric adopts a twill weave with a warp density of 410-430 threads / 10cm and a weft density of 390-410 threads / 10cm.

[0017] Furthermore, in step (3), the tension control range for weaving is 10-14cN for general models and 14-18cN for heavy-duty models, and the weaving speed control is 40-60m / min.

[0018] Furthermore, in step (4), the speed of the blank pre-forming locomotive is 35-45 m / min; in step (6), the speed of the finished product shaping locomotive is 30-40 m / min, and the fabric width shrinkage rate is controlled to ≤2% during the shaping process.

[0019] A high abrasion-resistant fabric, characterized in that it is prepared by the aforementioned method: the fabric is divided into two types: general abrasion-resistant type and heavy-duty abrasion-resistant type; the general abrasion-resistant type fabric is made of polyester staple fiber, high-strength nylon 6 staple fiber and viscose filament blended together, and the heavy-duty abrasion-resistant type fabric is made of industrial high-modulus polyester filament, aramid staple fiber and high-elastic nylon filament blended together, and the surface of the fabric is coated with an abrasion-resistant functional coating.

[0020] Furthermore, the wear-resistant functional coating is composed of a water-based polyurethane matrix and an anti-pilling agent; the wear-resistant functional coating of the heavy-duty wear-resistant fabric also contains uniformly dispersed nano-silica powder, and the amount of nano-silica powder added is 2% of the total mass of the fabric fibers.

[0021] Furthermore, the general-purpose abrasion-resistant fabric adopts a twill weave with a warp density of 370-390 threads / 10cm and a weft density of 350-370 threads / 10cm; the heavy-duty abrasion-resistant fabric adopts a twill weave with a warp density of 410-430 threads / 10cm and a weft density of 390-410 threads / 10cm.

[0022] Compared with the prior art, the present invention has the following technical advantages:

[0023] First, this invention sets up two differentiated fabric formulations and processes, one for general use and one for heavy-duty use, to specifically adapt to ordinary civilian wear-resistant scenarios and industrial heavy-duty high-intensity wear scenarios. This solves the problem of the limited adaptability and poor versatility of traditional wear-resistant fabrics, and greatly expands the application range of the fabric.

[0024] Secondly, this invention abandons the traditional fixed-parameter spinning mode and optimizes the yarn ratio and twist through working condition simulation and multi-model quantitative calculation. It reduces the probability of fiber slippage, wear and breakage from the internal structure level of the yarn, and improves the wear resistance and fatigue resistance of the fabric from the source. The yarn structure stability is far superior to the yarn prepared by traditional processes.

[0025] Third, this invention quantifies and limits the key parameters of the entire process, including warping, weaving, drying, baking, and setting, making the process highly controllable and repeatable. It effectively solves the problems of uneven fabric performance, poor dimensional stability, and high defect rate caused by the extensive production of traditional processes, resulting in good batch consistency of finished products.

[0026] Fourth, the present invention adopts a rigid-flexible composite wear-resistant coating structure. The general-purpose version relies on polyurethane film to achieve flexible wear resistance and anti-pilling effect, while the heavy-duty version is doped with nano-silica rigid powder, which greatly improves the wear resistance and bonding strength of the coating. The coating is resistant to friction, water washing, and is not easy to fall off, significantly improving the service life of the fabric.

[0027] Fifth, both fabrics of this invention adopt a high-density twill weave structure and are combined with optimized high-stability yarns. The fabrics have multiple properties such as high strength, tear resistance, fatigue resistance, and dimensional stability, and their overall performance is significantly better than that of conventional wear-resistant textile fabrics. Attached Figure Description

[0028] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, wherein:

[0029] Figure 1 This is a flowchart illustrating the production process of the high abrasion-resistant fabric of the present invention.

[0030] Figure 2 This is a schematic diagram illustrating the optimized relationship between yarn wear rate and yarn twist coefficient according to the present invention. Detailed Implementation

[0031] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0032] like Figure 1 As shown, the method for producing high abrasion-resistant fabric of the present invention includes the following process steps:

[0033] (1) Raw material compounding

[0034] Select general-purpose or heavy-duty abrasion-resistant fiber raw materials according to the application scenario of the fabric, complete the fiber blending according to the set mass percentage, and add the corresponding spinning auxiliaries.

[0035] The general-purpose abrasion-resistant version is composed of the following raw materials by weight percentage: 82% polyester staple fiber, 15% high-strength nylon 6 staple fiber, and 3% viscose filament, with an additional 0.3% spinning oil by weight of the total fiber. The polyester staple fiber has a specification of 1.56 dtex × 38 mm and a breaking strength ≥ 5.5 cN / dtex, while the nylon 6 staple fiber has a specification of 2.22 dtex × 40 mm. Polyester staple fiber serves as the base component, ensuring the fabric's basic mechanical strength and structural stability. Nylon 6 staple fiber enhances the fabric's resistance to friction and bending. Viscose filament optimizes the fabric's weaving performance and surface feel. The spinning oil reduces fiber friction damage during spinning and improves yarn evenness.

[0036] The heavy-duty abrasion-resistant material is composed of the following raw materials by weight percentage: 78% industrial high-modulus polyester filament, 12% aramid staple fiber, and 8% high-elastic nylon filament. In the subsequent abrasion-resistant finishing process, 2% of nano-silica abrasion-resistant powder by weight of the total fiber is added. The industrial high-modulus polyester filament has low deformation rate and strong structural stability; the aramid staple fiber possesses excellent abrasion resistance, tear resistance, and high-temperature resistance; the high-elastic nylon filament improves the fabric's toughness and fatigue resistance; and the nano-silica powder can construct a rigid abrasion-resistant protective structure on the fabric surface, making it suitable for heavy-duty, high-intensity abrasion conditions in industrial applications.

[0037] (2) Raw material pretreatment and spinning

[0038] The blended fiber raw materials are processed sequentially through opening and cleaning, carding, drawing, roving, spinning, and winding to produce yarn. The twist coefficient of the general-purpose abrasion-resistant yarn is controlled at 360–380 to balance the fabric's abrasion resistance and softness; the twist coefficient of the heavy-duty abrasion-resistant yarn is controlled at 400–420 to improve fiber cohesion, inhibit fiber slippage and loosening, and enhance the yarn's resistance to friction and breakage.

[0039] To optimize yarn structural stability and abrasion resistance / fatigue resistance, before finalizing the spinning process, the actual service conditions of the yarn—fiber slippage, reciprocating friction, and tensile fatigue—are simulated. Combining wear dynamics and fiber fatigue fracture probability models, the yarn wear rate and fiber fracture probability are quantitatively calculated. Based on the simulation results, the fiber ratio and yarn twist are iteratively optimized, and finally, the entire set of spinning process parameters is finalized. Figure 2 As shown, this is a curve illustrating the optimal relationship between yarn wear rate and yarn twist coefficient. The horizontal axis represents the yarn twist coefficient α, with scales of 360, 370, 380, 390, 400, 410, 420, and 430. The vertical axis represents the yarn mass wear rate ṁ, in mg / h. The curve first decreases as the twist coefficient increases, reaches an inflection point, and then rises again. The inflection point corresponds to the optimal twist coefficient. The horizontal axis range of 360–380 represents the twist coefficient range for general wear-resistant yarns, while the range of 400–420 represents the twist coefficient range for heavy-duty wear-resistant yarns.

[0040] The specific optimization process is as follows: A three-dimensional coupled mechanical model of a multi-fiber assembly is constructed to simulate three types of core damage conditions during fabric use. The influence of twist coefficient and fiber ratio on fiber slippage stability is quantitatively analyzed through the fiber slippage critical load formula and the twist-fiber clamping force correlation formula. The modified Archard wear model is used to calculate the yarn volume wear rate and mass wear rate to accurately characterize the yarn abrasion resistance under different process parameters. The fiber tensile fatigue fracture probability is calculated based on the Weibull fatigue distribution model to clarify the coupling relationship between twist and yarn fatigue resistance. With the minimum wear rate and the lowest fiber fracture probability as dual optimization objectives, a multi-objective optimization function is constructed and iteratively solved within a limited twist coefficient range to select the optimal combination of process parameters.

[0041] (2.1) Fiber slip mechanics modeling and compressive force quantitative calculation:

[0042] A three-dimensional coupled mechanical model of a multi-fiber assembly was constructed to simulate the relative slippage damage between fibers under bending and rubbing conditions of the fabric. The fiber slippage critical load was used to determine the loose wear trend of the yarn. The calculation formula is as follows:

[0043] Fiber slip critical load calculation formula: Fslip = μ × Fnormal × Lcontact

[0044] In the formula: F is the critical force for fiber slippage, in cN; μ is the coefficient of dynamic friction between fibers, with a value of 0.18 to 0.25 for polyester / nylon blended systems and 0.22 to 0.30 for high-strength systems containing aramid; F is the normal compressive force of fibers generated by yarn twisting, in cN; L is the effective contact length of a single fiber, in mm.

[0045] The fiber compression force inside the yarn is determined by both the twist coefficient and the yarn linear density, and the quantitative correlation formula is as follows:

[0046] Formula for normal compressive force of fibers: Fnormal = k × α² × Tt

[0047] In the formula: α is the yarn twist coefficient; Tt is the yarn linear density in tex; k is the fiber aggregate compression coefficient, with a value of 0.12–0.15 for general abrasion-resistant fiber systems and 0.16–0.19 for heavy-duty abrasion-resistant high-modulus fiber + aramid systems. The above formula accurately determines that a higher twist coefficient results in greater fiber compression force, higher fiber slippage resistance, and a more stable yarn structure.

[0048] (2.2) Calculation of yarn wear rate based on modified Archard model

[0049] To address the friction and wear characteristics of flexible fiber yarns, a modified Archard wear kinetic model was employed to quantitatively calculate the yarn wear rate under different process parameters, enabling a numerical evaluation of wear resistance. The formula for calculating the volumetric wear rate is as follows:

[0050] Formula for calculating yarn volume wear rate: V̇ = (K × Fload × vslide) / H

[0051] In the formula: V̇ is the yarn wear volume per unit time, mm³ / s; K is the fiber wear coefficient, which is 10 to 10 for conventional polyester and nylon systems, and 10 to 5×10 for wear-resistant modified and aramid-doped systems; Fload is the monofilament cyclic friction load, cN; vslide is the relative sliding velocity of the fiber, mm / s; H is the microhardness of the fiber surface, MPa.

[0052] The directly measurable wear rate in production can be obtained by converting fiber density:

[0053] Formula for calculating yarn wear rate: ṁ = V̇ × ρ

[0054] In the formula: ṁ represents the yarn mass wear rate, mg / h; ρ represents the overall equivalent density of the fiber, g / cm³. This index can be directly used as a quantitative indicator for comparing the quality of the process; the lower the wear rate, the better the fabric's durability and abrasion resistance.

[0055] (2.3) Calculation of fiber tensile fatigue fracture probability based on Weibull distribution

[0056] Simulating repeated stretching and bending fatigue conditions of the fabric, the Weibull probabilistic fatigue model is used to calculate the fiber breakage probability and quantitatively evaluate the yarn's resistance to fatigue failure. The formula is as follows:

[0057] The formula for calculating the fiber fatigue fracture probability is: Pf(t) = 1-exp[ - (σa / σ0)^m × (t / t0) ]

[0058] In the formula: P(t) is the probability of fiber tensile fatigue fracture at time t; σ is the amplitude of fiber alternating stress, MPa; σ is the characteristic fatigue strength of fiber, MPa; m is the Weibull modulus, which is uniformly taken as 3.0 to 5.0 in the synthetic fiber system of this invention; t is the fatigue time, s; t is the characteristic fatigue life of fiber, s.

[0059] Among them, the alternating stress amplitude is strongly coupled with the yarn twist coefficient and spinning tension, and the quantification formula is as follows:

[0060] Formula for calculating the amplitude of alternating stress in fibers: σa = (4 × T × α) / (π × d² × √Tt)

[0061] In the formula: T is the spinning tension, cN; α is the yarn twist coefficient; d is the diameter of the monofilament fiber, μm; Tt is the yarn linear density, tex. This formula can be used to correct fiber fatigue stress under different twist levels, avoiding stress concentration and embrittlement problems caused by high twist.

[0062] (2.4) Objective function and constraints of multi-objective process optimization (basis for production iteration)

[0063] With "minimum wear rate and minimum fiber breakage probability" as the dual core optimization objectives, a direct iterative solution objective function is constructed to achieve precise matching of fiber ratio and yarn twist coefficient.

[0064] Multi-objective optimization objective function: min Obj = w1 × ṁ + w2 × Pf

[0065] Constraints: General twist coefficient α∈[360,380], heavy-duty twist coefficient α∈[400,420], w1+w2=1

[0066] In the formula: w is the wear rate weight and w is the fracture probability weight; for general wear-resistant scenarios, w=0.6 and w=0.4; for heavy-duty high-strength wear-resistant scenarios, w=0.75 and w=0.25, prioritizing wear resistance and durability performance.

[0067] (3) Warping and weaving

[0068] The prepared yarn is subjected to zoned warping treatment, and the tension difference between each warping zone is strictly controlled to be ≤5 cN. This avoids defects such as uneven fabric density, local abrasion resistance differences, and fabric wrinkling and deformation caused by uneven tension, and ensures the overall uniformity of the fabric performance.

[0069] Both fabrics are twill-weave, with different warp and weft density parameters: the general-purpose abrasion-resistant fabric has a warp density of 370–390 threads / 10 cm and a weft density of 350–370 threads / 10 cm; the heavy-duty abrasion-resistant fabric has a warp density of 410–430 threads / 10 cm and a weft density of 390–410 threads / 10 cm. The heavy-duty version increases the warp and weft density, enhancing the fabric's structural density and further strengthening its abrasion and tear resistance.

[0070] During the weaving process, the tension on the loom and the speed of the equipment are precisely controlled. The tension on the loom for general-purpose weaving is controlled at 10-14 cN, and the tension on the loom for heavy-duty weaving is controlled at 14-18 cN. The uniform weaving speed is controlled at 40-60 m / min, which ensures smooth weaving while stabilizing the fabric structure.

[0071] (4) Pretreatment of grey fabric

[0072] The woven fabric undergoes desizing, scouring, bleaching, and pre-setting processes in sequence. The desizing and scouring processes thoroughly remove sizing, oil, and impurities from the surface and interior of the fabric, preventing residual impurities from affecting the penetration and adsorption of subsequent finishing solutions and the adhesion of coatings. The bleaching process unifies the fabric color and improves the cleanliness of the fabric.

[0073] The pre-forming process temperature is controlled at 160–170 ℃, and the pre-forming locomotive speed is controlled at 35–45 m / min. High-temperature pre-forming eliminates internal stress in the fabric weaving process, stabilizes the warp and weft dimensions of the fabric, effectively reduces the probability of shrinkage and deformation during subsequent processing and use, and provides a stable fabric foundation for subsequent abrasion-resistant finishing.

[0074] (5) Wear-resistant finishing

[0075] For different fabric styles, corresponding abrasion-resistant finishing solutions are formulated. The fabric is functionally finished using a two-dip and two-ply process. The pick-up rate is strictly controlled at 70%±5% to ensure that the finishing solution penetrates and adheres evenly to the surface of the fabric and the gaps between the yarns, thus ensuring that the thickness of the functional coating is uniform.

[0076] The concentrations of each component in the general-purpose abrasion-resistant finishing solution are as follows: water-based polyurethane abrasion-resistant finishing agent 120 g / L, anti-pilling agent 20 g / L, and penetrant 3 g / L. Water-based polyurethane can form a flexible and dense protective film on the fabric surface, improving its abrasion resistance; the anti-pilling agent effectively improves the problems of pilling and fuzzing on the fabric surface; and the penetrant promotes the penetration of the finishing solution into the yarn, enhancing the durability of the functional finishing.

[0077] The heavy-duty abrasion-resistant finishing liquid, based on the general formula, is compounded with nano-silica dispersion and crosslinking agent, along with pre-added nano-silica abrasion-resistant powder, to form a flexible polyurethane matrix composite rigid nano-powder abrasion-resistant structure inside and on the surface of the fabric, significantly improving the fabric's impact resistance and high-intensity friction resistance.

[0078] After finishing, a segmented drying combined with baking curing process is adopted to avoid coating cracking and fabric embrittlement caused by a single high-temperature treatment. The segmented drying is divided into two temperature control stages: the first stage drying temperature is 80-90 ℃ to remove free moisture from the fabric surface; the second stage drying temperature is 90-100 ℃ to remove bound moisture from the fabric interior. After drying, baking curing is carried out at a temperature controlled at 150-165 ℃ for 3-5 minutes. Through precise temperature control curing, the finishing agent is fully cross-linked and forms a film, ensuring a strong bond between the abrasion-resistant coating and the fabric substrate, resulting in excellent abrasion resistance and washability.

[0079] (6) Finished product finalization

[0080] The baked and cured fabric undergoes heat setting treatment, with the setting temperature controlled at 140–155 ℃ and the finishing machine speed controlled at 30–40 m / min. Low-speed setting ensures uniform heating and thorough setting of the fabric. During the setting process, the fabric width shrinkage rate is strictly controlled to ≤2%, ultimately obtaining a high-abrasion-resistant finished fabric with stable dimensions, excellent abrasion resistance, and a smooth and uniform surface.

[0081] This invention also provides a high abrasion-resistant fabric prepared by the above method, which is divided into two types: general abrasion-resistant type and heavy-duty abrasion-resistant type. The general abrasion-resistant type fabric is made of polyester staple fiber, high-strength nylon 6 staple fiber and viscose filament blended together, with a twill weave, a warp density of 370-390 threads / 10 cm and a weft density of 350-370 threads / 10 cm. The fabric surface is coated with an abrasion-resistant functional coating, which is composed of a water-based polyurethane matrix and an anti-pilling agent, and has good conventional abrasion resistance, anti-pilling and dimensional stability. The heavy-duty abrasion-resistant fabric is made of a blend of industrial high-modulus polyester filament, aramid staple fiber, and high-elastic nylon filament. It adopts a twill weave with a warp density of 410-430 threads / 10 cm and a weft density of 390-410 threads / 10 cm. The abrasion-resistant coating on the surface of the fabric and inside the yarn contains uniformly dispersed nano-silica powder. The amount of nano-silica powder added is 2% of the total fiber mass, forming a rigid-flexible composite abrasion-resistant structure, which is suitable for heavy-duty and high-strength abrasion-resistant industrial conditions.

[0082] Example 1: Preparation of general-purpose abrasion-resistant high-abrasion-resistant fabric:

[0083] (1) Raw material compounding: According to the mass percentage ratio, 82% of polyester staple fiber with a breaking strength of ≥5.5 cN / dtex (1.56 dtex×38 mm), 15% of high-strength nylon 6 staple fiber with a breaking strength of ≥5.5 cN / dtex, 3% of viscose filament, and add spinning oil agent with a total fiber mass of 0.3% and mix thoroughly and evenly;

[0084] (2) Raw material pretreatment and spinning: The mixed fibers are processed into yarn through opening and cleaning, carding, drawing, roving, spinning and winding processes. The twist coefficient of the spinning yarn is set to 370. The spinning process is solidified through working condition simulation and multi-objective optimization to control the winding tension fluctuation to ≤±3%.

[0085] (3) Warping and weaving: Partition warping is adopted, with a tension difference of ≤5 cN between partitions; twill weaving is used, with a warp density of 380 ends / 10 cm and a weft density of 360 ends / 10 cm, a machine tension of 12 cN, and a weaving speed of 50 m / min;

[0086] (4) Pretreatment of grey fabric: After desizing, scouring and bleaching, the grey fabric is pre-shaped at 165 ℃ and the locomotive speed is 40 m / min.

[0087] (5) Finishing with wear resistance: Prepare finishing solution with 120 g / L waterborne polyurethane wear-resistant finishing agent, 20 g / L anti-pilling agent and 3 g / L penetrant; adopt a two-dip and two-roll process with a roll-off rate of 70%; first-stage drying temperature is 85 ℃, second-stage drying temperature is 95 ℃, and baking and holding at 160 ℃ for 4 min.

[0088] (6) Finished product shaping: The finished product is heat-shaped at 148 ℃, the locomotive speed is 35 m / min, and the width shrinkage rate is controlled to ≤2% to obtain a general wear-resistant high wear-resistant fabric.

[0089] Example 2: Preparation of heavy-duty abrasion-resistant high-abrasion-resistant fabric:

[0090] (1) Raw material compounding: According to the mass percentage ratio, industrial high modulus polyester filament 78%, aramid staple fiber 12%, and high elastic nylon filament 8% are fully mixed evenly;

[0091] (2) Raw material pretreatment and spinning: The mixed fibers are processed into yarn through a complete spinning process, and the yarn twist coefficient is set to 410; the complete spinning parameters are optimized and solidified through simulation, and the winding tension fluctuation is ≤±3%;

[0092] (3) Warping and weaving: Warping in sections with tension difference ≤ 5 cN; twill weaving with a warp density of 420 ends / 10 cm and a weft density of 400 ends / 10 cm, a machine tension of 16 cN, and a weaving speed of 50 m / min;

[0093] (4) Pretreatment of grey fabric: Complete the desizing, scouring and bleaching processes of grey fabric, and pre-shape at 168 ℃ with a locomotive speed of 40 m / min;

[0094] (5) Wear-resistant finishing: Based on the general finishing liquid, nano silica dispersion and crosslinking agent are compounded, and 2% of nano silica wear-resistant powder by total fiber mass is added; a two-dip and two-roll process is adopted, with a roll residue of 70%; first-stage drying at 88℃, second-stage drying at 98℃, and baking at 162℃ for 4 min;

[0095] (6) Finished product shaping: The finished product is heat-shaped at 150 ℃, the locomotive speed is 35 m / min, and the width shrinkage rate is ≤2%, to obtain heavy-duty wear-resistant high wear-resistant fabric.

[0096] The following is a comparison table of the fabrics corresponding to the two embodiments described above:

[0097] Example 1 (General Version) 4.2 22000 86% 1.2% Example 2 (Heavy-duty version) 1.8 48000 92% 1.1% Comparison (traditional fabrics) 7.5 11000 62% 3.5%

[0098] As can be seen from the above, the fabric prepared by the process of the present invention has a lower wear rate, double the number of abrasion resistance cycles, better washability, and dimensional stability than existing conventional abrasion-resistant fabrics.

Claims

1. A method for producing a high abrasion-resistant fabric, characterized in that, Includes the following steps: (1) Raw material compounding: Select general wear-resistant or heavy-duty wear-resistant fiber raw materials according to the application scenario, complete the fiber compounding according to the mass percentage, and add the corresponding spinning auxiliary agent; (2) Raw material pretreatment and spinning: The mixed fibers are sequentially processed through opening and cleaning, carding, drawing, roving, spinning and winding to prepare yarn. The twist coefficient of the general-purpose yarn is set to 360-380, and the twist coefficient of the heavy-duty yarn is set to 400-420. The internal fiber slippage, reciprocating friction and tensile fatigue conditions of the yarn are simulated. The yarn wear rate and fiber breakage probability are calculated by combining the wear model. The fiber ratio and yarn twist are optimized according to the simulation results, and the spinning process parameters are solidified. (3) Warping and weaving: The yarn is warped in sections, and the tension difference between the warping sections is controlled to be ≤5cN; (4) Pretreatment of greige fabric: The greige fabric after weaving is subjected to desizing, scouring, bleaching and pre-setting treatment in sequence. The pre-setting temperature is controlled at 160-170℃. (5) Abrasion-resistant finishing: Prepare abrasion-resistant finishing solution, and treat the fabric with a two-dip and two-roll process, with the roll-off rate controlled at 70%±5%; then carry out segmented drying and baking curing. (6) Finished product setting: The finished fabric is heat-set at 140-155℃.

2. The method for producing high abrasion-resistant fabric according to claim 1, characterized in that: In step (1), the general wear-resistant raw material composition is: 82% polyester staple fiber, 15% high-strength nylon 6 staple fiber, 3% viscose filament, and 0.3% spinning oil agent of total fiber mass is added. The polyester staple fiber has a specification of 1.56dtex×38mm and a breaking strength ≥5.5cN / dtex. The nylon 6 staple fiber has a specification of 2.22dtex×40mm. The raw material composition of the heavy-duty wear-resistant version is: 78% industrial high-modulus polyester filament, 12% aramid staple fiber, and 8% high-elastic nylon filament. In the finishing process, an additional 2% of nano-silica wear-resistant powder by weight of the total fiber is added.

3. The method for producing high abrasion-resistant fabric according to claim 1, characterized in that: In step (5): The concentrations of each component in the general-purpose abrasion-resistant finishing liquid are: 120 g / L waterborne polyurethane abrasion-resistant finishing agent, 20 g / L anti-pilling agent, and 3 g / L penetrant; the heavy-duty abrasion-resistant finishing liquid is formulated with nano-silica dispersion and crosslinking agent in addition to the general-purpose formula.

4. The method for producing high abrasion-resistant fabric according to claim 1, characterized in that: In step (5), the segmented drying is divided into two temperature control levels: the first drying temperature is 80-90℃ and the second drying temperature is 90-100℃; the baking temperature is 150-165℃ and the baking holding time is 3-5min.

5. The method for producing high abrasion-resistant fabric according to claim 1, characterized in that: In step (3), the general abrasion-resistant fabric uses a twill weave with a warp density of 370-390 threads / 10cm and a weft density of 350-370 threads / 10cm; the heavy-duty abrasion-resistant fabric uses a twill weave with a warp density of 410-430 threads / 10cm and a weft density of 390-410 threads / 10cm.

6. The method for producing high abrasion-resistant fabric according to claim 1, characterized in that: In step (3), the tension control range for weaving is 10-14cN for general models and 14-18cN for heavy-duty models. The weaving speed control is 40-60m / min.

7. The method for producing high abrasion-resistant fabric according to claim 1, characterized in that: In step (4), the speed of the blank pre-forming locomotive is 35-45 m / min; in step (6), the speed of the finished product shaping locomotive is 30-40 m / min, and the fabric width shrinkage rate is controlled to ≤2% during the shaping process.

8. A highly abrasion-resistant fabric, characterized in that, Prepared by the production method according to any one of claims 1-7: The fabric is divided into two types: general wear-resistant and heavy-duty wear-resistant. The general wear-resistant fabric is made of polyester staple fiber, high-strength nylon 6 staple fiber and viscose filament blend, while the heavy-duty wear-resistant fabric is made of industrial high-modulus polyester filament, aramid staple fiber and high-elastic nylon filament blend, and the fabric surface is coated with a wear-resistant functional coating.

9. The high abrasion-resistant fabric according to claim 8, characterized in that: The wear-resistant functional coating is composed of a water-based polyurethane matrix and an anti-pilling agent; the wear-resistant functional coating of the heavy-duty wear-resistant fabric also contains uniformly dispersed nano-silica powder, and the amount of nano-silica powder added is 2% of the total mass of the fabric fibers.

10. The high abrasion-resistant fabric according to claim 8, characterized in that: The general-purpose abrasion-resistant fabric adopts a twill weave with a warp density of 370-390 threads / 10cm and a weft density of 350-370 threads / 10cm; the heavy-duty abrasion-resistant fabric adopts a twill weave with a warp density of 410-430 threads / 10cm and a weft density of 390-410 threads / 10cm.

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